Repair VW Sharan

. Diesel engines: 1,9 l TDI.
+ 1. Introduction
- 2. Engine VR6
   - 2.1. Cнятие and installation
      2.1.1. Removal and installation of a transmission from the engine
      2.1.2. Additional operations if on the car the conditioner is established
      2.1.3. An engine mount
   + 2.2. Dismantling and assemblage
   + 2.3. A head of the block of cylinders and valves
   + 2.4. Pistons and rods
   2.5. The block of cylinders
   + 2.6. A cranked shaft and radical bearings
   + 2.7. A mechanism drive газораспределения
   2.8. An intermediate shaft
   2.9. Compression check in engine cylinders
   + 2.10. System of release of the fulfilled gases
+ 3. The two-litre engine (ADY)
+ 4. System of greasing of the engine
+ 5. Cooling system
+ 6. System of injection of fuel of engine VR6
+ 7. System Simos of injection of fuel of the 2,0-litre engine
+ 8. Ignition system
+ 9. Coupling
+ 10. A mechanical 5-step transmission
+ 11. Shaft of a drive of wheels
+ 12. The steering hydraulic booster
+ 13. A forward suspension bracket
+ 14. A back suspension bracket
+ 15. Brake system
+ 16. An electric equipment
+ 17. The diesel engine
+ 18. System of greasing of the diesel engine
+ 19. System of cooling of the diesel engine
+ 20. The power supply system of the diesel engine and turbocharger
+ Maintenance service card
+ Specifications and characteristics
+ Electroschemes
Folksvagen Sharan/Sharan repair>> Engine VR6>> Cнятие and installation



The power unit consists of the engine and a transmission. Remove it by means of the hydrolift or тали, lowering from a motor compartment.
Before removal of the power unit execute the following:
- If on the car the anticreeping system with a protective code is established, the code needs to be had at itself to include system after connection АБ;
- At engine removal it will be necessary to disconnect a considerable quantity of electric wires, and also vacuum hoses and hoses of a cooling liquid. Before removal of wires and hoses designate them by means of labels;
- Before installation works in a motor compartment it is necessary to close a dense fabric forward wings of the car.
Removal of the power unit make in a following order:
- Switch off the engine and take out a key from the ignition lock;
- Disconnect the plug «–» from АБ;

The prevention
To avoid damage ЭБУ, it is necessary to disconnect plugs AB only at the switched off ignition. And for full deenergizing of ignition it is necessary to wait not less than 20 with and only after that it is possible to disconnect the plug «–» from АБ.


Fig. 18. Removal АБ: 1 — an air pipe casing; 2 — a partition





- Turn away screws (are shown by arrows, fig. 18) and remove a casing of 1 air pipe and a partition 2;
- Remove АБ (section 16.1 see);
- Merge cooling liquid from cooling system (section 19.1 see);
Fig. 19. Removal of casing АБ





- Turn away screws (are shown by arrows, fig. 19), shift aside and remove casing АБ together with a broad tank of system of cooling;
- Remove клиновой a belt of a drive of units of the engine;
- Disconnect a hose of an air pipe from the case of knot throttle заслонки;
- By means of a candle key unscrew spark plugs and combine them as an arrangement of cylinders. At engine VR6 caps of candles and candles can be removed only by means of a special candle key at number 3277А;
Fig. 20. Removal of the central cover on the top part of an inlet collector: 1, 3, 4 — directing high voltage wires; 2 — the central cover





