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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Sharan (from 1995 to 2000, the year of issue)

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Volkswagen Sharan
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Volkswagen
Sharan
Introduction
VR6 engine
Removing and installing
Disassembly and assembly
Cylinder head and valves
The pistons and connecting rods
Withdrawal
Measurement of the internal diameter of the cylinder
Check of pistons and rods
Measure the connecting rod bearing clearance
The assembly of pistons and rods
Installation of pistons and rods
Cylinder block
Crankshaft and main bearings
Drive timing
Countershaft
Compression check in engine cylinders
Exhaust
The two-liter engine (ADY)
Engine oil
Cooling
A fuel injection system VR6 engine
The system Simos injection 2.0-liter engine
The ignition system
Coupling
Manual 5-speed gearbox
The drive shafts
Power steering
Front suspension
Rear suspension
Brakes
Electrical
Diesel engine
The lubrication system of the diesel engine
The cooling system of the diesel engine
The power supply system of the diesel engine and turbocharger
Map service.
Applications
Wiring
 


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Installation of pistons and rods



Installation of pistons and rods performed as follows:
- Generously grease the engine oil inside the cylinder surface;

Details piston
Fig. 63. piston Details: 1 - compression piston rings; 2 - oil ring; 3 - the piston; 4 - a cover of a rod; 5 - a bolt of fastening of a rod; 6 - rod inserts; 7 - rod; 8 - cylinder block; 9 - a lock ring; 10 - the piston pin; Arrow A indicates the direction of the front part of the engine





- Lay all connecting rods according to the number of cylinders. Cast tabs on the rod and a rod cover should be directed toward the crankshaft pulley (see. Fig. 63). After mounting rods cast lugs should be located on the other side of the arrow;
- Arrow on the piston crown must point towards the front of the engine;
- Orient the piston rings relative to each other at an angle of 120 ?� with the surface of the cylinder;

Installation of the piston by means of a special tool VW3278
Fig. 66. Installation of the piston by means of a special tool VW3278





- Put on the clamping band clamp 3278 on the piston rings on the piston (Fig. 66) and push the piston rings into the grooves of the piston;

Alternative clamping band clamp to set the pistons
Fig. 67. An alternative coupling band clamp to set the pistons





- For this purpose it can also be used used by ?�Volkswagen?� assembly tool - clamping band clamp ( Fig. 67 );
- Check that the piston rings are fully engaged in their grooves;
- Rotate the crankshaft so that the two crank pins were in the bottom dead center (BDC);
- Set the connecting rod bearing in the connecting rod;
- Insert the rod into the hole on top of the cylinder. To put it on the engine side so that the connecting rod could be directed at the root neck. Make sure that it does not have scratched the cylinder bore and the connecting rod journals;
- Insert the pistons so that the piston rings in turn into the holes and the cylinder rod heel sat on the crank pin of the crankshaft;
- Insert the second insert in the bearing cap so that the folded liner mustache got into the groove of the bearing cap. Coat the surface of the liner motor oil;
- Push the connecting rod cap to the connecting rod and easily tap it. Apply engine oil to the connecting rod bolts and screw them;

Assembling the connecting rod and the connecting rod bearing caps. The arrows indicate the projections
Fig. 56. Assembling the connecting rod and the connecting rod bearing caps. The arrows indicate the projections





- Must once again make sure that the two protrusions are cast, as shown in Fig. 56. Both cast protrusion on the connecting rod and connecting rod cap must be placed in front and pointing in the direction of a pulley;
- Alternately tighten the bolts connecting rod bearing torque 30 Nm, and then turn them out of the end position 90 ?� (a quarter turn);
- After installation of the connecting rod rotate the crankshaft several times to make sure that it rotates easily, without jamming;
- Double-check the labeling of all rods to ensure that the pistons Hands pointing in the right direction;

Measurement of axial clearance between the side plane of the connecting rod bearing and the side surface of the crankshaft
Fig. 68. Measurement of axial clearance between the side plane of the connecting rod bearing and the side surface of the crankshaft





- With a feeler gauge, measure the axial clearance between the side of the plane of the connecting rod bearings and the side surface of the crankshaft (Fig. 68), which should not exceed 0.31 mm;
- Install oil sump (see. Sect. 4.1);
- All further work on the assembly produced in the reverse order.




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