VW Sharan repair

. Diesel engines: 1,9 l of TDI.
+ 1. Introduction
- 2. VR6 engine
   + 2.1. Cнятие and installation
   + 2.2. Dismantling and assembly
   + 2.3. Head of the block of cylinders and valves
   - 2.4. Pistons and rods
      2.4.1. Removal
      2.4.2. Measurement of internal diameter of the cylinder
      2.4.3. Check of pistons and rods
      2.4.4. Measurement of a gap of the bearing of a rod
      2.4.5. Assembly of pistons and rods
      2.4.6. Installation of 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>> Pistons and rods>> Installation of pistons and rods
Installation of pistons and rods carry out in the following order:
- plentifully grease with engine oil internal surfaces of cylinders;

Fig. 63. Details of piston group: 1 — kompressionny piston rings; 2 — a maslosjemny 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; the arrow A specifies the direction to a forward part of the engine





- spread out all rods according to numbers of cylinders. Cast ledges on a rod and a cover of a rod should be directed towards a pulley of a cranked shaft (see fig. 63 ). After installation of rods cast ledges should be located on other party of an arrow;
- shooters should point to the bottom of pistons in the direction of a forward part of the engine;
- сориентируйте locks of piston rings relatively each other at an angle in 120 ° on a cylinder surface;

Fig. 66. Piston installation by means of the special VW3278 tool





- put on a coupling tape collar 3278 piston rings on the piston (fig. 66) 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 also the replacement tool applied by Volkswagen firm — a coupling tape collar (fig. 67) ;
- check that piston rings completely entered into the flutes;
- turn a cranked shaft so that two shatunny necks of a cranked shaft appeared in the bottom dead point (NMT);
- establish the loose leaf of the bearing of a rod in a rod;
- insert a rod from above into a cylinder opening. For this purpose put the engine sideways so that the rod could be directed on a radical neck. Watch, that the opening of the cylinder and a rod neck thus were not scratched;
- insert pistons so that piston rings in turn entered into openings of cylinders and the heel of a rod sat down on a shatunny neck of a cranked shaft;
- insert the second loose leaf into a bearing cover so that the unbent short mustache of the loose leaf sat down 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 twist them;

Fig. 56. Assembly of a rod and cover of the bearing of a rod. Shooters showed ledges





- surely be once again convinced that both cast ledges are located, as is shown in fig. 56 . Both cast ledges on a rod and a cover of a rod should be located opposite and specify in the pulley direction;
- alternately tighten bolts of fastening of the bearing of a rod the moment of 30 N · m then turn them from this final situation on 90 ° (on a turn quarter);
- after installation of a rod turn a cranked shaft several times to be convinced that it rotates easily, without jammings;
- once again check marking of all rods to be convinced that cтрелки of pistons specify in the correct direction;

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





- with the help щупа measure an axial gap between the lateral plane of bearings of a rod and a lateral surface of a cranked shaft (fig. 68) which should not exceed 0,31 mm;
- establish an oil case (see подразд. 4.1);
- all further works on assembly are made as it should be, the return to dismantling.