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>> Engine assemblage
Engine assemblage, as well as dismantling, will be described in separate subsection. Sequence of actions at assemblage return concerning dismantling. However at each assemblage it is necessary to observe following recommendations:
- Details should be pure;
- Always grease any rotating or sliding details. It is necessary to do it before assemblage (instead of after details are already established) then oil will get to all necessary places. Especially important plentifully to grease with engine oil pistons, piston rings and walls of cylinders before assemblage;
- Carefully clear all parts of the block of cylinders if there was a full dismantling of the engine. At partial dismantling watch that in the disassembled engine or foreign matters have not got to its cavities. Stop up all apertures with pure rags to avoid it;
- Blow oil channels the compressed air. If you do not have such possibility clean oil channels and apertures a wooden stick, but at all do not do it by metal subjects.
In the table with the data for adjustment and the control borders of deterioration of the majority of mobile details are resulted. If you have doubts concerning any detail or the deterioration border will be soon reached, it is better to replace such detail to avoid repeated dismantling of the engine.
Further assemblage of the engine after its full dismantling is described. Thus we recognise that all details of the engine have been repaired or replaced according to the instructions resulted in following sections. Besides, we assume that separate constructive groups as, for example a head of the block of cylinders, are already collected.
Establish oil atomizers in the block of cylinders. Tighten bolts of fastening of atomizers the moment 10 Нм.

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)




Tighten a gear rim of the gauge of frequency of rotation of a cranked shaft. Bolts should be changed for the new always. The adjusting pin (rice 383 see) is inserted into a cranked shaft, this pin should to act on certain size from a surface of a cranked shaft (2,5—3,0 mm). Therefore before to fasten a gear rim (the moment 10 Нм), measure distance on which the adjusting pin acts.
Grease all working surfaces of bearings of a cranked shaft with engine oil and put a shaft on the enclosed loose leaves of bearings. Cautiously put a cranked shaft in bearings and establish adjusting washers at the left and to the right of the average bearing. Lubricant flutes of adjusting washers should settle down against a basic surface of a cranked shaft.
Establish in the block of cylinders according to labels of a cover of radical bearings (loose leaves of bearings should be inserted and well greased) and оббейте their plastic or rubber hammer.
Twist bolts of covers of radical bearings and tighten them in regular intervals from the middle outside the moment 65 Нм. From final position turn each bolt, again from the centre outside, for 90 (a turn quarter).

The prevention
Use only new bolts.

Check up an axial backlash of a cranked shaft as it is described in item 17.9.1.
Establish pistons and rods (item 17.5.5 see).
Впрессуйте a new epiploon outside in a flange of an intermediate shaft.
Grease basic necks of an intermediate shaft and insert an intermediate shaft in картер. Establish a new sealing ring in a flange of a shaft and establish a flange. Tighten both bolts the moment 25 Нм.

Fig. 384. Bolts of an epiploon of 1 cranked shaft and a flange 2 intermediate shaft should be tightened the moment 25 Нм





Beat out an epiploon from the case of a forward epiploon. Insert the case without an epiploon into the block of cylinders. Tighten 4 bolts the moment 25 Нм. On fig. 384 the way of its fastening is shown.
Establish a new forward epiploon as it is described in item 17.9.3.

Fig. 385. The shown flange of an epiploon on the back party of the engine is necessary for changing together with an epiploon. Tighten bolts (are shown by arrows) the moment 10 Нм




After that fasten the case of a back epiploon with a new lining. Tighten 385 bolts shown in drawing the moment 10 Нм.

The prevention
It is impossible to replace a sealing ring separately — it is necessary to establish all flange of an epiploon.


Fig. 386. The established oil pump. Tighten bolts the moment 25 Нм





Attach the oil pump to the bottom part картера (2 bolts, 25 Нм). On fig. 386 places of their fastening are shown.
Establish oil картер with a new lining. Tighten bolts on a circle the moment 20 Нм.
Establish an intermediate plate of the engine (3 bolts, 10 Нм).
Establish a flywheel. Bolts should be tightened in regular intervals cross-wise the moment 60 Нм. From final position turn all bolts for 90 (a turn quarter) (without using thus динамометрический a key).

The prevention
Use only new bolts.

Establish coupling as it is described in corresponding section. Thus the flywheel should be fixed in motionless position.
Establish a cogwheel of a cranked shaft. Grease a bolt. Fix a cranked shaft in motionless position, without allowing to be turned by a flywheel, and tighten a bolt the moment 90 Нм. From final position turn a bolt for 90 (without using thus динамометрический a key).

The prevention
Use a new bolt.

