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>> Engine assembly
Engine assembly, as well as dismantling, will be described in separate subsection. Sequence of actions at assembly return concerning dismantling. However at each assembly it is necessary to observe the following recommendations:
- details should be pure;
- always grease any rotating or sliding details. It is necessary to do it before assembly (instead of after details are already established), then oil will get to all necessary places. It is especially important to grease plentifully with engine oil pistons, piston rings and walls of cylinders before assembly;
- carefully clear all parts of the block of cylinders if there was a complete dismantling of the engine. At partial dismantling watch that in the disassembled engine or foreign matters did not get to his cavities. Stop up all openings with pure rags to avoid it;
- blow oil channels the compressed air. If you have no such possibility, clean oil channels and openings a wooden stick, but at all do not do it by metal subjects.
Limits of wear of the majority of mobile details are given in the table with data for adjustment and control. If you have doubts concerning any detail or the limit of wear will be reached soon, it is better to replace such detail to avoid repeated dismantling of the engine.
Further engine assembly after its complete dismantling is described. Thus we recognize that all details of the engine were repaired or replaced according to the instructions provided in the following sections. Besides, we assume that separate constructive groups as, for example a head of the block of cylinders, are already collected.
Establish oil nozzles in the block of cylinders. Tighten bolts of fastening of nozzles the moment of 10 N · m.

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




Tighten a gear rim of the sensor of frequency of rotation of a cranked shaft. Bolts should be changed for the new always. The adjusting pin is inserted into a cranked shaft (see rice 383 ), this pin should act on a certain size from a surface of a cranked shaft (2,5 — 3,0 mm). Therefore before fastening a gear rim (the moment of 10 N · м), measure distance on which the adjusting pin acts.
Grease everything working surfaces of bearings of a cranked shaft with engine oil and put a shaft on the enclosed loose leaves of bearings. Carefully put a cranked shaft in bearings and establish adjusting washers at the left and to the right of the average bearing. Lubricant flutes of adjusting washers should settle down against a basic surface of a cranked shaft.
Establish in the block of cylinders according to labels of a cover of radical bearings (loose leaves of bearings should be inserted and well greased) and upholster them with a plastic or rubber hammer.
Twist bolts of covers of radical bearings and tighten them evenly from the middle outside the moment of 65 N · m. From final situation turn each bolt, again from the center outside, for 90 ° (a turn quarter).

Prevention
Use only new bolts.

Check an axial gap of a cranked shaft as it is described in item 17.9.1.
Establish pistons and rods (see item 17.5.5).
Vpressuyte a new epiploon outside in a flange of an intermediate shaft.
Grease basic necks of an intermediate shaft and insert an intermediate shaft into a case. Establish a new sealing ring in a flange of a shaft and establish a flange. Tighten both bolts the moment of 25 N · m.

Fig. 384. Bolts of an epiploon of 1 cranked shaft and a flange 2 intermediate shaft should be tightened by the moment of 25 N · m





Beat out an epiploon from the case of a forward epiploon. Insert the case without an epiploon into the block of cylinders. Tighten 4 bolts the moment of 25 N · m. On fig. 384 the way of its fastening is shown.
Establish a new forward epiploon as it is described in item 17.9.3.

Fig. 385. The shown flange of an epiploon on the back party of the engine is necessary for changing together with an epiploon. Tighten bolts (are shown by shooters) the moment of 10 N · m




After that fasten the case of a back epiploon with new laying. Tighten the bolts shown in drawing 385 the moment of 10 N · m.

Prevention
It is impossible to replace a sealing ring separately — it is necessary to establish all flange of an epiploon.


Fig. 386. The established oil pump. Tighten bolts the moment of 25 N · m





Attach the oil pump to the lower part of a case (2 bolts, 25 N · м). On fig. 386 are shown places of their fastening.
Establish an oil case with new laying. Tighten bolts around the moment of 20 N · m.
Establish an intermediate plate of the engine (3 bolts, 10 N · м).
Establish a flywheel. Bolts should be tightened evenly cross-wise the moment of 60 N · m. From final situation turn all bolts for 90 ° (a turn quarter) (without using thus a dinamometrichesky key).

Prevention
Use only new bolts.

Establish coupling as it is described in appropriate section. Thus the flywheel should be fixed in motionless situation.
Establish a cogwheel of a cranked shaft. Grease a bolt. Fix a cranked shaft in motionless situation, let's be turned by a flywheel, and tighten a bolt the moment of 90 N · m. From final situation turn a bolt for 90 ° (without using thus a dinamometrichesky key).

Prevention
Use a new bolt.

