Repair VW Sharan

. Diesel engines: 1,9 l TDI.
+ 1. Introduction
+ 2. Engine VR6
- 3. The two-litre engine (ADY)
   3.1. Removal and installation
   + 3.2. Dismantling and assemblage
   + 3.3. A head of the block of cylinders and valves
   - 3.4. Pistons and rods
      3.4.1. Removal
      3.4.2. Measurement of internal diameter of the cylinder
      3.4.3. Check of pistons and rods
      3.4.4. Gauging of a backlash of a rod
      3.4.5. Assemblage of pistons and rods
      3.4.6. Installation of pistons and rods
   3.5. The block of cylinders
   + 3.6. A cranked shaft and radical bearings
   + 3.7. A mechanism drive газораспределения
   3.8. Tension adjustment приводного a belt of units of the engine
   3.9. An intermediate shaft
   3.10. Compression check in engine cylinders
   3.11. System of release of the fulfilled gases
   3.12. System of clearing with application of the activated coal
   3.13. System рециркуляции the fulfilled gases
+ 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>> The two-litre engine (ADY)>> Pistons and rods>> Removal
Pistons and rods are beaten out from the block of cylinders in a direction upwards by the hammer handle, after removal of covers and loose leaves шатунных bearings.
Before carrying out of these works it is necessary to observe following recommendations:

Fig. 130. Marks of the bottom of pistons before their removal

- Put marks (it is desirable colour) on each piston and a rod concerning it. It is necessary to specify that number of the cylinder from which the piston and a rod have been removed. On the piston is better to put number of the cylinder and an arrow specifying a direction towards a forward part of the engine at the bottom of the piston (fig. 130);

Fig. 55. Marks of a rod and a cover of the bearing of a rod

Fig. 56. Assemblage of a rod and a cover of the bearing of a rod. By arrows ledges are shown

- Right after removals put on a rod and a cover of the bearing of a rod sideways cylinder number (fig. 55 see). Is better to do it кернером (for example, for the cylinder №1 — one blow кернером etc.). The rod and a rod cover should be collected so that both cast ledges have been located opposite each other (fig. 56 see);

The prevention
Both cast ledges after rod installation always should be located from outside a pulley of a cranked shaft.

- Mark bearing loose leaves according to a rod and a rod cover. Also mark with colour the top and bottom loose leaves of the bearing on their back party;
- If it is necessary to replace pistons, right after dismantlings measure length of a finger of the piston. As shows experiment, this size can be another on new pistons, therefore it is necessary to select necessarily pistons with fingers of that length which old fingers of pistons had;
- At the order of new pistons specify model of the car and its year of release;

Fig. 131. A piston kind in a cut: a = 21,3 mm; b = 5,0 mm; c = 62,9 mm; d = 21,0 mm

- The geometrical sizes of pistons differ among themselves, therefore if establish the piston, for example from the old engine it is necessary to measure size b (fig. 131) which differs depending on the engine. Established pistons should have identical value b. Various pistons have differences and on size and;
- Diameters of pistons are presented in the table of adjustments and the control.
Removal of pistons spend in a following order:
- Remove covers of rods and loose leaves and beat out details. In case of need scratch out a scraper an oil deposit on the top part of the cylinder. For this purpose turn a cranked shaft a little to lower the piston more deeply in a cylinder aperture. Be cautious not to scratch a scraper the cylinder;

Fig. 57. Removal of a spring lock ring of a piston finger

- By means of a sharp subject or a small punch (fig. 57 see), remove the spring lock rings located on each party of a piston finger. The dredging which is available in an aperture for a piston finger, facilitates punch application;
- With the help оправки beat out a piston finger. At blow watch that оправка has not jumped out and has not struck on the piston;

Fig. 58. Removal of a piston ring by means of a stripper

- Mark piston rings (if they are again established) and remove them through the bottom of the piston by means of a stripper (fig. 58 see). At first it is necessary to remove the top piston ring;

The prevention
At all do not unclench piston rings too strongly.

Fig. 59. Removal of a piston ring by means of metal strips

- If the stripper for piston rings is not present, it is possible to insert under piston rings metal strips the friend opposite to the friend (fig. 59 see). One of metal strips enclose under the lock of a piston ring to avoid occurrence of scratches on a piston surface;

The note
Piston rings accurately pull out from piston flutes by means of a small screw-driver as they very easily break.

- Remove piston rings and hang up on them labels with cylinder number. At survey of piston rings be convinced that on one of the parties there is a mark «Oben» or "Top". At installation of piston rings this inscription should be visible from outside the piston bottoms.

Fig. 132. Details of shatunno-piston group: 1 — piston rings; 2 — a lock ring; 3 — a piston finger; 4 — the piston; 5 — a rod; 6 — a bolt of fastening of a rod; 7 — the loose leaf of the bearing of a rod; 8 — the block of cylinders; 9 — a cover of the bearing of a rod; 10 — a rod nut; And — labels on a rod and a cover; In — position of cast ledges

Details of shatunno-piston group of the engine are presented on fig. 132. The special attention should be turned on the places having letter designations A and B which specify in important points on an arrangement and orientation of details of shatunno-piston group.