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
      17.2.1 General dismantling
      17.2.2. Engine 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>> Dismantling and assemblage>> The general dismantling
Before the dismantling beginning carefully clear the engine outside. Stop up all apertures of the engine with pure rags not to admit hit in the engine of foreign matters.
The engine has the top arrangement of a camshaft. A camshaft drive a gear belt. The block of cylinders is cast from pig-iron, a head of the block of cylinders the aluminium.
In comparison with diesel engines which were established earlier, it has some changes in a design:
- Head of the block of cylinders, saddles of valves, valves and combustion chambers are made of materials which maintain more a heat;
- Special nozzles (atomizer) spray oil on the bottom part of pistons, cooling them;
- The design of pistons is changed;
- The forward end of a cranked shaft is modified;
- The oil radiator is located between the oil filter and a filter flange;
- In connection with installation turbochargerа the system of release of the fulfilled gases and inlet system have been modified.

The prevention
All diesel engines are very sensitive to a dirt, therefore at carrying out of any works in the engine watch that the dirt or other foreign matters have not got to apertures of pipelines and a place of their connections. Is better to stick at once all fuel pipelines, hoses and other apertures with a sticky tape.
Engine dismantling is in detail described in подразд. 17.3—17.10. Thus, we can consider works which can be spent or on the established engine, or on removed, without describing thus any operation on engine dismantling twice. If full dismantling of the engine simply it is necessary to combine separate operations with each other in the specified sequence is spent.
At dismantling it is necessary to mark an arrangement of all demountable parts and details that at assemblage to establish them in a starting position in the event that they will be repeatedly used. Especially important it for pistons, valves, covers and loose leaves of bearings. Combine details so that not to mix them.

The prevention
Do not mark bearings and consolidations by scratches on their surface or кернением. Many of details are executed from an easy alloy and consequently with them it is necessary to address accurately. If for removal of any detail it is necessary to use a hammer it can be only the hammer rubber, plastic or fitted by a skin.

If there is a possibility establish the engine at the corresponding assembly stand. At engine dismantling operate in the following sequence:
- Remove an arm of the persistent bearing of a power shaft, and also turbochargerа;
- Merge engine oil.

Fig. 374. At carrying out of any works on dismantling disconnect: 1 — bolts of fastening of an inlet pipe; 2 — an air hose from turbochargerа; 3 — a hose of forced air from inlet system; 4 — a ventilation hose картера

Following details remove from the engine, being guided by fig. 374:
- Turn away bolts 1 and disconnect an inlet pipe from turbochargerа;
- Disconnect an air hose 2 from turbochargerа and a radiator of forced air;
- Disconnect a hose of forced air from inlet system 3;
- Disconnect a ventilation hose картера 4 from the oil filter.
Disconnect the pipeline of a cooling liquid and remove a hose of a cooling liquid from the holder and an oil radiator.
Remove a hose collar from outside a flywheel and disconnect the pipeline of a cooling liquid.

Fig. 375. Remove гаситель крутильных fluctuations of a cranked shaft 1 and a pulley of the pump of the hydraulic booster of a steering 2. The pulley of the pump of the hydraulic booster of a steering can be fixed in motionless position with the help шестигранника

Remove located in a forward part of the engine a pulley of a cranked shaft (4 bolts) and a pulley of the pump of the hydraulic booster of a steering (fig. 375).

Fig. 376. Generator fastening. From below it is visible натяжитель клинового a belt

Remove the generator (fig. 376).
Turn away four bolts of fastening of a collar of an engine mount and remove it.

Fig. 377. Fastening of safety covers поликлинового a belt: 1 — the top cover; 2 — the bottom cover

Remove the top cover поликлинового a belt. It fastens spring collars 1 (fig. 377). Turn away the bottom cover. It fastens three bolts 2.

Fig. 378. Removal поликлинового a belt: 1 — a tension roller gear приводного a belt; 2 — a directing roller gear приводного a belt

Remove поликлиновой a belt. If you plan to establish again an old belt, mark a movement direction поликлинового a belt, having put a colour label on its surfaces. Turn away a nut and wring out a tension roller 1 (fig. 378) aside. Remove directing roller 2. Remove a gear belt. Remove the device for a belt tension.
Uncover heads of the block of cylinders. Disconnect a ventilation hose картера from the bottom connection and leave it on a cover of a head of the block of cylinders. Remove the safety caps located over nuts of fastening of a cover of a head of the block of cylinders, turn off nuts and uncover.

