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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
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
Adjust the brake system
Disc brakes front wheels
Check the thickness of brake linings
Removing and installing the front brake pads
Disassembly and reassembly of the front wheel brake
Removing and installing the front wheel brake caliper
The brakes of the rear wheels
Machining of brake discs
The main brake cylinder
Check of the vacuum brake booster
Bleeding the brakes
Parking brake
System ABS (Antilock Braking System)
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.
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Removing and installing the front brake pads



The operation to replace the brake pads spend their own only if there is an experience of this kind of work, since this depends on traffic safety and personal safety.
In the car must be only brake by ATE (Teves) and brake pads recommended by the manufacturer of the car brands.

A warning
Brake pads only change included. In no case do not rearrange blocks on the outer side of the brake disc on the inside, and vice versa, in order to equalize the possible wear. Use only the items recommended by the ?�Volkswagen?�.

If you plan to install the old brake pads before their withdrawal mark paint (marker Kern) the relative position of the brake pads against the caliper to the installation does not confuse the inner and outer brake pads and the wheel on which they were installed. Removing the front brake pads spend in the following order:
- Loosen the bolts of the front wheels;
- Paint mark (marker) the relative position of the wheels, brake discs and wheel hubs;
- Raise the front of the car, put it on the support, loosen the bolts and remove the front wheels;

Removal of the spring clip from the bracket of the wheel disk brake
Fig. 312. Removal of the spring clip from the bracket of the wheel disk brake





- Insert a screwdriver into a spring clamp (Fig. 312) and remove it from its mounting in the housing of the brake caliper;

The locations of the guide pin protection caps (arrowheads)
Fig. 313. The locations of the guide pin protection caps (arrowheads)





- With a narrow screwdriver, remove the protective cap (Fig. 313), the guide pin;

Unscrewing the lower and upper guide pin (caliper mounting bolts do not remove)
Fig. 314. Unscrewing the upper and lower guide pin (caliper mounting bolts do not remove)





- Loosen the upper and lower guide pins from the caliper Allen key (Fig. 314) and remove them;

Front wheel brake
Fig. 315. The brake mechanism of a forward wheel 1 - brake disc thickness of 25 mm; 2 - a bolt with hexagon 10 Nm; 3 - a bolt driving shaft 200 Nm; 4 - wheel bolt 140 Nm; 5 - a protective casing; 6 - bolt 10 Nm; 7 - sensor system ABS, which determines the speed of the wheel; 8 - bolt 10 Nm; 9 - ring gear speed sensor; 10 - the brake hose; 11 - a protective cap; 12 - the guide pin, 25 Nm; 13 - sliding sleeve; 14 - bolts 200 Nm; 15 - brake master cylinder assembly with a caliper; 16 - a spring collar; 17 - bracket (calliper); 18 - the brake pads





- Lift the brake caliper, moving it up and back, and tie it to the body of the wire clamp. Brake hose 10 (Fig. 315), do not disconnect, it should not twist, bend or be bent;
- Disconnect the internal brake shoe from the brake piston and pull it together with the clamp;
- Remove the brake caliper outer brake pad. If she become attached, gently peel it with a screwdriver.

A warning
Shot is prohibited in brake pads to press the brake pedal as it will lead to loss of the piston of the master cylinder, brake fluid leakage and depressurization system.

Check the technical condition of the brake mechanism spend before installing the front shoes in the following order:
- Clean all parts carefully and check their condition;
- Check the condition of the piston and cylinder. When they wear, damage, or severe corrosion, replace the cylinder and piston. Since the cylinder body, remove corrosion with a wire brush;
- Thoroughly clean the guide surfaces and the installation pad in the opening with a soft wire brush and wipe with a cloth soaked in alcohol (gasoline can not be used). Do not use this oleaginous solutions or sharp tools;

A warning
All cleaning brake spend in respiratory protective equipment - respirators, as the dust from the brake pads, released by the operation of the brakes is harmful to health.

- Check whether sitting in the holes staples disc brake protective caps guide pin. Solidified, torn, replace the protective caps;
- Check with your fingers clean working surfaces of brake discs. Remove them from the oil and dirt. On its surface are not allowed bullies, warping, profound risks as well as other injuries, from which increases or decreases the wear pads braking performance. Allowed grinding or turning of the disc at the same time on both sides, but both sides should be handled at the same depth, and thickness of the disc should be less than the permissible;

A warning
The brake discs with brake corroded surface must be replaced.

- Measure the actual thickness of the brake discs and brake linings. Brake discs with blue or gray bloom before installing new pads must be cleaned;
- Check for cracks in the dust cap of the piston cylinder. A damaged dust cover immediately replace as penetrating dust quickly leads to leakage of brake fluid.
The installation of front brake pads performed as follows:
- Remove the protective film from the supporting surface of the outer brake pad and gently insert the connector into the caliper;

Installation of the piston in the brake cylinder by means of a clamp
Fig. Installation of the piston 316 in the brake cylinder by means of a clamp





- Using the grip (Fig. 316) or a wooden (plastic) mandrel without skews move the piston inside the cylinder. Take care not to damage the surface of the piston and the dust cap. If indentation is an increase in the piston brake fluid level in the compensation tank, so before waterboarding piston is pumped from a tank siphon-blower part of the liquid to prevent it from spilling out of the tank;
- Together with an assistant check up ease of a piston stroke. To do this, install a support block of wood, and then slowly release the brake pedal. The piston cylinder must be easy to go out and come back (the rest of the brakes must be in working condition);
- Set the clips inner brake pad into the piston cylinder;
- Set the outer brake pad in the caliper, pad to the brake disc. Shoes should be clean and accurately enter into the guide;

Note
When installing the brake pads do not damage the adhesive on a metal plate.

- Carefully position the brake caliper on the brake disc, in its working position, please clean the guide fingers, wrap and alternately tighten them to 25 Nm;
- Wear on the head guide pin protection caps;
- Replace the spring caliper brake pads. Improper installation of automatic eyeliner outer brake pad does not work;
- Repeatedly press firmly on the brake pedal until you feel a strong resistance. At the same time the brake pads will take the position and provide a good fit to the brake disc;
- Bleed the brake system if needed;
- Establish and temporarily tighten (by hand) wheel bolts;
- Lower the car and tighten the wheel bolts crosswise;
- Check connections for leaks. Leaking fluids are not allowed;
- Check brake fluid level in the compensation tank and restore it to the required level;
- Check brake system for leaks with the engine running. What is click a few times on the brake pedal and hold it down for a few seconds. Pedal thus should not squander.

A warning
During the break-in new brake pads do not recommend sharp and prolonged braking to a full stop.




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Check the thickness of brake linings
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Disassembly and reassembly of the front wheel brake

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