VW Sharan repair

. Diesel engines: 1,9 l of TDI.
+ 1. Introduction
- 2. VR6 engine
   - 2.1. Cнятие and installation
      2.1.1. Removal and transmission installation from the engine
      2.1.2. Additional operations if on the car the conditioner is established
      2.1.3. Engine mount
   + 2.2. Dismantling and assembly
   + 2.3. Head of the block of cylinders and valves
   + 2.4. Pistons and rods
   2.5. Block of cylinders
   + 2.6. Cranked shaft and radical bearings
   + 2.7. Drive of the mechanism of a gazoraspredeleniye
   2.8. Intermediate shaft
   2.9. Compression check in engine cylinders
   + 2.10. System of production of the fulfilled gases
+ 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
+ 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>> VR6 engine>> Cнятие and installation



The power unit consists of the engine and a transmission. Remove it by means of the hydrolift or a waist, lowering from a motor compartment.
Before removal of the power unit execute the following:
- if on the car the anticreeping system with a protective code is established, the code needs to be had at itself to include system after AB connection;
- at removal of the engine it will be necessary to disconnect a large number of electric wires, and also vacuum hoses and hoses of cooling liquid. Before removal of wires and hoses designate them by means of labels;
- before installation works in a motor compartment it is necessary to close a dense fabric forward wings of the car.
Removal of the power unit make in the following order:
- switch off the engine and take out a key from the ignition lock;
- disconnect the plug «–» from AB;

Prevention
To avoid EBU damage, it is necessary to disconnect AB plugs only at the switched-off ignition. And for complete switching off of ignition it is necessary to wait for not less than 20 with and only after that it is possible to disconnect the plug «–» from AB.


Fig. 18. AB removal: 1 — an air pipe casing; 2 — a partition





- unscrew screws (are shown by shooters, fig. 18 ) and remove a casing of 1 air pipe and a partition 2;
- remove AB (see section 16.1);
- merge cooling liquid from cooling system (see section 19.1);

Fig. 19. Removal of a casing of AB





- unscrew screws (are shown by shooters, fig. 19 ), shift aside and remove AB casing together with a broad tank of system of cooling;
- remove maple a belt of a drive of units of the engine;
- disconnect an air pipe hose from the case of knot of a butterfly valve;
- by means of a candle key unscrew spark plugs and combine them as an arrangement of cylinders. At the VR6 engine caps of candles and candles can be removed only by means of a special candle key at number 3277А;

Fig. 20. Removal of the central cover on the top part of an inlet collector: 1, 3, 4 — directing wires of a high voltage; 2 — the central cover





- remove directing 1, 3 and 4 (fig. 20) of wires of a high voltage and remove the central cover of the 2nd top part of an inlet collector;
- remove a cable of a drive of a butterfly valve together with its support for what unscrew a support and take the cable end. Do not pull out a clip holding a cable of a butterfly valve in a support (as adjustment of a tension of a cable of a butterfly valve in this case will be necessary);

Fig. 26. Details of the top part of a head of the block of cylinders: 1 — bolts (5 N · м); 2 — the central cover (over the top part of the inlet pipeline); 3 — bolts (25 N · м); 4 — holders of wires of spark plugs; 5 — the holder of a cable of a butterfly valve; 6 — a back left arm of the top part of the inlet pipeline; 7 — a mouth stopper for the oil gulf; 8 — sealing laying; 9 — the ventilating valve of a case; 10 — a ring in a cover of a head of the block of cylinders; 11 — a nut (10 N · м); 12 — a cover of a head of the block of cylinders; 13 — sealing laying of a cover of a head of the block of cylinders; 14 — holders топливопроводов; 15 — a bolt (10 N · м); 16 — a vacuum hose; 17 — sealing laying of the top part of an inlet collector; 18 — the top part of an inlet collector; 19 — a back right arm of the top part of the inlet pipeline





- disconnect spring clips of holders топливопроводов 14 (see fig. 26 ) a supply and removal of fuel;
- mark топливопроводы and disconnect hoses of a supply and removal of fuel from the fuel distributor;

Prevention
Toplivoprovoda are under pressure. Before disconnecting a fuel hose from its fastening, clasp a place of accession of a fuel hose a thick rag, and, carefully pulling together it from a fastening place, dump in system pressure.

- disconnect a big shtekerny block with 42 sockets, located nearby from the ignition coil;
- disconnect a vacuum hose of the amplifier of a brake drive;
- disconnect the pipeline of the hydraulic booster of the steering mechanism from the union at the engine. The pump of the hydraulic booster of the steering mechanism unscrew together with an arm and suspend on a wire to a body. Do not overwind hoses and track, that the pump did not hang on a hose;

Fig. 100. Elements of a forward part of system of production of the fulfilled gases: 1 — the screen of thermal protection of the engine; 2 — a final collector, two-piece; 3 — an elevating eye; 4 — a nut, 40 N · m; 5 — the screen of thermal protection of the engine; 6 — a nut of the screen of thermal protection of the engine; 7 — laying, on replacement; 8 — a reception pipe; 9 — a nut, 10 N · m; 10 — the union for EGR system connection, 35 N · m





- disconnect a reception pipe 8 and an average part of system of release with the catalyst from a final collector 2 (see.

