VW Sharan repair

. Diesel engines: 1,9 l of TDI.
+ 1. Introduction
+ 2. VR6 engine
+ 3. Two-liter engine (ADY)
+ 4. System of greasing of the engine
+ 5. Cooling system
+ 6. System of injection of fuel of the VR6 engine
+ 7. Simos system of injection of fuel of the 2,0-liter engine
+ 8. Ignition system
+ 9. Coupling
- 10. Mechanical 5-step transmission
   - 10.1. Removal and installation
      10.1.1. Removal
      10.1.2. Transmission installation
   + 10.2. Gear shifting mechanism
   10.3. Check of level of oil in a transmission
+ 11. Shaft of a drive of wheels
+ 12. Hydraulic booster of a steering
+ 13. Forward suspension bracket
+ 14. Back suspension bracket
+ 15. Brake system
+ 16. Electric equipment
+ 17. Diesel engine
+ 18. System of greasing of the diesel engine
+ 19. System of cooling of the diesel engine
+ 20. Power supply system of the diesel engine and turbokompressor
+ maintenance Card
+ Specifications and characteristics
+ Elektroskhema




Repair Sharan/Sharan Volkswagen>> Mechanical 5-step transmission>> Removal and installation>> Transmission installation
Installation of a transmission carry out as it should be, the return to removal, observing the next moments:
- shlitsevy connections of a power shaft clear and process G 000 100 lubricant;
- if the conducted disk was removed, he needs to be put on shlitsa of primary shaft of a transmission and to check, as far as it easily slides forward-back on a shaft;
- at installation of a transmission check correctness of an arrangement of an intermediate plate of the engine and put on a transmission directing plugs;
- check, whether there are in the block of cylinders directing plugs for its centering with a transmission. Otherwise take out directing plugs from a transmission and insert them into the block of cylinders;
- lift a transmission on an automobile jack, expose it in the correct situation, get in coupling and put on directing plugs of the engine. In case at installation primary shaft of a transmission does not enter in a shlitsa of a nave of a conducted disk of coupling, ask the assistant to turn a little by hand a cranked shaft forward-back, having pulled for this purpose for maple a belt. As soon as the transmission will appear opposite to the engine, screw and easily tighten one of fastening bolts;
- screw other bolts of fastening the transmissions located on the bottom surface and tighten them the moment of 80 N · m;
- establish a starter, wrap its bolts of fastening and tighten them the moment of 45 N · m;

Fig. 246. The locations of bolts of fastening (are shown by shooters) suspension bracket arm on a transmission





- mount arm fastening (see fig. 246 ) suspension brackets of a box of transfer and previously wrap bolts by hand;

Fig. 245. Locations of bolts (1 and 2) fastenings of a suspension bracket of a transmission





- adjust position of the engine and a transmission relatively each other and wrap by hand suspension bracket fastening (see fig. 245 );

Fig. 244. Fastening of a balansirny (pendular) suspension bracket of a transmission: 1 — a balansirny suspension bracket; 2 — bolts and nuts of fastening of a balansirny suspension bracket





- mount balansirny (pendular) (see fig. 244 ) a transmission suspension bracket. Wrap bolts and nuts and tighten them the moment of 100 N · m;
- tighten a bolt 1 (see fig. 245 ) suspension bracket fastenings by the moment of 20 N · m, and a nut on a bolt the 2nd moment of 100 N · m;
- tighten bolts (see fig. 246 ) suspension bracket fastenings by the moment of 90 N · m;
- establish a new persistent ring for the end of the left power shaft;
- insert the left power shaft into shlitsa and a short push move it, if necessary strike on the external end of a shaft with a plastic hammer so that the lock ring rose in a groove on inside of a gear wheel of differential;
- insert into a wheel nave the external end of the left power shaft;
- establish a new persistent ring for the end of the right power shaft;
- insert the right power shaft in the same way, as well as left. The lock ring should rise in the groove and be latched;
- establish a lock ring of an intermediate shaft;

Fig. 247. Fastening bolts (are shown by shooters) bearing of an intermediate shaft





- insert an intermediate shaft (fig. 247) , if necessary hammer a shaft with a plastic hammer;
- tighten fastening of the bearing of an intermediate shaft by the moment of 27 N · m;
- establish connecting draft with an amortization rack. Tighten a nut the moment of 100 N · m;

Fig. 242. The location of fastening of the bearing lever of a suspension bracket to a rotary fist (it is shown by an arrow)





- connect the case of the bearing of a wheel (a rotary fist) to a spherical support and tighten two bolts (see fig. 242 ) fastenings of the bearing lever of a suspension bracket to a rotary fist the moment of 55 N · m;
- establish a head of cross-section steering draft. Tighten nuts the moment of 30 N · m then tighten them for 90 °;

Fig. 241. Fastening nuts (are shown by shooters) right support of an engine mount





- mount the right fastening of a suspension bracket (see fig. 241 ) the engine. Tighten nuts of fastening the moment of 50 N · m;
- wrap the top bolts of fastening of a transmission to the engine and tighten them the moment of 80 N · m;
- tighten a "weight" wire;

Fig. 239. Accession of cables to transmission levers: 1 — the lever of a choice of transfers; 2 — the lever of inclusion of transfers





- insert both cables of gear shifting into clips on a transmission against the stop. The cable 1 (see fig. 239 ) should cross a cable 2;
- put on the ends of cables the corresponding levers on a transmission. A cable 1 put on the lever of a choice of transfers, and a cable 2 on the lever of inclusion of transfers;
- the pipeline press in the holder on a transmission and connect to the working cylinder of a hydraulic actuator of coupling;
- fix the pipeline a bracket;
- establish the case of the air filter;
- establish the bottom casing of a motor compartment;
- establish forward wheels. Wheels tighten and lower the car. Bolts of fastening of wheels in the cross way tighten the moment of 170 N · m. Tighten the central bolt of a nave;
- attach a "weight" wire to AB;
- remove air from hydraulic system of coupling (see item 9.4.3);
- adjust a gear shifting drive;
- check level of transmission oil in a transmission. At insufficient quantity add it in a transmission.