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  • Examplepage for repair manual 4-cylinder diesel engine (1.9 l engine)
  • Examplepage for repair manual 2 4-cylinder diesel engine (1.9 l engine)
  • Examplepage for repair manual 3 4-cylinder diesel engine (1.9 l engine)

4-cylinder diesel engine (1.9 l engine)

For Sharan

Original Volkswagen repair manual


15,46 €7% VAT incl.

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  • English

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Language: English

Digital PDF file

5.867 KB

184 Sites

Detailed technical data

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This repair manual contains: Removing and installing engine, Sealing flange and flywheel, Crankshaft, Pistons and conrods, Cylinder head, Engine oil, Oil filter bracket, oil pressure, engine oil cooler and oil supply line, Charge air system with turbocharger and Repairing diesel direct injection system. Show more
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Repair manual Sharan 4-cylinder diesel engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Engine number
    1
  • 1.2 Engine data
    1
  • Removing and installing engine
    2
  • 1 Removing and installing engine
    2
  • 1.1 Notes on removing
    3
  • 1.2 Securing engine to assembly stand
    6
  • 1.3 Notes on installing
    7
  • 1.4 Assembly mountings
    9
  • 1.5 Additional information and assembly work for vehicles with air conditioner
    10
  • Crankshaft group
    12
  • 1 Dismantling and assembling engine
    12
  • 1.1 Assembly overview - poly V-belt drive
    12
  • 1.2 Removing and installing poly V-belt
    14
  • 1.3 Assembly overview - toothed belt drive
    15
  • 1.4 Assembly overview - crankcase
    17
  • 2 Sealing flange and flywheel
    19
  • 2.1 Assembly overview - sealing flanges and flywheel
    19
  • 2.2 Renewing crankshaft oil seal - pulley end
    21
  • 2.3 Removing and installing sealing flange - pulley end
    23
  • 2.4 Removing and installing drive plate
    27
  • 3 Crankshaft
    29
  • 3.1 Assembly overview - crankshaft
    29
  • 3.2 Crankshaft dimensions
    30
  • 3.3 Checking dowel pin projection out of crankshaft
    30
  • 4 Pistons and conrods
    32
  • 4.1 Assembly overview - pistons and conrods
    32
  • 4.2 Piston and cylinder dimensions
    35
  • 4.3 Checking piston projection at TDC
    35
  • Cylinder head, valve gear
    37
  • 1 Cylinder head
    37
  • 1.1 Assembly overview - cylinder head
    37
  • 1.2 Removing and installing cylinder head cover
    40
  • 1.3 Removing, installing and tensioning toothed belt
    42
  • 1.4 Removing and installing cylinder head
    55
  • 1.5 Compression test
    59
  • 2 Valve gear
    62
  • 2.1 Assembly overview - valve gear
    62
  • 2.2 Checking valve guides
    65
  • 2.3 Renewing valve stem seals
    65
  • 2.4 Removing and installing camshaft
    67
  • 2.5 Removing and installing camshaft oil seal
    71
  • Lubrication
    74
  • 1 Engine oil
    74
  • 1.1 Oil capacities
    74
  • 1.2 Checking engine oil level
    74
  • 2 Parts of lubrication system
    75
  • 2.1 Assembly overview - oil pump, sump
    75
  • 2.2 Removing and installing oil sump
    77
  • 3 Oil filter bracket, oil pressure, engine oil cooler and oil supply line
    80
  • 3.1 Assembly overview - oil filter bracket and engine oil cooler: Engine codes ANU, AUY, BVK
    80
  • 3.3 Assembly overview - oil supply line to turbocharger
    83
  • 3.4 Removing and installing oil supply line to turbocharger
    83
  • 3.5 Checking oil pressure and oil pressure switch
    86
  • Cooling
    88
  • 1 Removing and installing parts of cooling system
    88
  • 1.1 Assembly overview - cooling system, body side: Engine codes ANU, AUY, BVK
    89
  • 1.2 Assembly overview - cooling system, body side: Engine codes ASZ, BTB