- Remove directing 1, 3 and 4 (fig. 20) wires of a high voltage and remove the central cover 2 top parts of an inlet collector;
- Remove a cable of a drive throttle заслонки together with its support for what turn away a support and take the cable end. Do not pull out a clip keeping a cable throttle заслонки in a support (as adjustment of a tension of a cable throttle заслонки in this case will be necessary);
Fig. 26. Details of the top part of a head of the block of cylinders: 1 — bolts (5 Н·м); 2 — the central cover (over the top part of the inlet pipeline); 3 — bolts (25 Н·м); 4 — holders of wires of spark plugs; 5 — the holder of a cable throttle заслонки; 6 — a back left arm of the top part of the inlet pipeline; 7 — a stopper of a mouth for an oil gulf; 8 — a sealing lining; 9 — the ventilating valve картера; 10 — a ring in a cover of a head of the block of cylinders; 11 — a nut (10 Н·м); 12 — a cover of a head of the block of cylinders; 13 — a sealing lining of a cover of a head of the block of cylinders; 14 — holders топливопроводов; 15 — a bolt (10 Н·м); 16 — a vacuum hose; 17 — a sealing lining of the top part of an inlet collector; 18 — the top part of an inlet collector; 19 — a back right arm of the top part of the inlet pipeline





- Disconnect spring clips of holders топливопроводов 14 (fig. 26 see) supply and fuel tap;
- Mark топливопроводы and disconnect hoses of a supply and tap of fuel from the fuel distributor;

The prevention
Топливопроводы are under pressure. Before to disconnect a fuel hose from its fastening, clasp a place of joining of a fuel hose a thick rag, and, cautiously pulling together it from a fastening place, dump in system pressure.

- Disconnect big штекерную колодку with 42 sockets, located nearby from the ignition coil;
- Disconnect a vacuum hose of the amplifier of a brake drive;
- Disconnect the pipeline of the hydraulic booster of the steering mechanism from the union at the engine. The pump of the hydraulic booster of the steering mechanism turn on together with an arm and suspend on a wire to a body. Do not overwind hoses and track, that the pump did not hang on a hose;
Fig. 100. Elements of a forward part of system of release of the fulfilled gases: 1 — the screen of thermal protection of the engine; 2 — a final collector, two-piece; 3 — an elevating eye; 4 — a nut, 40 Н·м; 5 — the screen of thermal protection of the engine; 6 — a nut of the screen of thermal protection of the engine; 7 — a lining, on replacement; 8 — a reception pipe; 9 — a nut, 10 Н·м; 10 — the union for system EGR connection, 35 Н·м





- Disconnect a reception pipe 8 and an average part of system of release with the catalyst from a final collector 2 (see

Fig. 101. Elements of an average part of system of release of the fulfilled gases (are located between a reception pipe and the muffler of the catalyst): 1 — a nut of the screen of thermal protection; 2 — the screen of thermal protection; 3 — a direction to the first muffler; 4 — the catalyst; 5 — a protective collar; 6 — the screen of thermal protection; 7 — a bolt, 10 Н·м; 8 — a protective collar; 9 — a bolt, 10 Н·м; 10 — a nut, 40 Н·м; 11 — a ljambda-probe; 12 — штекерная колодка black colour



- In engine VR6 the system of secondary giving of air which basic details are located near to a radiator is established. For engine dismantle it is necessary to remove a casing with the fan and the motor of the pump of secondary air (see подразд. 5.2.2);
- Disconnect from the engine all hoses of a cooling liquid, vacuum hoses and hoses of ventilation of the engine;
- Disconnect from the engine and a transmission all electric wires. Among them a wire: the generator of an alternating current, a starter, the hydropressure head oil switch, various gauges. The majority of connections is carried out with the help штекерных колодок;
- Remove the generator;
If the mechanical transmission is established:
- Disconnect from the working cylinder of coupling a hose;
- Remove draught of a gear change from a transmission (section 10.1 see);
- Take both power shafts from fastenings in a transmission (section 11.1 see);
On the car with an automatic transmission:
- Remove draught of the lever of a choice of an operating mode;
- Take both power shafts from fastenings in a transmission,
- If on the car the conditioner in addition to this section it is necessary to read corresponding recommendations necessarily is established;
Fig. 21. An engine prop: 1 — bolts; 2 — an elevating ski lift; 3 — the lift





- Prop up the engine from below. On HUNDRED the special device (fig. 21) under which then the automobile jack is substituted is for this purpose used. Besides it is necessary to make secure the lift which from above for loops supports the engine. If the automobile jack slides off, the engine will be kept in this case by the lift;
- Remove балансирную (pendular) suspension bracket. It is connected with a forward support, therefore it is necessary to read corresponding section more in detail to learn about its fastening;
Fig. 22. The right engine mount: 1 — fastening bolts





