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
   3.5. Block of cylinders
   - 3.6. Cranked shaft and radical bearings
      3.6.1. Removal of a cranked shaft
      3.6.2. Check of details of a cranked shaft
      3.6.3. Installation of a cranked shaft
      3.6.4. Epiploons of a cranked shaft
      3.6.5. Removal and flywheel installation (the car from mechanical KP)
      3.6.6. A driving pulley of the hydrotransformer (for cars with AKP)
   + 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)>> Cranked shaft and radical bearings>> Removal of a cranked shaft
For removal of a cranked shaft it is necessary to remove the engine from the car.
As the engine should be disassembled completely, carry out the following to recommendations about complete dismantling of the engine:
- remove a transmission from the engine;

Fig. 70. Blocking by a flywheel clamp





- on the car with a mechanical transmission a screw-driver inserted into a gear wreath of a flywheel fix a flywheel in motionless situation and turn out bolts of fastening of a flywheel. For a reliable zablokirovaniye of a flywheel it is possible to use a clamp (see fig. 70 ) then to unscrew flywheel bolts;
- before flywheel removal by a center punch mark a relative positioning of a press disk and a flywheel to avoid a mistake at installation;
- unscrew from a forward part of the engine a bolt of a pulley of a cranked shaft;
- on the car with an automatic transmission unscrew a driving pulley.
- remove a head of the block of cylinders (see item 3.3.1) together with an inlet and final collector;

Fig. 106. Details of a drive of the mechanism of a gazoraspredeleniye: 1 — bolts, 55 N · m; 2 — a bolt, 20 N · m; 3 — an engine mount collar; 4 — the top part of a protective cover; 5 — a roller of the tension adaptation; 6 — a dustproof cap; 7 — bolts, 10 N · m; 8 — the lower part of a protective cover; 9 — a pulley of a drive of the pump of system of cooling; 10 — poliklinovy a belt; 11 — a flywheel; 12 — maple a belt; 13 — a pulley of the pump of system of cooling; 14 — a bolt, 25 N · m; 15 — a pulley of a cranked shaft; 16 — a bolt, 25 N · m; 17 — the lever of the tension adaptation of a poliklinovy belt





- unscrew a bolt of fastening 14 (see fig. 106 ) and remove a pulley of the 13th pump of cooling liquid and the bottom protective cover 8 gear driving belts;
- note (its direction of rotation is desirable color) on outer side of a gear driving belt;
- weaken nuts of a natyazhitel of a belt and remove a gear driving belt from pulleys and from a natyazhitel;

Prevention
After removal of a gear driving belt it is impossible to turn a camshaft.

- unscrew bolts of fastening and remove the case pallet (see подразд. 4.1);
- remove the oil pump (see item 4.2.1);
- if it is required to remove only a cranked shaft, pistons and rods can remain in the block of cylinders. In this case in turn mark and remove covers of bearings of rods and leave them assembled with loose leaves. Otherwise remove pistons and rods (see item 2.4.1). Remember that used «pliable screws» always should be changed;

Fig. 80. Check of an axial free wheeling of a cranked shaft by means of the measuring device




Fig. 104. The block of cylinders in the disassembled condition: 1 — the bearing No. 1, 2, 4 and 5 loose leaf; 2 — cover bolts; 3 — covers of bearings; 4 — the bearing No. 3 loose leaf; 5 — a persistent half ring on a bearing cover; 6 — a gear rim of the sensor of frequency of rotation of a cranked shaft; 7 — a bolt, 10 N · m (to tighten for 90 °); 8 — a cranked shaft; 9 — persistent half rings of the block of cylinders




- measure an axial free wheeling of a cranked shaft. For this purpose establish on a forward part of the block of cylinders a rack with the indicator so that the leg of the indicator rested against a flange of the forward end of a cranked shaft (see fig. 80 ). A screw-driver shift a cranked shaft aside and expose the device on a zero then, move a shaft to other party. The arrow of the device will show an axial free wheeling of a shaft which should be no more than 0,25 mm. If the course is more, it should be considered at assembly and to bring it into norm, having replaced old half rings new or having established half rings of the increased thickness. Loose leaves 4 (see fig. 104 ) the bearing No. 3 have on two top 5 and two bottom 9 persistent half rings by which the axial free wheeling of a cranked shaft is regulated;

Fig. 81. Measurement of an axial free wheeling of a cranked shaft shchupy





- in the absence of the measuring device it is possible to measure an axial free wheeling with the help щупа (see fig. 81 ), on the average bearing, between a flange of the bearing of a rod where persistent half rings, and a surface of a cranked shaft settle down;

Fig. 136. Separate elements of a forward part of the block of cylinders: 1 — an epiploon cover; 2 — a bolt, 20 N · m; 3 — a forward epiploon of a cranked shaft; 4 — an epiploon of an intermediate shaft; 5 — a bolt, 25 N · m; 6 — a cover of an epiploon of an intermediate shaft; 7 — an O-shaped sealing ring; 8 — an intermediate shaft; 9 — a bolt, 10 N · m; 10 — laying





- unscrew bolts 2 (fig. 136) of fastening and uncover 1 in a forward part of the engine. In a flange there is a sealing ring which should be beaten out at once as it is necessary to replace it;

Fig. 137. Separate elements of a back part of the block of cylinders: 1 — an adjusting pin; 2 — laying; 3 — a cover; 4 — an intermediate plate of the engine; 5 — a flywheel; 6 — a bolt, 60 N · m (to tighten for 90 °), always on replacement





- remove an intermediate plate 4 (fig. 137) of the engine. The plate goes adjusting pins;
- unscrew bolts of a cover of a flange and remove a flange with a sealing ring. The sealing ring can be beaten out at once outside as it should be changed always;
- gradually cross-wise unscrew bolts 2 (see fig. 104 ) covers of 3 bearings of a cranked shaft 8, and in turn remove them. Check, that covers were marked with the corresponding numbers. Numbering of covers of bearings carry out from a pulley of a drive of units of the engine;
- remove loose leaves of bearings of radical necks and put them together with the corresponding covers of bearings. The bottom loose leaves of support of a cranked shaft have no flute on an internal surface. On them it is impossible to make any podgonochny operations. At teases, risks or otsloyeniye replace loose leaves new;
- mark (it is desirable in color) the back parties of each loose leaf;
- remove from the average bearing of a cranked shaft two top persistent half rings 5 (see fig. 104 ). Also it is necessary to mark them correctly to establish at assembly;
- take out from nests of bearings a cranked shaft;
- take out the remained loose leaves from a case of the engine and put them together with other loose leaves and covers;
- remove the bottom persistent half rings 9 from the average bearing.