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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
Removing and installing the gearbox from the engine
Additional operations, if the car is equipped with air conditioning
Engine Mount
Disassembly and assembly
Cylinder head and valves
The pistons and connecting 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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Removing and installing






The power unit consists of an engine and gearbox. Shoot it using the hydraulic lift or hoist, dropping from the engine compartment.
Before removing the power unit, do the following:
- If the car has an alarm system with security code, the code is necessary to have at itself, to turn the system on after connecting AB;
- When removing the engine will need to disconnect a large number of electric wires and vacuum hoses and coolant hoses. Before removing wires and hoses tag them using tags;
- Before the assembly work in the engine compartment must be closed with a thick cloth front wings of the car.
Removal of the power unit in the following order:
- Turn off the engine and remove the ignition key;
- Disconnect terminal "-" of the AB;

A warning
In order to avoid damage to the computer, you must disconnect the terminals AB only with the ignition off. And for a complete ignition is switched off wait at least 20 seconds and only then you can disable the "-" terminal of the AB.


Removing AB
Fig. 18. Removing AB: 1 - a casing of the air duct; 2 - partition





- Remove the screws (arrows, Fig. 18) and remove the casing of the air duct 1 and partition 2;
- Remove the AB (see. Section 16.1);
- Drain the coolant from the cooling system (see. Section 19.1);

Remove the cover AB
Fig. 19. Remove the cover AB





- Remove the screws (arrows, Fig. 19), slide to the side and remove the cover AB together with expansion tank of cooling system;
- Remove the V-belt drive system of the engine;
- Disconnect the hose from the air duct assembly housing throttle;
- When a spark plug wrench, remove the spark plugs and put them in the order of the cylinders. In VR6 engine caps candles and candles themselves can be removed only with a special spark plug wrench under number 3277A;

Removing the central cover on the upper portion of the inlet manifold
Fig. 20. Removal of the center cover at the upper portion of the inlet manifold 1, 3, 4 - high voltage rail; 2 - the central cover





- Remove the rails 1, 3 and 4 (Fig. 20) high voltage and remove the central part of the top cover 2 intake manifold;
- Remove the accelerator cable along with its support for undoing the support and remove the cable end. Do not remove the clip that holds the throttle cable to support (as in this case it will be necessary tension adjustment throttle cable);

Details top of the cylinder head
Fig. 26. Details of the upper part of the cylinder head: 1 - screws (5 Nm); 2 - the central cover (above the upper part of the inlet pipeline); 3 - bolts (25 Nm); 4 - holders spark plug wires; 5 - the holder of the throttle cable; 6 - rear left bracket upper portion of the inlet pipe; 7 - tube neck for Gulf oil; 8 - gasket; 9 - crankcase ventilation valve; 10 - ring to the cylinder head cover; 11 - a nut (10 Nm); 12 - the cylinder head cover; 13 - gasket cylinder head cover; 14 - holders of the fuel; 15 - a bolt (10 Nm); 16 - a vacuum hose; 17 - gasket top of the intake manifold; 18 - the top of the intake manifold; 19 - rear right arm upper part of the inlet pipeline





- Disconnect the spring clamp holders 14 fuel (see. Fig. 26) supply and discharge of fuel;
- Mark the fuel hoses and disconnect the supply and removal of fuel from the fuel distributor;

A warning
The fuel lines are under pressure. Before disconnecting the fuel hose from its mounting, grasp the point of attachment of the fuel hose thick cloth, and gently pulling it to the site of attachment, release pressure in the system.

- Disconnect the plug connector with a large 42 connectors located in the vicinity of the ignition coil;
- Disconnect the vacuum hose brake booster;
- Disconnect the power steering pipe from the engine nozzle. Power steering pump, unscrew with the bracket and hang on a wire to the body. Do not twist the hoses and make sure the pump is hung on the hose;

Elements of the front of the exhaust system
Fig. 100. Elements of the front of the exhaust system: 1 - Screen thermal motor protection; 2 - an exhaust manifold consisting of two parts; 3 - lifting eye; 4 - nut 40 Nm; 5 - Screen thermal motor protection; 6 - a nut screen thermal protection; 7 - a lining, to replace; 8 - a reception pipe; 9 - nut 10 Nm; 10 - socket for connecting the EGR, 35 Nm





- Disconnect a reception pipe 8 and the middle part of the exhaust system with catalytic converter from the exhaust manifold 2 (see.

