Volkswagen Polo 3 with 1994 for 2001 of release.
1. The general data
2. The engine
3. Greasing system
4. Cooling system
5. Systems of injection of fuel
6. Ignition system
7. Coupling
8. A mechanical transmission
8.1. Removal and transmission installation
8.2. Dismantling and check
8.2.1. Full dismantling of a transmission
8.2.2. Repair картера couplings
8.2.3. Removal of a primary and conducted shaft
8.2.4. Dismantling of a primary shaft
8.2.5. Dismantling of a conducted shaft
8.3. Check of details of a transmission
8.4. Transmission assemblage
8.5. Differential
8.6. The gear change mechanism
9. A drive of wheels
10. A steering without the amplifier
11. A steering with the hydraulic amplifier
12. A forward suspension bracket
13. A back suspension bracket
14. Brake system
15. An electric equipment
16. Heating and ventilation system
17. An automatic transmission
18. Appendices
 











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8.2.2. Repair картера couplings

On fig. 172 coupling details are presented. If works on the further dismantling it is necessary to execute following operations are provided:
- To turn away directing 14 plug of a gear wheel of a drive of a speedometer and to take out a gear wheel 15 drives of a speedometer from an aperture;
- маслоуплотнительное 16 приводного a flange it is easy to replace a ring. To take out an old sealing ring, using the big screw-driver or mount. The case of a sealing ring 17 at replacement of a sealing ring also is subject to replacement. To take out the old case by means of a screw-driver and запрессовать the new case corresponding оправкой. Запрессовать a new sealing ring by means of a steel core of the corresponding diameter. Space of a working edge of a cuff to grease universal with plastic greasing;
- To beat out маслоуплотнительное a ring 18 internal levers of a gear change by means of corresponding оправки. The new sealing ring follows запрессовать so that it has risen заподлицо with an end face картера. For removal of the internal lever of a gear change it is necessary to beat out the plug 19 and to take out the lever. The new plug запрессовывают on 10 mm below a plane картера;
- To take out the plug 13 shaft of a starter a corresponding stripper (for example, special adaptation VW 228b and 204b). The new plug follows запрессовать so that its end face has been located заподлицо. It is preliminary necessary before запрессовкой to grease the plug with plastic greasing;

Fig. 173. Removal of an adjusting persistent ring of the conic roller bearing of a primary shaft: And — stripper Kukko 21/5; B — bridge Kukko 22/2




Fig. 172. Coupling details: 1 — the fixing screw for the internal lever of a gear change; 2 — the adjusting plug; 3 — an adjusting persistent ring, the conic roller bearing; 4 — a compensatory washer for a power shaft; 5 — the lever of deenergizing of coupling; 6 — the condensing screw with a stopper; 7 — a ventilating tube; 8 — картер couplings; 9 — маслоуплотнительное a power shaft ring; 10 — the directing plug for the bearing of deenergizing of coupling; 11 — a bolt, 20 Нм; 12 — the bearing of deenergizing of coupling; 13 — the plug; 14 — the directing plug for a gear wheel of a drive of a speedometer; 15 — a shaft of a small gear wheel with a small gear wheel; 16 — маслоуплотнительное a ring for приводного a flange; 17 — the directing plug for маслоуплотнительного rings; 18 — маслоуплотнительное a ring for the internal lever of a gear change; 19 — the ball plug for the internal lever of a gear change; 20 — the internal lever of a gear change; 21 — a shaft of the mechanism of a gear change; 22 — a bolt, 35 Нм; 23 — a compensatory washer for differential (it is necessary to pick up); 24 — an adjusting persistent ring / a conic roller bearing (differential); 25 — a compensatory washer for a conducted shaft (it is necessary to pick up); 26 — an adjusting persistent ring / a conic roller bearing for a conducted shaft; 27 — the plug for the internal lever of a gear change




