Repair VW Sharan

. Diesel engines: 1,9 l TDI.
+ 1. Introduction
+ 2. Engine VR6
+ 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
   17.1. Removal and installation
   + 17.2. Dismantling and assemblage
   + 17.3. A head of the block of cylinders
   + 17.4. Privodnye belts — поликлиновой and gear
   + 17.5. Shatunno - piston group
   + 17.6. An intermediate shaft
   17.7. A flywheel
   + 17.8. A camshaft and a camshaft epiploon
   + 17.9. A cranked shaft and radical bearings
   + 17.10. The block of cylinders
   17.11. Compression check in engine cylinders
   17.12. System of release of the fulfilled gases
+ 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>> The diesel engine>> Removal and installation
Order of performance of operations:
- Disconnect from АБ the plug –, then +;
- Remove АБ;

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





- Remove a partition of a compartment of the storage battery (fig. 18 see);
- Having put a forward part of the car on support remove engine protection;

Fig. 358. Removal of a hose of forced air and дефлектора air givings. By arrows detachment places are shown





- Disconnect the right hose of forced air (fig. 358) from a radiator of cooling of forced air. Having turned away two bolts, remove дефлектор air givings in a radiator of cooling of forced air;

Fig. 359. A place of joining of the left hose of forced air to a radiator of forced air (it is shown by an arrow)





- Disconnect the left hose (fig. 359). Remove the pipeline of forced air from the holder on a transmission;
- Disconnect wires from a starter: separate штекерную колодку (the plug 50), disconnect a cable (the plug 30) and remove a cable collar;
- Lower the car on a ground;
- Merge cooling liquid from cooling system according to the description for the petrol engine. Is better to disconnect the bottom hose for this purpose;
- Remove headlights;
- Remove the top part of the air filter;

Fig. 360. Removal of the top part of the air filter: 1 — a hose; 2 — the inlet pipeline; 3 — штекерная колодка the gauge of the mass expense of air; 4 — a clamp





- Disconnect a hose 1 (fig. 360), going to a vacuum regulator of system рециркуляции ОГ and disconnect the inlet pipeline 2;
- Separate штекерную колодку 3 gauges of the mass expense of air;
- Disconnect three clamps 4;

Fig. 361. A place of joining of the top hose of forced air (it is shown by an arrow)





- Remove the bottom part of the air filter. For this purpose at first squeeze out the holder from an external lateral partition. Disconnect the top hose of forced air (fig. 361), preliminary having weakened a hose collar.

Fig. 362. Removal of a cover of the engine. Cover fastening is shown by an arrow





- Uncover the engine (fig. 362);

Fig. 363. An arrangement of hoses: 1 — to a regulator of pressure of pressurisation in a control mean; 2 — forced air; 3 — a cooling liquid (to a broad tank); 4 — штекерная колодка the gauge of temperature of let in air; 5 — the top hose of a cooling liquid





- Disconnect 363 hoses shown on fig. and штекерную колодку;
- Disconnect vacuum hoses from an inlet pipe turbochargerа and from the system valve рециркуляции ОГ (valve EGR);
- Disconnect топливопроводы and the vacuum pipeline from the vacuum pump;
- Disconnect an electric cable from the generator and separate the tip of the fuel pump of a high pressure (ТНВД);

Fig. 364. Disconnect штекерные колодки: 1, 2 — the gauge of position of a cranked shaft; 3 — a plait of wires of the engine





- Separate штекерные колодки 1 and 2 (fig. 364) the gauge of position of a cranked shaft, штекерную колодку a plait of wires of the engine 3. For this purpose remove corresponding spring collars to liberate all cable;
- Separate штекерную колодку the switch of lanterns of a backing;
- Disconnect "a mass" cable from a transmission. Disconnect the pipeline of system of coupling for what remove a spring collar and release coupling. Закупорьте the open ends of pipelines;

The prevention
At performance of operation pay attention to a following brake liquid.

