Diesel engine repair car Volkswagen Sharan 1
Diesel engine — general information
The car is equipped with a 4-cylinder diesel engine with a working volume of 1.9 liters with direct fuel injection and turbocharging. The intake air compressed by the turbocharger...
The car is equipped with a 4-cylinder diesel engine with a working volume of 1.9 liters with direct fuel injection and turbocharging. The intake air compressed by the turbocharger...
Removal and installation of the engine
The order of operations: disconnect the terminal from AB «–», then «+»; remove AB; Pic. 18. AB removal: 1 - air duct casing; 2 - partition remove the battery compartment baffle...
The order of operations: disconnect the terminal from AB «–», then «+»; remove AB; Pic. 18. AB removal: 1 - air duct casing; 2 - partition remove the battery compartment baffle...
Engine disassembly
Thoroughly clean the outside of the engine before starting disassembly. Plug all engine openings with clean rags to prevent foreign bodies from getting inside the engine. The...
Thoroughly clean the outside of the engine before starting disassembly. Plug all engine openings with clean rags to prevent foreign bodies from getting inside the engine. The...
Engine Assembly
Engine assembly, as well as disassembly, will be described in a separate subsection. The sequence of actions during assembly is the reverse of disassembly. However, the following...
Engine assembly, as well as disassembly, will be described in a separate subsection. The sequence of actions during assembly is the reverse of disassembly. However, the following...
Cylinder head — removal on installed engine
The five-bearing camshaft has an upper arrangement and is driven by a toothed belt. During the operation of the car, it is not necessary to periodically adjust the valve...
The five-bearing camshaft has an upper arrangement and is driven by a toothed belt. During the operation of the car, it is not necessary to periodically adjust the valve...
Dismantling of a head of the block of cylinders
If the parts of the gas distribution mechanism are reused, then each of the parts should be installed again in the same place where it stood before disassembly. To avoid...
If the parts of the gas distribution mechanism are reused, then each of the parts should be installed again in the same place where it stood before disassembly. To avoid...
Cylinder head repair
Checking valve springs Pic. 396. Details of valves: 1 - poppet pusher; 2 - half of the conical chamfer of the valve; 3 - upper plate of the valve spring; 4 - external valve...
Checking valve springs Pic. 396. Details of valves: 1 - poppet pusher; 2 - half of the conical chamfer of the valve; 3 - upper plate of the valve spring; 4 - external valve...
Cylinder head assembly
The cylinder head must be assembled according to the following instructions, in reverse order of the disassembly process: generously lubricate the valve stems with engine oil and...
The cylinder head must be assembled according to the following instructions, in reverse order of the disassembly process: generously lubricate the valve stems with engine oil and...
Installing the cylinder head
Cylinder head gaskets are commercially available in various thicknesses. The thickness of the cylinder head gasket depends on how far the pistons protrude from the surface of the...
Cylinder head gaskets are commercially available in various thicknesses. The thickness of the cylinder head gasket depends on how far the pistons protrude from the surface of the...
Hydraulic tappets — removal and installation
A few words should be said about hydraulic tappets, as improper handling can damage the engine. Sometimes you can still hear noises from the valve cover area, which, however, do...
A few words should be said about hydraulic tappets, as improper handling can damage the engine. Sometimes you can still hear noises from the valve cover area, which, however, do...
V-ribbed and timing belts
Pic. 414. Elements of the drive mechanism located on the front side of the engine: 1 - upper protection of the toothed belt; 2 - toothed belt; 3 - nut, 20 Nm; 4 - tension roller...
Pic. 414. Elements of the drive mechanism located on the front side of the engine: 1 - upper protection of the toothed belt; 2 - toothed belt; 3 - nut, 20 Nm; 4 - tension roller...
Removing the toothed belt
The toothed belt can be removed on the installed engine and we will proceed from this in the following description. Remove terminal «mass» wires with AB. Pic. 390. To remove the...
The toothed belt can be removed on the installed engine and we will proceed from this in the following description. Remove terminal «mass» wires with AB. Pic. 390. To remove the...
Installing a toothed drive belt and adjusting the timing drive
Pic. 415. The upper figure shows the adjusting gauge 1 mounted on the camshaft. The lower figure shows how the flywheel with the TDC mark should be located When installing a new...
Pic. 415. The upper figure shows the adjusting gauge 1 mounted on the camshaft. The lower figure shows how the flywheel with the TDC mark should be located When installing a new...
Connecting rod and piston group — design description
Pic. 420. Piston sections. The arrow shows the combustion chamber Pic. 421. Type of piston and connecting rod: 1 - piston rings; 2 - piston; 3 - piston pin; 4 - retaining ring; 5...
Pic. 420. Piston sections. The arrow shows the combustion chamber Pic. 421. Type of piston and connecting rod: 1 - piston rings; 2 - piston; 3 - piston pin; 4 - retaining ring; 5...
Removal and disassembly of the connecting rod and piston group
Pistons and connecting rods are knocked out of the cylinder block in an upward direction with a hammer handle, after removing the covers and shells of the connecting rod bearings....
Pistons and connecting rods are knocked out of the cylinder block in an upward direction with a hammer handle, after removing the covers and shells of the connecting rod bearings....
Checking pistons and connecting rods
Check all details carefully. If they have nicks, scratches, or signs of wear, these parts should be replaced. Pic. 427. Checking clearance between piston rings and grooves Measure...
Check all details carefully. If they have nicks, scratches, or signs of wear, these parts should be replaced. Pic. 427. Checking clearance between piston rings and grooves Measure...
Assembly of pistons and connecting rods
Heat pistons to 60°C (to do this, put them in hot water). Find a suitable mandrel that fits inside the piston pin. Pic. 429. Removal and installation of the piston pin using a...
