Diesel engine repair car Volkswagen Sharan 1
Diesel engine — general information
The vehicle 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...
The vehicle 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...
Removal and installation the engine
The order of operations: disconnect the "–" terminal from the battery, then the "+" terminal; remove AB; Fig. 18. Removing the battery: 1 - air duct casing; 2 - partition remove...
The order of operations: disconnect the "–" terminal from the battery, then the "+" terminal; remove AB; Fig. 18. Removing the battery: 1 - air duct casing; 2 - partition remove...
Disassembling the engine
Before disassembling, thoroughly clean the outside of the engine. Plug all engine openings with clean rags to prevent foreign bodies from getting inside the engine. The engine has...
Before disassembling, thoroughly clean the outside of the engine. Plug all engine openings with clean rags to prevent foreign bodies from getting inside the engine. The engine has...
Engine assembly
The 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...
The 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...
Cylinder Head — Removal with Engine Installed
The five-bearing camshaft is located above and is driven by a toothed belt. During the operation of the car, there is no need to periodically adjust the valve clearances, since...
The five-bearing camshaft is located above and is driven by a toothed belt. During the operation of the car, there is no need to periodically adjust the valve clearances, since...
Disassembling the cylinder head
If the timing mechanism parts are to be reused, each part should be installed back in the same place where it stood before disassembly. To avoid confusion, it is recommended to...
If the timing mechanism parts are to be reused, each part should be installed back in the same place where it stood before disassembly. To avoid confusion, it is recommended to...
Cylinder head repair
Checking valve springs Fig. 396. Valve details: 1 - plate pusher; 2 - halves of the valve conical chamfer; 3 - upper valve spring plate; 4 - outer valve spring; 5 - inner valve...
Checking valve springs Fig. 396. Valve details: 1 - plate pusher; 2 - halves of the valve conical chamfer; 3 - upper valve spring plate; 4 - outer valve spring; 5 - inner valve...
Cylinder head assembly
The cylinder head should be assembled in accordance with the following instructions, in the reverse order of the disassembly process: generously lubricate the valve stems with...
The cylinder head should be assembled in accordance with the following instructions, in the reverse order of the disassembly process: generously lubricate the valve stems with...
Installing the cylinder head
There are cylinder head gaskets available that come in different thicknesses. The thickness of the cylinder head gasket depends on how much the pistons protrude above the cylinder...
There are cylinder head gaskets available that come in different thicknesses. The thickness of the cylinder head gasket depends on how much the pistons protrude above the cylinder...
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, does...
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, does...
Poly V-belt and toothed drive belts
Fig. 414. Elements of the drive mechanism located on the front side of the engine: 1 - Upper toothed belt guard; 2 - toothed belt; 3 - nut, 20 Nm; 4 - tension roller eccentric; 5...
Fig. 414. Elements of the drive mechanism located on the front side of the engine: 1 - Upper toothed belt guard; 2 - toothed belt; 3 - nut, 20 Nm; 4 - tension roller eccentric; 5...
Removal the timing belt
The timing belt can be removed with the engine installed, and we will assume this in the following description. Remove the ground wire terminal from the battery. Fig. 390. To...
The timing belt can be removed with the engine installed, and we will assume this in the following description. Remove the ground wire terminal from the battery. Fig. 390. To...
Installing the toothed drive belt and adjusting the timing drive
Fig. 415. The upper figure shows the adjusting gauge 1 installed on the camshaft. The lower figure shows how the flywheel with the TDC mark should be positioned When installing a...
Fig. 415. The upper figure shows the adjusting gauge 1 installed on the camshaft. The lower figure shows how the flywheel with the TDC mark should be positioned When installing a...
Connecting rod and piston group — design description
Fig. 420. Piston sections. The arrow shows the combustion chamber Fig. 421. View of piston and connecting rod: 1 - piston rings; 2 - piston; 3 - piston pin; 4 - retaining ring; 5...
Fig. 420. Piston sections. The arrow shows the combustion chamber Fig. 421. View 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
The pistons and connecting rods are knocked out of the cylinder block in an upward direction using a hammer handle, after removing the covers and connecting rod bearing shells....
The pistons and connecting rods are knocked out of the cylinder block in an upward direction using a hammer handle, after removing the covers and connecting rod bearing shells....
Checking pistons and connecting rods
Check all parts carefully. If they have nicks, scratches or signs of wear, these parts should be replaced. Fig. 427. Checking the clearance between the piston rings and grooves...
