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
+ 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
   17.1. Removal and installation
   - 17.2. Dismantling and assembly
      17.2.1 General dismantling
      17.2.2. Engine assembly
   + 17.3. Head of the block of cylinders
   + 17.4. Driving belts — poliklinovy and gear
   + 17.5. Shatunno-piston group
   + 17.6. Intermediate shaft
   17.7. Flywheel
   + 17.8. Camshaft and camshaft epiploon
   + 17.9. Cranked shaft and radical bearings
   + 17.10. Block of cylinders
   17.11. Compression check in engine cylinders
   17.12. System of production of the fulfilled gases
+ 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>> Diesel engine>> Dismantling and assembly>> General dismantling
Before the dismantling beginning carefully clear the engine outside. Stop up all openings of the engine with pure rags not to allow hit in the engine of foreign matters.
The engine has the top arrangement of a camshaft. Camshaft drive gear belt. The block of cylinders is cast from cast iron, a head of the block of cylinders the aluminum.
In comparison with diesel engines which were established earlier, it has some changes in a design:
- a head of the block of cylinders, saddles of valves, valves and chambers of combustion are made of materials which maintain more high temperature;
- special nozzles (nozzles) spray oil on the lower part of pistons, cooling them;
- the design of pistons is changed;
- the forward end of a cranked shaft is modified;
- the oil radiator is located between the oil filter and a filter flange;
- in connection with installation of a turbokompressor the system of production of the fulfilled gases and inlet system was modified.

Prevention
All diesel engines are very sensitive to dirt therefore at carrying out any works in the engine watch that dirt or other foreign matters did not get to openings of pipelines and a place of their connections. It is best of all to stick at once all fuel pipelines, hoses and other openings with a sticky tape.
Dismantling of the engine is in detail described in подразд. 17.3 — 17.10. Thus, we can consider works which can be carried out or on the established engine, or on removed, without describing thus any operation on engine dismantling twice. If complete dismantling of the engine is carried out, simply it is necessary to combine separate operations with each other in the specified sequence.
When dismantling it is necessary to mark an arrangement of all demountable parts and details in order that at assembly to establish them in a starting position in case they will be repeatedly used. Especially important it for pistons, valves, covers and loose leaves of bearings. Combine details so that not to mix them.

Prevention
Do not mark bearings and consolidations by scratches on their surface or a kerneniye. Many of details are executed from an easy alloy and consequently with them it is necessary to address accurately. If for removal of any detail it is necessary to use a hammer, it can be only the hammer rubber, plastic or fitted by skin.

If there is a possibility, establish the engine at the corresponding assembly stand. When dismantling the engine act in the following sequence:
- remove an arm of the persistent bearing of a power shaft, and also a turbokompressor;
- merge engine oil.

Fig. 374. At carrying out any works on dismantling disconnect: 1 — bolts of fastening of an inlet pipe; 2 — an air hose from a turbokompressor; 3 — a hose of forced air from inlet system; 4 — a hose of ventilation of a case





The following details remove from the engine, being guided by fig. 374 :
- unscrew bolts 1 and disconnect an inlet pipe from a turbokompressor;
- disconnect an air hose 2 from a turbokompressor and a radiator of forced air;
- disconnect a hose of forced air from inlet system 3;
- disconnect a hose of ventilation of a case 4 from the oil filter.
Disconnect the pipeline of cooling liquid and remove a hose of cooling liquid from the holder and an oil radiator.
Remove a hose collar from a flywheel and disconnect the pipeline of cooling liquid.

Fig. 375. Remove a quencher of krutilny fluctuations of a cranked shaft 1 and a pulley of the pump of the hydraulic booster of a steering 2. The pulley of the pump of the hydraulic booster of a steering can be fixed in motionless situation by means of a shestigrannik





Remove located in a forward part of the engine a pulley of a cranked shaft (4 bolts) and a pulley of the pump of the hydraulic booster of a steering (fig. 375) .

Fig. 376. Generator fastening. From below the natyazhitel of a maple belt is visible





Remove the generator (fig. 376) .
Unscrew four bolts of fastening of a collar of an engine mount and remove it.

Fig. 377. Fastening of safety covers of a poliklinovy belt: 1 — the top cover; 2 — the bottom cover





Remove the top cover of a poliklinovy belt. It fastens spring collars 1 (fig. 377) . Unscrew the bottom cover. It fastens three bolts 2.

Fig. 378. Removal of a poliklinovy belt: 1 — a tension roller of a gear driving belt; 2 — a directing roller of a gear driving belt





Remove poliklinovy a belt. If you plan to establish again an old belt, mark the direction of movement of a poliklinovy belt, having put a color label on its surfaces. Unscrew a nut and wring out a tension roller 1 (fig. 378) aside. Remove directing roller 2. Remove a gear belt. Remove the device for a belt tension.
Uncover heads of the block of cylinders. Disconnect a hose of ventilation of a case from the bottom connection and leave it on a cover of a head of the block of cylinders. Remove the safety caps located over nuts of fastening of a cover of a head of the block of cylinders, turn off nuts and uncover.