Heat pistons to 60°C (to do this, put them in hot water). Find a suitable mandrel that fits inside the piston pin. Pic. 429. Removal and installation of the piston pin using a...
Installation of pistons and connecting rods
If the piston cooling nozzles were removed, then reinstall them and tighten the bolts to 10 Nm. Lubricate the cylinder bores liberally. Lay out all connecting rods according to...
If the piston cooling nozzles were removed, then reinstall them and tighten the bolts to 10 Nm. Lubricate the cylinder bores liberally. Lay out all connecting rods according to...
Removing the intermediate shaft
To remove the intermediate shaft, the engine must be removed from the vehicle. The intermediate shaft is located at the front of the engine. To be able to remove the intermediate...
To remove the intermediate shaft, the engine must be removed from the vehicle. The intermediate shaft is located at the front of the engine. To be able to remove the intermediate...
Installation of an intermediate shaft
Pic. 434. Pressing the stuffing box out of the intermediate shaft flange If the flange has been unscrewed, then the sealing ring located on the inside of the flange should be...
Pic. 434. Pressing the stuffing box out of the intermediate shaft flange If the flange has been unscrewed, then the sealing ring located on the inside of the flange should be...
Flywheel — removal and installation
Pic. 383. Flywheel: 1 - gear rim; 2 - bolts for fastening the gear rim; 3 - set screw (should protrude a distance a) The engine flywheel is equipped with a toothed rim of the...
Pic. 383. Flywheel: 1 - gear rim; 2 - bolts for fastening the gear rim; 3 - set screw (should protrude a distance a) The engine flywheel is equipped with a toothed rim of the...
Camshaft and oil seal
Pic. 435. Individual elements of the camshaft: 1 - camshaft; 2 - camshaft bearing cap; 3 - washer; 4 - nut, 20 Nm; 5 - rear bearing cover; 6 - camshaft gear; 7 - washer; 8 - bolt,...
Pic. 435. Individual elements of the camshaft: 1 - camshaft; 2 - camshaft bearing cap; 3 - washer; 4 - nut, 20 Nm; 5 - rear bearing cover; 6 - camshaft gear; 7 - washer; 8 - bolt,...
Removing the camshaft
To remove the camshaft, on the installed cylinder head, first remove the timing belt ( 17.4.1 ). If you want to remove the camshaft gear, then it should be fixed in a stationary...
To remove the camshaft, on the installed cylinder head, first remove the timing belt ( 17.4.1 ). If you want to remove the camshaft gear, then it should be fixed in a stationary...
Camshaft oil seal
Pic. 437. Remove the camshaft sealing ring using a special puller The camshaft oil seal can be replaced on an installed engine if traces of oil have been noticed near it. The oil...
Pic. 437. Remove the camshaft sealing ring using a special puller The camshaft oil seal can be replaced on an installed engine if traces of oil have been noticed near it. The oil...
Installing the camshaft and oil seal in the cylinder head
Lubricate well and insert the pushrods in accordance with the markings on them into the holes. If pushrods have been removed, be sure to read the instructions. Lubricate the...
Lubricate well and insert the pushrods in accordance with the markings on them into the holes. If pushrods have been removed, be sure to read the instructions. Lubricate the...
Determination of the axial clearance of the crankshaft
Pic. 440. Crankshaft bearings: 1 - bearing shells No. 1, 2, 4 and 5. The shells with grooves for lubrication are located in the cylinder block, the shells without lubrication...
Pic. 440. Crankshaft bearings: 1 - bearing shells No. 1, 2, 4 and 5. The shells with grooves for lubrication are located in the cylinder block, the shells without lubrication...
Crankshaft seals — removal and installation
The front and rear crankshaft oil seals should be replaced each time the crankshaft or oil seal flange is removed. If you follow the instructions given, you will not need a...
The front and rear crankshaft oil seals should be replaced each time the crankshaft or oil seal flange is removed. If you follow the instructions given, you will not need a...
Checking the parts of the crankshaft
Carefully check the crankshaft for damage and accurately measure the journals of the main and connecting rod bearings. The main bearing journals and the crankshaft journals can be...
Carefully check the crankshaft for damage and accurately measure the journals of the main and connecting rod bearings. The main bearing journals and the crankshaft journals can be...
Measuring cylinder bores
When completely disassembled, the cylinder block should be thoroughly cleaned and all foreign bodies should be removed from the cavities and lubrication channels. Be sure to...
When completely disassembled, the cylinder block should be thoroughly cleaned and all foreign bodies should be removed from the cavities and lubrication channels. Be sure to...
Checking the mating surface of the cylinder block
Pic. 402. Checking the cylinder head for deformation using a measuring ruler and a feeler gauge Check the surface of the cylinder block for deformation in a manner similar to...
Pic. 402. Checking the cylinder head for deformation using a measuring ruler and a feeler gauge Check the surface of the cylinder block for deformation in a manner similar to...
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Similar sections from other manuals for VW cars:
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Petrol engine: Engine repair Volkswagen Golf 3 (1991-1997)
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Sharan 1
- General information
- Introduction to guide
- Maintenance
- Petrol engines
- Engine repair 2.8 l (AAA)
- Engine repair 2.0 l (ADY)
- Lubrication system
- Cooling system
- Fuel injection system
- Ignition system
- Diesel engines
- Engine repair
- Lubrication system
- Cooling system
- Supply system
- Transmission
- Clutch
- Manual gearbox and shafts
- Chassis
- Steering
- Car suspension
- Brake system
- Electrical equipment
- Equipment and devices
- Power devices
- Electrical circuits
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