Put on a cogwheel of an intermediate shaft a shaft. On a shaft already there should be a segment shponka. Fix a cogwheel in motionless situation and tighten a bolt the moment of 45 N · m.
Establish the details which have been removed on the left side of the engine. Tighten the sensor of provision of a cranked shaft the moment of 10 N · m, and connection of ventilation of a case by the moment of 25 N · m.
Establish the vacuum pump with a new sealing ring (20 N · м).
Establish the basis of the oil filter with new laying (3 bolts, 25 N · м).

Fig. 387. Installation of an arm of 1 fuel pump of a high pressure and oil radiator 2





Fasten an arm of 1 fastening of TNVD (fig. 387) three bolts. Tighten bolts the moment of 20 N · m, and then tighten for 90 °. Establish an oil radiator with new laying. Tighten a nut in the lower part of an oil radiator the moment of 25 N · m.

Fig. 388. Bolts of a bearing arm of fastening of units are located in the shown places, figures indicate an order of an inhaling of bolts of fastening





Establish bearing arm of units. Replace a sealing ring of the block of cylinders. Establish an arm on directing openings and twist five bolts. Attach a hose of cooling liquid to an oil radiator. Thus fasten also oil filter (subsection 18.3). Tighten bolts of a bearing arm of units in the sequence shown on fig. 388 , the moment of 25 N · m.
Measure, pistons (see item 16.3.5) how act and pick up laying of a head of the block of cylinders according to the received value of measurement.
Establish a head of the block of cylinders (item 16.2.5).
Establish an inlet collector with new laying and fasten it six bolts (25 N · м).
Establish new laying of an exhaust pipe so that they looked curves up, establish a pipe together with a turbokompressor and fasten them (25 N · м). Establish a hose of a retsirkulyatsiya of oil, tighten a hollow bolt of ring connection (30 N · м) also fasten the screen of thermal protection (two nuts).
Connect the oil pipeline of a turbokompressor (a cap nut). Tighten it the moment of 25 N · m. Tighten a hollow bolt in a head of the block of cylinders the moment of 25 N · m.
Tighten the connecting pipeline of system of a retsirkulyatsiya of OG (25 N · м).
Connect a shtekerny block of additional heating.

Fig. 389. Installation of nozzles and incandescence candles: 1 — the tension holder, 22 N · m; 2 — glow plugs, 15 N · m; 3 — a wire tip





Establish nozzles together with solderings. Tighten solderings by the moment of 22 N · m. On fig. 389 it is shown, where nozzles fasten.
Screw glow plugs. Tighten them the moment of 15 N · m (see fig. 389 ). Connect a shtekerny block of the sensor of temperature of cooling liquid on the right side.
Fasten the electric tire of candles of an incandescence and establish hoses oil plum.

Fig. 381. Details which are necessary for removing: 1 — the switch of pressure of oil; 2 — the sensor of temperature of oil; 3 — the sensor of provision of a cranked shaft; 4 — the sensor of lifting of a needle; 5 — a hose of cooling liquid





Connect all wires to sensors (see fig. 381 ). The Shtekerny block with a dark blue/black wire is established on the dark blue switch of pressure of oil, the shtekerny block with a yellow/black wire is established on the gray switch of pressure of oil.
Establish TNVD (see appropriate section).
Establish internal protection of a gear driving belt (2 bolts in a head of the block of cylinders, 1 bolt on the fuel pump of a high pressure).
Establish TNVD cogwheel. At first put on a segment shponka. Fix a cogwheel in motionless situation and tighten a nut the moment of 55 N · m. Twirl also tension roller of a gear driving belt, without tightening it it is final.
Establish poliklinovy a belt as it is described in appropriate section. Having fixed a camshaft cogwheel in motionless situation, tighten a bolt of fastening the moment of 45 N · m.
Connect pipelines of supply of fuel to injection system. Tighten cap nuts the moment of 25 N · m. Connect the shtekerny block located nearby.
Establish a cover of a head of the block of cylinders. Use new laying. Tighten nuts the moment of 10 N · m also put on safety caps. Connect a ventilating hose. After that establish protection of a gear driving belt now.
Fasten a forward collar of an engine mount. Tighten bolts the moment of 60 N · m.
Establish the generator (25 N · м).
Put on a pulley of a cranked shaft through an adjusting pin a distributive gear wheel of a cranked shaft and twirl bolts. Tighten bolts the moment of 25 N · m. Fasten a pulley of the water pump (23 N · м).
Fasten the persistent bearing of a power shaft (43 N · м) and a basic collar of a turbokompressor (25 N · м).
Carry out everything the works not mentioned specially in return sequence, concerning dismantling process.