Check all parts carefully. If they have nicks, scratches or signs of wear, these parts should be replaced. Fig. 427. Checking the clearance between the piston rings and grooves...
Assembly of pistons and connecting rods
Heat the pistons to 60°C (to do this, put them in hot water). Find a suitable drift that fits inside the piston pin. Fig. 429. Removing and installing the piston pin using a...
Heat the pistons to 60°C (to do this, put them in hot water). Find a suitable drift that fits inside the piston pin. Fig. 429. Removing and installing the piston pin using a...
Installing pistons and connecting rods
If the piston cooling nozzles have been removed, reinstall them and tighten the bolts to 10 Nm. Lubricate the cylinder bores generously. Lay out all connecting rods according to...
If the piston cooling nozzles have been removed, reinstall them and tighten the bolts to 10 Nm. Lubricate the cylinder bores generously. Lay out all connecting rods according to...
Removal 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...
Installing the intermediate shaft
Fig. 434. Pressing out the oil seal from the intermediate shaft flange If the flange has been unscrewed, the sealing ring located on the inside of the flange should be replaced....
Fig. 434. Pressing out the oil seal from the intermediate shaft flange If the flange has been unscrewed, the sealing ring located on the inside of the flange should be replaced....
Flywheel — removal and installation
Fig. 383. Flywheel: 1 - toothed rim; 2 - toothed rim mounting bolts; 3 - Set screw (must protrude a distance a) The engine flywheel is equipped with a toothed rim of the engine...
Fig. 383. Flywheel: 1 - toothed rim; 2 - toothed rim mounting bolts; 3 - Set screw (must protrude a distance a) The engine flywheel is equipped with a toothed rim of the engine...
Camshaft and oil seal
Fig. 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 wheel; 7 - washer; 8 -...
Fig. 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 wheel; 7 - washer; 8 -...
Removal the camshaft
To remove the camshaft, on the installed cylinder head, first remove the timing belt ( p. 17.4.1 ). If it is necessary to remove the camshaft gear, it should be fixed in a...
To remove the camshaft, on the installed cylinder head, first remove the timing belt ( p. 17.4.1 ). If it is necessary to remove the camshaft gear, it should be fixed in a...
Camshaft oil seal
Fig. 437. Remove the camshaft sealing ring using a special puller The camshaft seal can be replaced on an installed engine if traces of oil are observed near it. The seal is...
Fig. 437. Remove the camshaft sealing ring using a special puller The camshaft seal can be replaced on an installed engine if traces of oil are observed near it. The seal is...
Installing the camshaft and oil seal into the cylinder head
Lubricate well and insert the tappets into the holes according to the marks on them. If the tappets were removed, be sure to read the instructions. Generously lubricate the...
Lubricate well and insert the tappets into the holes according to the marks on them. If the tappets were removed, be sure to read the instructions. Generously lubricate the...
Determination of axial clearance of the crankshaft
Fig. 440. Crankshaft bearings: 1 - bearing shells No.1, 2, 4 and 5. Shells with lubrication grooves are located in the cylinder block, shells without lubrication grooves are...
Fig. 440. Crankshaft bearings: 1 - bearing shells No.1, 2, 4 and 5. Shells with lubrication grooves are located in the cylinder block, shells without lubrication grooves are...
Crankshaft seals — removal and installation
The front and rear crankshaft seals should be replaced each time the crankshaft or seal flange is removed. If you follow these instructions, you will not need any special tools to...
The front and rear crankshaft seals should be replaced each time the crankshaft or seal flange is removed. If you follow these instructions, you will not need any special tools to...
Checking the crankshaft parts
Carefully inspect the crankshaft for damage and take accurate measurements of the main and connecting rod bearing journals. The main bearing journals and connecting rod journals...
Carefully inspect the crankshaft for damage and take accurate measurements of the main and connecting rod bearing journals. The main bearing journals and connecting rod journals...
Measuring cylinder bores
When completely disassembling, thoroughly clean the cylinder block and remove all foreign bodies from the cavities and lubrication channels. Be sure to remove all residues of...
When completely disassembling, thoroughly clean the cylinder block and remove all foreign bodies from the cavities and lubrication channels. Be sure to remove all residues of...
Checking the mating surface of the cylinder block
Fig. 402. Checking the cylinder head for deformation using a measuring ruler and feeler gauge Check the cylinder block surface for deformation in a manner similar to that used for...
Fig. 402. Checking the cylinder head for deformation using a measuring ruler and feeler gauge Check the cylinder block surface for deformation in a manner similar to that used for...
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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