Put on a cogwheel of an intermediate shaft a shaft. On a shaft already should be segment шпонка. Fix a cogwheel in motionless position and tighten a bolt the moment 45 Нм.
Establish the details which have been removed on the left side of the engine. Tighten the gauge of position of a cranked shaft the moment 10 Нм, and ventilation connection картера the moment 25 Нм.
Establish the vacuum pump with a new sealing ring (20 Нм).
Establish the basis of the oil filter with a new lining (3 bolts, 25 Нм).

Fig. 387. Installation of an arm of 1 fuel pump of a high pressure and an oil radiator 2





Fasten an arm of 1 fastening ТНВД (fig. 387) three bolts. Tighten bolts the moment 20 Нм, and then tighten for 90 . Establish an oil radiator with a new lining. Tighten a nut in the bottom part of an oil radiator the moment 25 Нм.

Fig. 388. Bolts of a bearing arm of fastening of units are located in the shown places, figures specify 10 times inhalings of bolts of fastening





Establish bearing arm of units. Replace a sealing ring of the block of cylinders. Establish an arm on directing apertures and twist five bolts. Attach a hose of a cooling liquid to an oil radiator. Thus fasten also the oil filter (subsection 18.3). Tighten bolts of a bearing arm of units in the sequence shown on fig. 388, the moment 25 Нм.
Measure, pistons (item 16.3.5 see) how much act and pick up a lining of a head of the block of cylinders according to the received value of measurement.
Establish a head of the block of cylinders (item 16.2.5).
Establish an inlet collector with a new lining and fasten its six bolts (25 Нм).
Establish new linings of an exhaust pipe so that they looked закруглениями upwards, establish a pipe together with turbochargerом and fasten them (25 Нм). Establish a hose рециркуляции oils, tighten a hollow bolt of ring connection (30 Нм) and fasten the screen of thermal protection (two nuts).
Connect the oil pipeline turbochargerа (накидная a nut). Tighten its moment 25 Нм. Tighten a hollow bolt in a head of the block of cylinders the moment 25 Нм.
Tighten the connecting pipeline of system рециркуляции ОГ (25 Нм).
Connect штекерную колодку additional heating.

Fig. 389. Installation of atomizers and candles накаливания: 1 — the tension holder, 22 Нм; 2 — candles накаливания, 15 Нм; 3 — a wire tip





Establish atomizers together with solderings. Tighten solderings by the moment 22 Нм. On fig. 389 it is shown, where atomizers fasten.
Screw candles накаливания. Tighten their moment 15 Нм (fig. 389 see). Connect штекерную колодку the gauge of temperature of a cooling liquid on the right side.
Fasten the electric tyre of candles накаливания and establish hoses oil plum.

Fig. 381. Details which are necessary for removing: 1 — the switch of pressure of oil; 2 — the gauge of temperature of oil; 3 — the gauge of position of a cranked shaft; 4 — the gauge of lifting of a needle; 5 — a hose of a cooling liquid





Connect all wires to gauges (fig. 381 see). Штекерная колодка with a dark blue/black wire it is established on the dark blue switch of pressure of oil, штекерная колодка with a yellow/black wire it is established on the grey switch of pressure of oil.
Establish ТНВД (the corresponding section see).
Establish internal protection gear приводного a belt (2 bolts in a head of the block of cylinders, 1 bolt on the fuel pump of a high pressure).
Establish cogwheel ТНВД. At first put on segment шпонку. Fix a cogwheel in motionless position and tighten a nut the moment 55 Нм. Twirl also a tension roller gear приводного a belt, without tightening it it is definitive.
Establish поликлиновой a belt as it is described in corresponding section. Having fixed a camshaft cogwheel in motionless position, tighten a bolt of fastening by the moment 45 Нм.
Connect pipelines of giving of fuel to injection system. Tighten накидные nuts the moment 25 Нм. Connect located nearby штекерную колодку.
Establish a cover of a head of the block of cylinders. Use a new lining. Tighten nuts the moment 10 Нм and put on safety caps. Connect a ventilating hose. After that establish protection gear приводного a belt now.
Fasten a forward collar of an engine mount. Tighten bolts the moment 60 Нм.
Establish the generator (25 Нм).
Put on a pulley of a cranked shaft through an adjusting pin a distributive gear wheel of a cranked shaft and twirl bolts. Tighten bolts the moment 25 Нм. Fasten a pulley of the water pump (23 Нм).
Fasten the persistent bearing of a power shaft (43 Нм) and a basic collar turbochargerа (25 Нм).
Spend all works not mentioned specially in return sequence, concerning dismantling process.