- Disconnect the hoses of a cooling liquid going to a broad tank and a heater;
- If by the car the conditioner separate штекерную колодку electromagnetic coupling is established;
- ослабьте поликлиновой a belt as it will be described further;
- ослабьте bolts of fastening of wheels. Establish a forward part of the car on support and remove forward wheels;
- Remove a forward suspension bracket of the right wheel:

Fig. 365. A suspension bracket of a forward wheel. Connecting draught 1 connects the stabilizer of cross-section stability with амортизаторной a rack





- Disconnect draught 1 (fig. 365) the stabilizer of cross-section stability;
- Disconnect a brake hose and remove gauge ABS cable (shows frequency of rotation of a wheel) from the holder on амортизаторной to a rack;
- Turn away a nut of a bolt of cross-section steering draught on сошке a wheel and remove the hinge by means of a stripper with сошки a wheel;
- Turn on in the bottom part of a suspension bracket of a wheel two bolts and wring out the spherical hinge of a suspension bracket from the case of the bearing of a wheel (a rotary fist);
- Perform the described operations and on a car left-hand side;

Fig. 366. Steering removal. Adhere steering draughts at the left and on the right by means of wire loops that they have not fallen





- Adhere steering draughts a wire as it is shown on fig. 366, to both амортизаторным to racks. Now turn away a steering from a cross-section beam, and draughts remain to hang on a wire;
- Turn off балансирную a suspension bracket from outside transmissions;

Fig. 367. The cross-section beam of a forward suspension bracket fastens in the places shown by arrows





- Substitute a jack with a suitable support under a cross-section beam, lift a jack so that it has raised a cross-section beam, and turn away it in the places shown on fig. 367;
- Merge трансмиссионное oil. Clear a stopper, and then at once again screw it;

Fig. 368. Turn away the basic bearing of 1 right power shaft and squeeze out a shaft from a transmission in the shown place 2





- Remove from a transmission a shaft of a drive of the right wheel. At first turn away the persistent bearing 1 (fig. 368) and after that extend a shaft in a place 2 of шлицевого connections with a transmission.

The prevention
At performance of operation the car should be established on support.


Fig. 369. Removal of the left shaft of a drive of a wheel





Take a shaft of a drive of the left wheel by means of the inserted mount (fig. 369).
Disconnect cables of a gear change from a transmission. The ends of cables are fixed by means of clamps. After removal of clamps take both cables in a direction upwards from their holders.

Fig. 370. The reception pipe fastens to the catalyst in the places specified by arrows





Turn away three bolts (fig. 370) and separate a reception pipe from a catalyst flange.
Disconnect an exhaust pipe from turbochargerа (4 bolts).
Disconnect a hose from the heating pipeline (hose connection).

Fig. 371. Disconnect hoses 1 from turbochargerа and 2 — from a vacuum box and liberate them from fastenings





Disconnect hoses from turbochargerа 1 (fig. 371) and a vacuum box 2 and release them from hose fastenings.
Turn on the holder of the pipeline of the pump of the hydraulic booster of a steering (it is located nearby from a pulley on cranked to a shaft). Turn away a pulley of a drive of the pump of the hydraulic booster. To fix a pulley in motionless position, insert suitable face шестигранный a key into an internal part of a shaft of the pump.
Turn away bolts of fastening of the pump of the hydraulic booster of a steering (one of bolts is located in its bottom part), remove the pump, take him aside and adhere a wire.

Fig. 372. Removal of the compressor of the conditioner





If on the car the conditioner remove the compressor is established. At first turn by means of a wrench 1 (fig. 372) a tension roller приводного a belt in a direction shown by an arrow, so that приводной a belt ослаб. After that turn away bolts 2 and 3 and remove the compressor so that not to damage thus any pipelines.

The prevention
Pipelines do not disconnect.

Substitute a jack under the power unit.

The prevention
Be convinced of that the power unit is well fixed.

Turn away four bolts of a back engine mount.