- To take out an adjusting persistent ring 3 conic roller bearings of a power shaft by means of a corresponding stripper, as is shown in fig. 173. For this work stripper Кukko 21/6 with bridge Kukko 22/2 approaches. To remove a compensatory washer 4 (fig. 172 see), being under an adjusting persistent ring. Запрессовать the new adjusting persistent ring corresponding оправкой for запрессовки, in case of bearing replacement is necessary to adjust a power shaft. Power shaft adjustment to spend also at replacement картеров transmissions and couplings, and also the shaft;
- The stripper also is necessary for removal of an adjusting persistent ring 26 conic roller bearings of a conducted shaft. To remove the compensatory washer 25 which are under an adjusting persistent ring. Запрессовать a new adjusting persistent ring corresponding оправкой for запрессовки, preliminary having adjusted a conducted shaft. Last is subject to adjustment if the shaft or the bearing were replaced картеры transmissions and couplings;
- For replacement of a cuff 9 power shafts to remove the bearing of 12 deenergizings of coupling and directing муфту 10 and to take out a cuff in the corresponding way. Запрессовать a new cuff before its installation on 2,5 mm below half of transmission, that is almost against the stop. Again to establish directing муфту and to tighten bolts the moment 20 Нм;
- If the connecting plug 21 (after unscrewing of a bolt 22 acts in film and removals of an internal shaft of the mechanism of a gear change), adjustment of details at installation is necessary. The same adjustment should be spent and at replacement of a finger of a gear change, картеров couplings and transmissions, the internal lever of a gear change or a stopper 1 (rice 172 see) for the internal lever of a gear change. Special adaptations are necessary for adjustment. Adjustment is necessary for spending as follows:
- To establish an adjusting plate with adjusting plugs on картере transmissions;
- To fix on картере стрелочный the indicator with the corresponding holder, as is shown in

Fig. 174. Adjustment of the connecting plug and a gear change finger: 1 — a bolt



Fig. 174;
- To establish a measuring pin стрелочного the indicator on directing a backing. To establish a preliminary tension of 1 mm стрелочного the indicator that the measuring pin has appeared under a tension;
- To take away to the left directing inclusions of a backing and to establish an arrow стрелочного the indicator on zero;
- From the bottom party to press on стрелочный the indicator in other direction and to consider the shown value. We will assume that it makes, for example, 0,70 mm;
- To fix directing on the average position, that is to reduce the received value twice, and to move transfer directing with the bottom party until the value equal of 0,35 mm (half) will be reached. To tighten in this position transfer directing a bolt 1;
- To translate a finger of a gear change by means of special adaptation VW 709, as is shown in

Fig. 175. Adjustment of a finger of a gear change and the connecting plug: 1 — measuring calibre 3154/1



Fig. 175, in a direction of a backing and to establish measuring calibre 3154/1 (poses. 1);
- To move measuring calibre from an emphasis against the stop and to fix the indication on стрелочном the indicator. We will admit that it is equal, for example, 0,60 mm. To establish measuring calibre in the middle, that is the indication makes 0,30 mm, and to tighten a bolt 1 (

Fig. 176. For adjustment of a finger of a gear change and the connecting plug: 1 — a bolt



Fig. 176);
- Again to turn away the screw of fastening of the holder стрелочного the indicator;
- To weaken a bolt 1 (

Fig. 177. For adjustment of a finger of a gear change and the connecting plug: 1 — a bolt



Fig. 177) so that the connecting plug could move freely on the internal lever of a gear change and establish the gear change lever on an average stopper;
- запрессовать adjusting plugs in картер couplings and to establish calibre 3154 on картер couplings, having developed it on 180 so that the finger of a gear change and the connecting plug have appeared aligned under the relation to each other. If it is necessary, to spend additional updating by a screw-driver, as is shown in

Fig. 178. Additional adjustment of a finger of a gear change and the connecting plug



Fig. 178.



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8.2.1. Full dismantling of a transmission
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8.2.3. Removal of a primary and conducted shaft