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
8.3. Check of details of a transmission
8.4. Transmission assemblage
8.4.1. Assemblage of a conducted shaft
8.4.2. Assemblage of a primary shaft
8.4.3. Definitive 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
 











8-4-3-okonchatelnaya-sborka.html

8.4.3. Definitive assemblage

Transmission assemblage is spent in sequence, return dismantling, at use fig. 161. At assemblage it is necessary to execute following operations:


Fig. 197. Installation of a conducted shaft and other details: 1 — a backing gear wheel; 2 — a backing shaft; 3 — a conducted shaft; 4 — a plug of inclusion of the first and second transfer




- To establish a conducted shaft 3 (fig. 197) with a plug of 4 inclusions of the first and second transfer. To spread on a shaft a gear wheel of 1 backing and to establish a shaft;
- To raise the cranked lever a backing gear wheel, later to establish the lever of inclusion of a backing;

Fig. 198. Installation of a power shaft with a plug of inclusion of the first and second transfer: 1 — a conducted shaft; 2 — an inclusion plug; 3 — a primary shaft




- A few to raise a conducted shaft 1 (fig. 198) with a plug of 2 inclusions of the first and second transfer to deduce a primary shaft 3 in gearing with a plug of inclusion and again to establish these details in картере. At installation of a primary shaft of a gear wheel of inclusion of the third and fourth transfer it is necessary to spend near to a gear wheel of inclusion of the fourth transfer which are on conducted shaft. On fig. 198 it is shown, how these details are established;
- To screw the screw with head Torx in located separately carving aperture, to fix a shaft of a gear wheel of a backing;
- To establish the rotary lever of a backing in a plug of inclusion and to collect details. The rotary lever should be latched in ring bore of a gear wheel of inclusion of a backing;
- To screw in a carving aperture screw Torx for fastening of the rotary lever. This bottom from two apertures located on one party. Used for приподнятия the cranked lever can be cleaned now gear wheels of inclusion of a backing;
- To establish a plug of inclusion of the fifth transfer and to fix it;


Fig. 199. Installation of the console of inclusion: 1 — inclusion plugs; 2 — the inclusion console; 3 — a shaft of the mechanism of a choice of transfers




- To deduce all plugs of inclusion 1 (fig. 199) in position of idling and to fix the console of inclusion 2 by means of the plug and a bolt. Now it is necessary to centre the inclusion console. For this purpose the shaft of the mechanism of a choice of transfers 3 is used and the bolt specified by an arrow is tightened. After that the shaft of the mechanism of a choice of transfers is again cleaned;

Fig. 200. Assemblage of a finger of a gear change with the inclusion console: 1 — a switching finger; 2 — the inclusion console




- To establish a finger of a gear change 1 (fig. 200) in the console of inclusion 2, as is shown in fig. 200. The plug is established in a groove of a finger of a gear change;
- To establish between a finger of a gear change and the inclusion console призматическую шпонку and to deduce a plug in gearing with a finger of a gear change and the inclusion console;
- To muffle an aperture sideways transmissions герметизирующей a stopper;
- To establish differential. It is supposed that differential adjustment is already spent, as is described in подразд. 8.5;
- To grease a surface картера transmissions with hermetic and to establish картер couplings. Запрессовать in картер adjusting plugs;
- To establish bolts and in regular intervals to tighten them on a circle the moment of the inhaling equal 25 Нм;
- To collect details of power shafts according to fig. 161 and to tighten both bolts 1 and 17 moment 25 Нм;

Fig. 161. Details картера transmissions and картера couplings: 1 — a bolt, 25 Нм; 2 — приводной a flange, right; 3 — a spring; 4 — an adjusting washer; 5 — a conic ring; 7 — a bolt, 25 Нм; 6 — картер couplings; 8 — a gear wheel of a drive of a speedometer; 9 — the directing plug; 10 — differential; 11 — a magnet; 12 — an adjusting pin; 13 — a conic ring; 14 — an adjusting washer; 15 — a spring; 16 — приводной a flange; 17 — a bolt, 25 Нм; 18 — a persistent ring; 19 — a gear wheel, the fifth transfer; 20 — картер transmissions; 21 — an adjusting pin




- запрессовать on a shaft a gear wheel of the fifth transfer, having established it скосом in a direction of the conic roller bearing, and to establish a persistent ring;
- To establish a new bolt of fastening of a gear wheel of the fifth transfer with a spring washer. The convex party of a spring washer should be turned towards a gear wheel;
- To establish on other to a shaft an adjusting washer for a gear wheel of the fifth transfer. In internal diameter of an adjusting washer there is a flute. It is directed towards the needle bearing;
- To heat up on an electric plate the basic plug intended for the needle bearing of the fifth transfer, to 100 With and quickly напрессовать it on a shaft;
- To establish a spring on a ring of the synchronizer of the fifth transfer and to establish a ring on a gear wheel;
- To take in hands a nave of the synchronizer of the fifth transfer and to check up, on what party a fillet wider. This party should be turned to a lateral face картера transmissions. To spread a nave blows on a shaft. Thus to be convinced that the synchronizer ring will not be заедать. Crackers should be in dredging of a ring of the synchronizer;
- To establish a persistent ring on the end of a shaft by means of the special flat-nose pliers used at repair of water pumps;

Fig. 201. Assemblage of details of the synchronizer of the fifth transfer




- To establish sliding муфту inclusions of the fifth transfer, using thus fig. 201. At sliding муфты three acting teeth (marksman), and in a nave in the middle a hollow between teeths (marksman). They should coincide, as is shown in drawing. Sliding муфта it is established while temporarily;
Fig. 164. Removal of details of a gear wheel of the fifth transfer (to block transfers according to arrows 1, 2 and 3)




- To tighten a bolt of fastening of a gear wheel of the fifth transfer. For this purpose again to include two transfers, as is shown in fig. 164;
- Again to remove sliding муфту, to insert into a groove a plug of inclusion and to establish sliding муфту with an inclusion plug;

Fig. 163. Removal of a plug of a gear change: 1 — a nut; 2 — a plug bolt




- To turn away a counternut 1 (fig. 163 see) while it will not appear below an inclusion plug, and to screw a bolt 2 with a spherical head. The carving of this screw is greased with a protection frame from отворачивания D 000 600 (Loctite);
- To translate all transfers to neutral position and to adjust gear wheels of the fifth transfer;
- To establish a transmission in normal position;
- To weaken a counternut 1 (fig. 163 see);
- To turn on a bolt 2 with a spherical head while sliding муфта will not rise заподлицо with an inclusion nave;
- To include the fifth transfer and to roll a bolt with a spherical head until the plug of inclusion of the fifth transfer will not have more backlash in a groove sliding муфты;
- Again to turn on a bolt, there will be no yet absolutely small backlash between a wall of a groove and the lever of a plug of inclusion (approximately 1/8 turns);
- To fix from проворачивания a bolt with a spherical head by means of a counternut;
- Again to switch off the fifth transfer. Sliding муфта should be in "neutral" position, and the synchronizer ring should move freely;
- To establish a cover with a new lining and to tighten in regular intervals bolts of fastening of a cover on a circle the moment 8 Нм.



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8.4.2. Assemblage of a primary shaft
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8.5. Differential