The prevention
Once again check up that the engine is reliably fixed.

The note
In car-care centre for an engine raising the special device under which then the automobile lift is substituted is used. On fig. 21 it has already been shown, how the engine is supported from below, i.e. it is necessary to prop up reliably the engine a jack that it after untwisting of fastenings of an engine mount remained in former position. To provide it, it is necessary for you to have at the order the crane with a manual drive. Arrange a crane arrow over a motor compartment and fix the engine with the help строповочных loops on a crane hook. If the jack casually slides off, the arrow will keep the engine in former position.


Fig. 373. Fastenings of a forward support (are shown by arrows)





Turn away fastening of a forward support of the engine (fig. 373).
Slowly lower the engine downwards. For this purpose the assistant who will lower an automobile jack or the crane while you will continuously watch process of lowering of the engine through a motor compartment is required to you. If the engine for something is hooked, it should be liberated at once to avoid damage of details of a body or other knots and units. It concerns first of all the removed and tied up details. Besides, if there is such possibility, it is possible to raise a forward part of the car to have more spaces for engine removal.
Engine installation is carried out in sequence, to removal process, however it is necessary to pay attention of return to following moments:
- Check up on deterioration выжимной the coupling bearing in the working cylinder of coupling. In case of need replace the working cylinder together выжимным with the coupling bearing. On their cars considered in the book always it is necessary to change together;
- Put on шлицевое connection of a shaft of coupling of a few lubricant. Volkswagen recommends to use in this place greasing with designation G 000 100;
- Establish the engine and a transmission in correct position in a motor compartment of the engine. At lifting of the power unit pay attention, that it has not touched power shafts and be necessarily convinced that the engine together with a transmission is well fixed on a jack or the lift. As it has already been told, thus it is the most convenient to use the crane with a manual drive and an arrow;
- After the engine will be levelled concerning engine mount fastenings, tighten fastening bolts (approximately on 5–6 turns). Shake the engine here and there (it should not be definitively drawn yet) a little and tighten bolts of forward and back fastenings of an engine mount. Tighten fastening of a forward beam of a suspension bracket, and also an arm of a back suspension bracket the moment 55 Нм (in front in the hydraulic bearing).
Establish shaft of a drive of wheels and tighten bolts the corresponding moment.
Tighten bolts of fastening of the pump of the hydraulic booster of a steering the moment 25 Нм. Do not forget about a bolt in the bottom part of fastening of the pump. Establish a pump pulley, having fixed in motionless position a shaft of the pump of the hydraulic booster of a steering with the help шестигранного a key, and tighten three bolts the moment 23 Нм. Tighten an arm fixing the pipeline of the pump of the hydraulic booster of a steering (20 Нм).
At installation of an exhaust pipe on turbocharger, and also in a junction of an exhaust pipe and the catalyst use new linings.
Insert a shaft of a drive of the right wheel into a transmission and tighten the persistent bearing (27 Нм).
Before installation of a shaft of a drive of the left wheel replace the persistent ring located on the end of a shaft.
Again establish a cross-section beam in correct position and tighten 367 four bolts shown on fig. the moment 110 Нм.
Establish балансирную a suspension bracket on a transmission. Tighten a bolt on an outer side the moment 95 Нм.
Remove a steering from a wire and fasten from below to a cross-section beam. Bolts are tightened by the moment 50 Нм.
Establish a wheel suspension bracket (fig. 365 see). Tighten both bolts of the spherical hinge the moment 55 Нм, a nut of the hinge of cross-section steering draught the moment 30 Нм, a nut of fastening of connecting draught tighten the moment 100 Нм. Perform the described operations from both parties of the car.
Lower the car on a ground and tighten bolts of fastening of wheels (140 Нм).
Put on поликлиновой a belt, release a tension roller that he has pulled a belt.
Connect the pipeline to the working cylinder of coupling and fix its spring clip. Remove air from coupling system.
Establish details of the air filter in return sequence concerning removal process.