Fig. 379. A way of fixing of a cogwheel of a camshaft

Fix a camshaft pulley in motionless position, remove it. The emphasis intended for it is shown on fig. 379. To use a stripper for this operation it is impossible, it is possible to insert оправку through an aperture of the metal wall located behind a wheel and to force down a pulley on a circle.
Remove cogwheel ТНВД. It should be removed by means of the special three-contact stripper which teeth should be inserted into apertures on a pump cogwheel. At first turn off a cogwheel nut. For cogwheel fixing in a motionless condition insert оправку into an aperture on a cogwheel of the pump and keep it, having rested оправку against the block of cylinders.
Turn away two bolts on a head of cylinders and a bolt on ТНВД and remove internal protection поликлинового a belt.
Take out щуп for measurement of level of oil in the engine.
Disconnect a wire tip запорного the valve of fuel and from the electromagnetic valve of adjustment of injection.
Turn on топливопроводы a high pressure from atomizers and ТНВД. They fasten with the help накидных nuts.
Remove ТНВД. For this purpose turn on two nuts on the one hand and a bolt with a nut on the other hand.
After that disconnect various wires and hoses. They are shown in drawing 380:
- Separate штекерную колодку the switch of 1 pressure of oil;
- Separate штекерную колодку the gauge of 2 temperatures;
- Remove from an arm штекерную колодку the gauge of 3 positions of a cranked shaft;
- Disconnect штекерную колодку the gauge 4 liftings of a needle from the holder;
- Disconnect a hose 5 cooling liquids from the distributive chamber of a head of the block of cylinders.
Turn away the electric tyre of candles накаливания and disconnect hoses oil plum.
Ослабьте fastenings of atomizers also remove atomizers from a head of the block of cylinders.
Unscrew candles накаливания.
Separate штекерную колодку the gauge of temperature of a cooling liquid.
Ослабьте located nearby from turbochargerа a hollow bolt, ring connection, накидную a nut on turbochargerе also turn off connection. Separate штекерную колодку additional heating, remove a plait of wires on the engine and turn off the connecting pipeline for рециркуляции ОГ (4 bolts).
Remove final a pipe and turbocharger. At first release a hollow bolt of ring connection of the oil pipeline, then turn off the screen of thermal protection of an exhaust pipe (2 bolts) and after that turn away 8 bolts of fastening of an exhaust pipe.
Turn away 6 bolts of fastening of a final collector and remove it.

Fig. 382. An order of untwisting of bolts of a head of the block of cylinders. At installation of a head of the block of cylinders bolts tighten in return sequence

Turn away bolts of fastening of a head of the block of cylinders in regular intervals in return sequence concerning an order of an inhaling of bolts (fig. 382) and take out them. For отворачивания bolts it is necessary special шестигранный a key without which it is possible to damage an internal part шестигранной heads of bolts so they cannot be turned out. Remove a lining of a head of the block of cylinders.

The prevention
Bolts are unsuitable to repeated application and are subject to replacement by the new.

Remove an arm of fastening of auxiliary units and the oil filter.
Turn on скобу fastenings ТНВД (3 bolts) and remove an oil radiator (one nut, in the centre).
Turn away three bolts in the basis of the oil filter and remove the basis of the oil filter. Remove a tension plate of the vacuum pump and remove the pump.
Remove the knots established on a left-hand side of the engine: ventilation connection картера (2 bolts), the gauge of position of a cranked shaft (1 bolt, 1 spring clip) and щуп for measurement of level of oil in the engine.
Fix a cranked shaft in motionless position, having inserted into a gear wreath a screw-driver. Turn on in regular intervals cross-wise 6 bolts of fastening of coupling so that they could be taken out. After that completely remove coupling.
Remove from a face sheet of the engine cogwheels of cranked and intermediate shaft. Fix cranked and intermediate shaft in motionless position.
Fix in motionless position a flywheel and turn away 6 bolts of its fastening.
Turn away an intermediate plate of the engine.
Turn the engine and turn on oil картер (20 bolts). Remove a lining.
Turn away the oil pump located in the bottom part картера and remove it.
Turn away six bolts and remove a back flange of a sealing ring. Remove a lining.

The prevention
The flange is unsuitable to repeated application and are subject to replacement by the new.

Turn on from the forward party of the engine a flange of an epiploon of a cranked shaft. Remove a lining. Beat out an epiploon.
Turn away a flange of an intermediate shaft and wring out a flange. Under a flange there is a sealing ring. Remove a shaft from the engine.
Turn a cranked shaft so that two rods were in the bottom dead point. Mark covers of bearings of a rod, having put on them numbers of cylinders (colour) and by turns turn away a cover of bearings. Take by turns rods together with pistons in a direction upwards from a cylinder aperture. Pay attention, that loose leaves of bearings and a cover of bearings have been attached at once to corresponding rods.
Remove a cranked shaft. Bearing covers in this case are marked by numbers (№ 1 – from outside pulleys, № 5 – from outside a flywheel). Look subsection 17.9.

Fig. 383. A flywheel: 1 — a gear rim; 2 — bolts of fastening of a gear rim; 3 — the adjusting screw (should act on distance a)

Turn away the gear rim serving for definition of frequency of rotation of a cranked shaft, from a sock of a cranked shaft. On fig. 383 the way of its fastening is shown.
Remove from the bottom part картера oil atomizers (turn away bolts).