    91
  • 1.3 Assembly overview - cooling system, engine side: Engine codes ANU, AUY, BVK
    92
  • 1.5 Assembly overview - additional cooler
    95
  • 1.6 Coolant hose schematic diagram: Engine code ANU
    97
  • 1.7 Coolant hose schematic diagram: Engine codes AUY, BVK
    98
  • 1.8 Coolant hose schematic diagram: Engine codes ASZ, BTB
    99
  • 1.9 Draining and filling coolant
    100
  • 1.10 Removing and installing radiator and fan
    103
  • 1.11 Removing and installing coolant pump
    105
  • 1.12 Removing and installing thermostat
    107
  • 1.13 Checking cooling system for leaks
    109
  • 1.14 Checking engine oil cooler for leaks
    111
  • Fuel supply system
    114
  • 1 Removing and installing parts of fuel supply system
    114
  • 1.1 Safety precautions when working on fuel supply system
    115
  • 1.2 Rules for cleanliness
    115
  • 1.3 Assembly overview - fuel tank
    115
  • 1.4 Assembly overview - fuel filter: Engine codes ANU, AUY, BVK
    117
  • 1.5 Assembly overview - fuel filter: Engine codes ANU, ASZ, AUY, BTB, BVK
    119
  • 1.6 Assembly overview - heat exchanger for fuel cooler
    120
  • 1.7 Removing and installing fuel cooler: Engine codes ANU, AUY, BVK
    122
  • 1.8 Emptying fuel tank
    123
  • 1.9 Removing and installing fuel tank
    125
  • 1.10 Removing and installing fuel delivery unit
    128
  • 1.11 Removing and installing fuel gauge sender
    130
  • 1.12 Checking fuel pump
    130
  • 1.13 Checking tandem pump
    132
  • 1.14 Removing and installing tandem pump
    136
  • 1.15 Assembly overview - accelerator mechanism
    138
  • Turbocharging/supercharging
    140
  • 1 Charge air system with turbocharger
    140
  • 1.1 Safety precautions
    141
  • 1.2 Rules for cleanliness
    141
  • 1.3 Hose connections with push-on connectors
    141
  • 1.4 Assembly overview - turbocharger: Engine code ANU
    142
  • 1.5 Assembly overview - turbocharger: Engine codes ASZ, BTB
    145
  • 1.6 Assembly overview - turbocharger: Engine codes AUY, BVK
    147
  • 1.7 Assembly overview - charge air cooling: Engine codes ANU, AUY, BVK
    149
  • 1.8 Assembly overview - charge air cooler: Engine codes ASZ, BTB
    151
  • 1.9 Checking charge air system for leaks
    152
  • 1.10 Charge pressure control hose routing diagram: Engine code ANU
    153
  • Mixture preparation - injection
    156
  • 1 Repairing diesel direct injection system
    156
  • 1.1 Safety precautions
    156
  • 1.2 Rules for cleanliness
    157
  • 1.3 General notes on injection
    157
  • 1.4 Overview of fitting locations
    157
  • 1.5 Assembly overview - intake manifold flap
    158
  • 1.6 Assembly overview - air filter
    160
  • 1.7 Assembly overview - unit injector
    160
  • 1.8 Removing and installing O-rings for unit injector
    161
  • 1.9 Removing and installing unit injector
    163
  • 2 Engine control unit
    168
  • 2.1 Reading and erasing engine control unit fault memory
    168
  • 2.2 Removing and installing engine control unit
    169
  • Exhaust system
    170
  • 1 Removing and installing parts of exhaust system
    170
  • 1.1 Assembly overview - front exhaust pipe with catalytic converter
    170
  • 1.2 Assembly overview - silencers
    171
  • 2 Exhaust gas recirculation system
    173
  • 2.1 Assembly overview - exhaust gas recirculation: Engine code ANU
    173
  • 2.3 Checking mechanical exhaust gas recirculation valve
    176
  • Glow plug system
    177
  • 1 Checking glow plug system
    177
  • 1.1 Checking glow plugs
    178
Manufacturer's designation 4-cylinder diesel engine (1.9 l engine)
Manufacturer Volkswagen
Suitable for Sharan (1995 - 2010)
Suitable car types 7M
Engine code ANU, ASZ, AUY, BTB
Category Reparaturanleitung

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