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>> Installation of pistons and rods
Installation of pistons and rods spend in a following order:
- Plentifully grease with engine oil internal surfaces of cylinders;

Fig. 63. Details of piston group: 1 — компрессионные piston rings; 2 — маслосъемное a ring; 3 — the piston; 4 — a rod cover; 5 — a bolt of fastening of a rod; 6 — rod loose leaves; 7 — a rod; 8 — the block of cylinders; 9 — a lock ring; 10 — a piston finger; arrow A specifies a direction to a forward part of the engine





- Spread out all rods according to numbers of cylinders. Cast ledges on a rod and a rod cover should be directed towards a pulley of a cranked shaft (fig. 63 see). After installation of rods cast ledges should be located on other party of an arrow;
- Arrows should specify in the bottom of pistons in a direction of a forward part of the engine;

Fig. 134. An arrangement of locks of piston rings rather each other





- Arrange locks of piston rings rather each other at an angle in 120 on a cylinder surface (fig. 134);

Fig. 66. Installation of the piston by means of special tool VW3278





- Put on a coupling tape collar 3278 piston rings on the piston (fig. 66 see), and press piston rings into piston flutes;

Fig. 67. An alternative coupling tape collar for installation of pistons





- For this purpose it is possible to use the replacement tool applied by firm "Volkswagen" — a coupling tape collar (fig. 67 see);
- Check up that piston rings have completely entered into the flutes;
- Turn a cranked shaft so that two шатунные necks of a cranked shaft have appeared in НМТ;
- Establish the loose leaf of the bearing of a rod in a rod;
- Insert a rod from above into a cylinder aperture. For this purpose put the engine sideways so that the rod could be directed on шатунную a neck. Watch, that the aperture of the cylinder and a rod neck thus have not been scratched;
- Insert pistons so that piston rings have by turns entered into apertures of cylinders and a heel of a rod of village on шатунную a neck of a cranked shaft;
- Insert the second loose leaf into a bearing cover, so that the unbent short moustache of the loose leaf of villages in a groove of a cover of the bearing. Grease surfaces of loose leaves with engine oil;
- Press a rod cover to a rod and easily knock on it. Grease with engine oil bolts of fastening of a rod and screw them;

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





- Necessarily once again be convinced that both cast ledges are located together (see fig. 56). Both cast ledges on a rod and a rod cover should be located opposite each other and specify in a direction to a pulley;
- Alternately tighten bolts of fastening of the bearing of a rod the moment 30 Нм then tighten them for 90 (on a turn quarter);
- After rod installation turn a cranked shaft some times to be convinced that it rotates easily, without jammings;
- Once again check up marks of all rods to be convinced that cтрелки pistons specify in a correct direction;

Fig. 68. Measurement of an axial backlash between a lateral plane of the bearing of a rod and a lateral surface of a cranked shaft





- With the help щупа (fig. 68 see) measure an axial backlash of the rods established on a cranked shaft that it was possible to estimate degree of deterioration of details. For this purpose press a rod to one side that it was possible to insert щуп. If it is possible to insert щуп in the thickness more than 0,37 mm most likely rods were erased in pressing places. At worst places of pressing of a cranked shaft were erased;
- Establish oil картер (see подразд. 4.1);
- All further works on assemblage are made in an order, the return to dismantling.