Fig. 101. Elements of an average part of system of production of the fulfilled gases (are located between a reception pipe and the catalyst exhaust silencer): 1 — a nut of the screen of thermal protection; 2 — the screen of thermal protection; 3 — the direction to the first exhaust silencer; 4 — the catalyst; 5 — a protective collar; 6 — the screen of thermal protection; 7 — a bolt, 10 N · m; 8 — a protective collar; 9 — a bolt, 10 N · m; 10 — a nut, 40 N · m; 11 — a lambda probe; 12 — a shtekerny block of black color



- in the VR6 engine the system of secondary supply of the air which main details are located near a radiator is established. For dismantle of the engine it is necessary to remove a casing with the fan and the motor of the pump of secondary air (see подразд. 5.2.2);
- disconnect from the engine all hoses of cooling liquid, vacuum hoses and hoses of ventilation of the engine;
- disconnect from the engine and a transmission all electric wires. Among them wires: generator of an alternating current, starter, hydropressure head oil switch, various sensors. The majority of connections is carried out by means of shtekerny blocks;
- remove the generator;
if the mechanical transmission is established:
- disconnect from the working cylinder of coupling a hose;
- remove draft of gear shifting from a transmission (see section 10.1);
- take both power shafts from fastenings in a transmission (see section 11.1);
on the car with an automatic transmission:
- remove draft of the lever of a choice of an operating mode;
- take both power shafts from fastenings in a transmission,
- if on the car the conditioner is established, in addition to this section it is necessary to read the corresponding recommendations surely;

Fig. 21. Engine prop: 1 — bolts; 2 — an elevating ski lift; 3 — the lift





- prop up the engine from below. On HUNDRED the special device (fig. 21) under which then the automobile jack is substituted is for this purpose used. Besides it is necessary to make secure the lift which from above for loops supports the engine. If the automobile jack slides off, the engine will be kept in this case by the lift;
- remove a balansirny (pendular) suspension bracket. It is connected with a forward support, therefore it is necessary to read appropriate section in more detail to learn about its fastening;

Fig. 22. Right engine mount: 1 — fastening bolts





- turn out bolts 1 (fig. 22) of fastening of a support of the right engine mount. Pay attention that for an inhaling of bolts and nuts of an engine mount the various moments of an inhaling are used;

Fig. 23. An engine mount in the disassembled condition on the car with a mechanical transmission. Moments of an inhaling of bolts of fastening of support of an engine mount: 1= 55 N · m; 2= 110 N · m; 3= 100 N · m; 4= 20 N · m





- turn out bolts of fastening of a support of the left engine mount. The fixture of a support of the left suspension bracket (fig. 23) of the engine depends on type of the established transmission. At this stage of works it is necessary to turn out only the bolts 1 which arrangement is identical to all types of a transmission;
- together with the assistant slowly lower the power unit from a motor compartment. Watch, that the engine did not damage thus a body.
Installation of the power unit is carried out as it should be, the return to removal, thus execute the following:
- check thickness of overlays of a conducted disk of coupling. In case of wear a conducted disk replace;
- carefully get the power unit in a motor compartment. Watch to damaging details and car knots;
- at engine alignment with крепежами suspension bracket support, wrap by hand on 5–6 turns bolts of fastening of support. Shake the engine forward-back (it should not be energized);
- finally tighten bolts of fastening of support of a suspension bracket of the power unit the next moments:
- poses. 1= 55 N · m; poses. 2= = 110 N · m; poses. 3= 100 N · m; poses. 4= 20 N · m (see fig. 23 ) — for the engine with a mechanical transmission;

Fig. 24. The right engine mount in the disassembled condition. Moments of an inhaling of bolts of fastening of support of a suspension bracket: 1= 55 N · m; 2= 60 N · m





- poses. 1= 55 N · m; poses. 2= = 60 N · m (fig. 24) – the right engine mount;

Fig. 25. The right engine mount in the disassembled condition on the car with an automatic transmission. Moments of an inhaling of bolts of fastening of support of a suspension bracket: 1= 55 N · m; 2= 110 N · m; 3= 60 N · m





- poses. 1= 55 N · m; poses. 2= = 110 N · m; poses. 3= 60 N · m (fig. 25) — the right engine mount on the car with an automatic transmission;
- establish a balansirny (pendular) suspension bracket (see section 13);
- establish power shafts. A special key tighten many-sided bolts with the ordered moment of an inhaling. For mechanical and automatic transmissions the inhaling moments various (see. «Table of the moments of an inhaling»);
- depending on type of a transmission establish drafts and if necessary adjust the gear shifting mechanism;
- attach a hose to the working cylinder of coupling and fix it a spring clip (for a mechanical transmission);
- attach to a final collector a reception pipe with the catalyst. After alignment of the exhaust silencer and an exhaust pipe hang up them on suspension bracket rings. Watch correctness of installation. Rings of a suspension bracket should have a uniform tension and should not be deformed;
- establish the pump of the hydraulic booster of the steering mechanism;
- establish a casing with the fan and the motor of the pump of secondary air;
- establish maple a belt of a drive of units of the engine;
- establish a cable of a butterfly valve and check its work;
- establish a hose of let-in air and the air filter;
- establish all disconnected earlier electric wires;
- fill in cooling liquid in cooling system at the open crane of a heater. Finish level of cooling liquid in a broad tank to demanded level, twirl a cover of a broad tank. Turn on for some minutes the engine in order that, to let out all air jams. Then check level of cooling liquid in a broad tank and if necessary add cooling liquid;
- remove air from a hydraulic actuator of switching off of coupling by pumping with obligatory participation of the assistant;
- connect AB and make a trial trip. Check all connections of hoses on tightness;
- enter a code of anticreeping system (if it is established on the car).
As soon as possible it is necessary to call in on HUNDRED to check memory of the registrar of malfunctions of system of self-diagnostics.