- Turn out bolts 1 (fig. 22) fastenings of a support of the right engine mount. Pay attention that for an inhaling of bolts and engine mount nuts the various moments of an inhaling are used;
Fig. 23. The Engine mount in the disassembled condition on the car with a mechanical transmission. The moments of an inhaling of bolts of fastening of support of an engine mount: 1 = 55 Н·м; 2 = 110 Н·м; 3 = 100 Н·м; 4 = 20 Н·м





- Turn out bolts of fastening of a support of the left engine mount. The fixture of a support of the left suspension bracket (fig. 23) the engine depends on type of the established transmission. At the given stage of works it is necessary to turn out only the bolts 1 which arrangement is identical to all types of a transmission;
- Together with the assistant slowly lower the power unit from a motor compartment. Watch, that the engine has not damaged thus a body.
Installation of the power unit is carried out in an order, the return to removal, thus execute the following:
- Check up a thickness of overlays of a conducted disk of coupling. In case of deterioration a conducted disk replace;
- Cautiously get the power unit in a motor compartment. Watch to damaging details and car knots;
- At alignment of the engine with крепежами suspension bracket support, wrap by hand on 5–6 turns bolts of fastening of support. Shake the engine forward-back (it should not be energised);
- Definitively tighten bolts of fastening of support of a suspension bracket of the power unit following moments:
- Poses. 1 = 55 Н·м; poses. 2 = = 110 Н·м; poses. 3 = 100 Н·м; poses. 4 = 20 Н·м (fig. 23 see) — for the engine with a mechanical transmission;
Fig. 24. The right engine mount in the disassembled condition. The moments of an inhaling of bolts of fastening of support of a suspension bracket: 1 = 55 Н·м; 2 = 60 Н·м





- Poses. 1 = 55 Н·м; poses. 2 = = 60 Н·м (fig. 24) – the right engine mount;
Fig. 25. The right engine mount in the disassembled condition on the car with an automatic transmission. The moments of an inhaling of bolts of fastening of support of a suspension bracket: 1 = 55 Н·м; 2 = 110 Н·м; 3 = 60 Н·м





- Poses. 1 = 55 Н·м; poses. 2 = = 110 Н·м; poses. 3 = 60 Н·м (fig. 25) — the right engine mount on the car with an automatic transmission;
- Establish балансирную (pendular) suspension bracket (section 13 see);
- Establish power shafts. A special key tighten many-sided bolts with the ordered moment of an inhaling. For mechanical and automatic transmissions the inhaling moments various (see «the Table of the moments of an inhaling»);
- Depending on transmission type establish draughts and if necessary adjust the gear change mechanism;
- Attach a hose to the working cylinder of coupling and fix its spring clip (for a mechanical transmission);
- Attach to a final collector a reception pipe with the catalyst. After alignment of the muffler and an exhaust pipe hang up them on suspension bracket rings. Watch correctness of installation. Suspension bracket rings should have a uniform tension and should not be deformed;
- Establish the pump of the hydraulic booster of the steering mechanism;
- Establish a casing with the fan and the motor of the pump of secondary air;
- Establish клиновой a belt of a drive of units of the engine;
- Establish a cable throttle заслонки and check up its work;
- Establish a hose of let in air and the air filter;
- Establish all disconnected earlier electric wires;
- Fill in cooling liquid in cooling system at the open crane of a heater. Finish level of a cooling liquid in a broad tank to demanded level, twirl a cover of a broad tank. Include for some minutes the engine that, to let out all air stoppers. Then check up level of a cooling liquid in a broad tank and if necessary add cooling liquid;
- Remove air from a hydrodrive of deenergizing of coupling by prorolling at obligatory participation of the assistant;
- Connect АБ and make a trial trip. Check up all connections of hoses on tightness;
- Enter a code of anticreeping system (if it is established on the car).
As soon as possible it is necessary to call in on HUNDRED to check up memory of the registrar of malfunctions of system of self-diagnostics.