VW Sharan repair

. Diesel engines: 1,9 l of TDI.
+ 1. Introduction
+ 2. VR6 engine
- 3. Two-liter engine (ADY)
   3.1. Removal and installation
   + 3.2. Dismantling and assembly
   + 3.3. Head of the block of cylinders and valves
   - 3.4. Pistons and rods
      3.4.1. Removal
      3.4.2. Measurement of internal diameter of the cylinder
      3.4.3. Check of pistons and rods
      3.4.4. Measurement of a gap of a rod
      3.4.5. Assembly of pistons and rods
      3.4.6. Installation of pistons and rods
   3.5. Block of cylinders
   + 3.6. Cranked shaft and radical bearings
   + 3.7. Drive of the mechanism of a gazoraspredeleniye
   3.8. Adjustment of a tension of a driving belt of units of the engine
   3.9. Intermediate shaft
   3.10. Compression check in engine cylinders
   3.11. System of production of the fulfilled gases
   3.12. Cleaning system with absorbent carbon application
   3.13. System of a retsirkulyatsiya of the fulfilled gases
+ 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>> Two-liter engine (ADY)>> 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;

Fig. 134. Arrangement of locks of piston rings relatively each other





- arrange locks of piston rings relatively each other at an angle in 120 ° on a cylinder surface (fig. 134) ;

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





- put on a coupling tape collar 3278 piston rings on the piston (see 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 the replacement tool applied by Volkswagen firm — a coupling tape collar (see 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 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 shatunny 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 screw 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 together (see fig. 56 ). Both cast ledges on a rod and a cover of a rod should be located opposite to each other and specify in the direction to a pulley;
- alternately tighten bolts of fastening of the bearing of a rod the moment of 30 N · m then tighten them for 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 (see fig. 68 ) measure an axial gap of the rods established on a cranked shaft that it was possible to estimate degree of wear of details. For this purpose press a rod to one side that it was possible to insert щуп. If it is possible to insert щуп in the thickness more than 0,37 mm, most likely rods were erased in pressing places. At worst places of pressing of a cranked shaft were erased;
- establish an oil case (see подразд. 4.1);
- all further works on assembly are made as it should be, the return to dismantling.