Fig. 379. Way of fixing of a cogwheel of a camshaft





Fix a camshaft pulley in motionless situation, remove it. The emphasis intended for this purpose is shown on fig. 379 . To use a stripper for this operation it is impossible, it is possible to insert an opravka through an opening of the metal wall located behind a wheel and to force down a pulley around.
Remove TNVD cogwheel. It should be removed by means of the special three-contact stripper which teeth should be inserted into openings on a pump cogwheel. At first turn off a cogwheel nut. For cogwheel fixing in a motionless condition insert an opravka into an opening on a cogwheel of the pump and hold it, having rested an opravka against the block of cylinders.
Unscrew two bolts on a head of cylinders and a bolt on TNVD and remove internal protection of a poliklinovy belt.
Take out щуп for measurement of level of oil in the engine.
Disconnect a tip of a wire of the locking valve of fuel and from the electromagnetic valve of adjustment of injection.
Turn on топливопроводы a high pressure from nozzles and TNVD. They fasten by means of cap nuts.
Remove TNVD. For this purpose unscrew two nuts on the one hand and a bolt with a nut on the other hand.
After that disconnect various wires and hoses. They are shown in drawing 380:
- separate a shtekerny block of the switch of 1 pressure of oil;
- separate a shtekerny block of the sensor of 2 temperatures;
- remove from an arm a shtekerny block of the sensor of 3 provisions of a cranked shaft;
- disconnect a shtekerny block of the sensor 4 liftings of a needle from the holder;
- disconnect a hose 5 cooling liquids from the distributive chamber of a head of the block of cylinders.
Unscrew the electric tire of candles of an incandescence and disconnect hoses oil plum.
Weaken fastenings of nozzles and remove nozzles from a head of the block of cylinders.
Unscrew glow plugs.
Separate a shtekerny block of the sensor of temperature of cooling liquid.
Weaken located nearby from a turbokompressor a hollow bolt, ring connection, a cap nut on a turbokompressor and turn off connection. Separate a shtekerny block of additional heating, remove a plait of wires on the engine and turn off the connecting pipeline for OG retsirkulyatsiya (4 bolts).
Remove final a pipe and a turbokompressor. At first release a hollow bolt of ring connection of the oil pipeline, then turn off the screen of thermal protection of an exhaust pipe (2 bolts) and after that unscrew 8 bolts of fastening of an exhaust pipe.
Unscrew 6 bolts of fastening of a final collector and remove it.

Fig. 382. Order of untwisting of bolts of a head of the block of cylinders. At installation of a head of the block of cylinders bolts tighten in return sequence





Unscrew bolts of fastening of a head of the block of cylinders evenly in return sequence relatively about an inhaling of bolts (fig. 382) and take out them. The special six-sided key without which it is possible to damage an internal part of a six-sided head of bolts so they cannot be turned out is necessary for an otvorachivaniye of bolts. Remove laying of a head of the block of cylinders.

Prevention
Bolts are unsuitable to repeated application and are subject to replacement by the new.

Remove an arm of fastening of auxiliary units and the oil filter.
Unscrew a bracket of fastening of TNVD (3 bolts) and remove an oil radiator (one nut, in the center).
Unscrew three bolts in the basis of the oil filter and remove the basis of the oil filter. Remove a tension plate of the vacuum pump and remove the pump.
Remove the knots established on the left side of the engine: connection of ventilation of a case (2 bolts), the sensor of provision of a cranked shaft (1 bolt, 1 spring clip) and щуп for measurement of level of oil in the engine.
Fix a cranked shaft in motionless situation, having inserted into a gear wreath a screw-driver. Unscrew evenly cross-wise 6 bolts of fastening of coupling so that they could be taken out. After that completely remove coupling.
Remove from the engine face cogwheels of cranked and intermediate shaft. Fix cranked and intermediate shaft in motionless situation.
Fix in motionless situation a flywheel and unscrew 6 bolts of its fastening.
Unscrew an intermediate plate of the engine.
Overturn the engine and unscrew an oil case (20 bolts). Remove laying.
Unscrew the oil pump located in the lower part of a case and remove it.
Unscrew six bolts and remove a back flange of a sealing ring. Remove laying.

Prevention
The flange is unsuitable to repeated application and are subject to replacement by the new.

Unscrew from the forward party of the engine a flange of an epiploon of a cranked shaft. Remove laying. Beat out an epiploon.
Unscrew a flange of an intermediate shaft and wring out a flange. Under a flange there is a sealing ring. Remove a shaft from the engine.
Turn a cranked shaft so that two rods were in the bottom dead point. Mark covers of bearings of a rod, having put on them numbers of cylinders (color) and in turn unscrew covers of bearings. Take in turn rods together with pistons in the direction up from a cylinder opening. Pay attention, that loose leaves of bearings and a cover of bearings were attached at once to the corresponding rods.
Remove a cranked shaft. Bearing covers in this case are marked with numbers (No. 1 – from pulleys, No. 5 – from a flywheel). Look subsection 17.9.

Fig. 383. Flywheel: 1 — a gear rim; 2 — bolts of fastening of a gear rim; 3 — the adjusting screw (should act on a distance)





Unscrew the gear rim serving for determination of frequency of rotation of a cranked shaft, from a sock of a cranked shaft. On fig. 383 the way of its fastening is shown.
Remove from the lower part of a case oil nozzles (unscrew bolts).