Elements of the middle part of the exhaust system (located between the receiving pipe and silencer catalyst)
Fig. 101. Elements of the middle part of the exhaust system (arranged between the receiving pipe and the muffler catalyst): 1 - a nut thermal protection screen; 2 - Screen thermal protection; 3 - the direction of the first muffler; 4 - catalyst; 5 - a protective collar; 6 - Screen thermal protection; 7 - bolt 10 Nm; 8 - a protective collar; 9 - a bolt 10 Nm; 10 - nut 40 Nm; 11 - lambda probe; 12 - plug connector black



Fig. 100 and 101);
- In the VR6 engine installed secondary air supply, the basic details of which are located close to the radiator. To remove the engine casing must be removed from the fan and secondary air pump motor (see. Sect. 5.2.2);
- Disconnect all hoses from the engine coolant hoses and vacuum hoses of ventilation of the engine;
- Disconnect from the engine and gearbox all electric wires. Among these wires: alternator, starter, gidronapornogo oil switch, various sensors. Most of the compounds is carried out by means of plug-in pads;
- Remove the generator;
if installed Manual Transmission:
- Disconnect from the clutch slave cylinder hose;
- Remove the draft of a gear with a transmission (see. Section 10.1);
- Remove both drive shafts from the gearbox mountings (see. Section 11.1);
a car with an automatic transmission:
- Remove the thrust lever mode selection;
- Remove both drive shafts from the gearbox mountings,
- If the car is equipped with air conditioning, in addition to this section, be sure to read the relevant recommendations;

Backup Engine
Fig. 21. Backup Engine: 1 - bolts; 2 - lifting yoke; 3 - Lift





- Support the engine underneath. In SRT it uses a special device (fig. 21), which is then substituted by a car jack. Besides hedge should lift that supports the top of the loop engine. If the vehicle jack slip, the motor in this case will hold a lift;
- Remove the balancer (pendulum) suspension. It is connected with the front support, so you should read the relevant section in order to learn more about its mounting;

The right engine mount
Fig. 22. The right engine mount 1 - bolts





- Turn out bolts 1 (fig. 22) securing the support of the right engine mount. Please note that for tightening nuts and bolts of an engine mount, various torques;

Mounting the engine exploded in a car with a manual transmission. Tightening torques of mounting bolts the engine mount
Fig. 23. Suspension of the engine exploded in a car with a manual transmission. Tightening torques of mounting bolts the engine mount 1 = 55 Nm; 2 = 110 Nm; 3 = 100 Nm; 4 = 20 N ? m





- Remove the mounting bolts left engine mount. Fixing support suspension left (Fig. 23) depends on the type of engine installed gearbox. At this stage of work is necessary to unscrew bolts 1 only, the location of which is the same for all types of transmission;
- Together with an assistant slowly lower the powerplant from the engine compartment. Make sure the engine is not damaged while the bodywork.
Installation of the power unit is carried out in reverse order of removal, and the do the following:
- Check the thickness of the lining on the clutch disc. In the case of wear, replace the clutch disc;
- Carefully rewound the power unit in the engine compartment. Take care not to damage the parts and components of the vehicle;
- The alignment of the engine with fasteners supports suspension, tighten by hand for 5-6 turns of mounting bolts. Shake the engine back and forth (he must not be energized);
- Tighten the bolts supports suspension of the power unit the following points:
- Pos. 1 = 55 Nm; Pos. 2 = 110 Nm; Pos. 3 = 100 Nm; Pos. 4 = 20 N ? m (see. Fig. 23) - for the engine with manual transmission;

The right engine mount disassembled. Tightening torques of fastening of support suspension
Fig. 24. The right engine mount exploded. Tightening torques of fastening of support arm: 1 = 55 Nm; 2 = 60 Nm





- Pos. 1 = 55 Nm; Pos. 2 = 60 Nm (fig. 24) - the right-hand engine mounting;

The right engine mount exploded in a car with automatic transmission. Tightening torques of fastening of support suspension
Fig. 25. The right engine mount exploded in a car with automatic transmission. Tightening torques of fastening of support arm: 1 = 55 Nm; 2 = 110 Nm; 3 = 60 Nm





- Pos. 1 = 55 Nm; Pos. 2 = 110 Nm; Pos. 3 = 60 Nm (fig. 25) - the right-hand engine mounting on a vehicle with automatic transmission;
- Set equalizer (pendulum) suspension (see. Section 13);
- Set the drive shafts. Special key to tighten the multifaceted bolts specified torque. For manual and automatic gearboxes different torques (see. "Table of tightening torques");
- Depending on the type of transmission rod set and adjust the gearshift control;
- Attach the hose to the clutch slave cylinder and secure with spring clip (for manual transmission);
- Attach to the exhaust manifold exhaust pipe with catalytic converter. After aligning the muffler and exhaust pipe hang them on the ring suspension. Watch for correct installation. Rings suspension must have a uniform tension and should not be twisted;
- Set the power steering pump;
- Replace the cover with the fan and the motor secondary air pump;
- Install V-belt drive system of the engine;
- Set the throttle cable and check her work;
- Set the air intake hose and the air filter;
- Install all previously disconnected electrical wires;
- Pour coolant in the cooling system when the heater tap is open. Bring the coolant level in the expansion tank to the required level, screw the expansion tank cap. Turn on the engine for a few minutes to, release all air pockets. Then, check the coolant level in the expansion tank and if necessary add coolant;
- Bleed the clutch by pumping with the obligatory participation assistant;
- Connect the battery and take a test drive. Check all hose connections for leaks;
- Enter the code anti-theft system (if installed on the vehicle).
At the first opportunity should call the service station to check the memory self-test fault recorder system.




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Removing and installing the gearbox from the engine

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