VW Sharan repair

. Diesel engines: 1,9 l of TDI.
+ 1. Introduction
- 2. VR6 engine
   + 2.1. Cнятие and installation
   + 2.2. Dismantling and assembly
   - 2.3. Head of the block of cylinders and valves
      2.3.1. Removal of a head of the block of cylinders
      2.3.2. Dismantling of a head of the block of cylinders
      2.3.3. Repair of a head of the block of cylinders
      2.3.4. Assembly of a head of the block of cylinders
      2.3.5. Installation of a head of the block of cylinders
      2.3.6. Hydraulic pusher
   + 2.4. Pistons and rods
   2.5. Block of cylinders
   + 2.6. Cranked shaft and radical bearings
   + 2.7. Drive of the mechanism of a gazoraspredeleniye
   2.8. Intermediate shaft
   2.9. Compression check in engine cylinders
   + 2.10. System of production of the fulfilled gases
+ 3. Two-liter engine (ADY)
+ 4. System of greasing of the engine
+ 5. Cooling system
+ 6. System of injection of fuel of the VR6 engine
+ 7. Simos system of injection of fuel of the 2,0-liter engine
+ 8. Ignition system
+ 9. Coupling
+ 10. Mechanical 5-step transmission
+ 11. Shaft of a drive of wheels
+ 12. Hydraulic booster of a steering
+ 13. Forward suspension bracket
+ 14. Back suspension bracket
+ 15. Brake system
+ 16. Electric equipment
+ 17. Diesel engine
+ 18. System of greasing of the diesel engine
+ 19. System of cooling of the diesel engine
+ 20. Power supply system of the diesel engine and turbokompressor
+ maintenance Card
+ Specifications and characteristics
+ Elektroskhema




Repair Sharan/Sharan Volkswagen>> VR6 engine>> Head of the block of cylinders and valves>> Removal of a head of the block of cylinders

Fig. 26. Details of the top part of a head of the block of cylinders: 1 — bolts (5 N · м); 2 — the central cover (over the top part of the inlet pipeline); 3 — bolts (25 N · м); 4 — holders of wires of spark plugs; 5 — the holder of a cable of a butterfly valve; 6 — a back left arm of the top part of the inlet pipeline; 7 — a mouth stopper for the oil gulf; 8 — sealing laying; 9 — the ventilating valve of a case; 10 — a ring in a cover of a head of the block of cylinders; 11 — a nut (10 N · м); 12 — a cover of a head of the block of cylinders; 13 — sealing laying of a cover of a head of the block of cylinders; 14 — holders топливопроводов; 15 — a bolt (10 N · м); 16 — a vacuum hose; 17 — sealing laying of the top part of an inlet collector; 18 — the top part of an inlet collector; 19 — a back right arm of the top part of the inlet pipeline





Details which are required to be removed to dismantle a head of the block of cylinders from the block of cylinders, are shown on fig. 26 .
Head of the block of cylinders remove from the engine on the car if for elimination of malfunction it is not required to assort all engine. Removal of a head of the block of cylinders carry out in the following order:
- disconnect the plug «–» from AB;
- remove the top part of the air filter;
- separate shtekerny sockets of the switch of a butterfly valve, a heating element, the sensor of a mass consumption of air and the sensor of temperature of inlet air;
- take the ventilating valve of a case 9 (see fig. 26 ) from a cover of a head of the block of cylinders 12;
- disconnect from the top part of an inlet collector 18 vacuum hose of the 16th system with absorbent carbon. Thus watch, that the hose did not concern other details;
- remove an airpro-water hose with the sensor of a mass consumption of air from the butterfly valve case;
- remove wires of a high voltage (VN) from spark plugs;

Fig. 27. Top part of an inlet collector: 1, 3, 4 — directing wires of a high voltage; 2 — the central cover





- remove directing 1, 3, and 4 (fig. 27) of wires of VN and unscrew the bolts 1 shown on fig. 26 , and remove the central cover of the 2nd top part of an inlet collector;
- remove a cable of a drive of a butterfly valve together with its support for what unscrew a support and take the cable end. Do not pull out a clip holding a cable of a butterfly valve in a support as adjustment of a tension of a cable of a butterfly valve in this case will be necessary;
- open a cover of a broad tank of system of cooling to remove possible excess of pressure, and merge cooling liquid;
- mark attached to the butterfly valve case hoses of system of cooling and remove them from unions;
- disconnect a vacuum hose of the inlet valve for secondary system of supply of air;
- disconnect a vacuum hose of the amplifier of a brake drive from an inlet collector. A place of this connection 16 (see fig. 26 );
- take топливопроводы (a supply and removal of fuel) from holders 14 on a head of the block of cylinders and carefully disconnect fuel hoses. Before removal of hoses wind a thick rag round a junction as the fuel system is under pressure;
- unscrew directing tube maslomerny щупа, located in the bottom of an inlet collector;
- unscrew bolts of fastening and remove back left 6 (see fig. 26 ) and right the 19th arms between the top part of an inlet collector and a head of the block of cylinders;
- remove the top part of an inlet collector 18 together with the butterfly valve case. Watch that unloading plugs did not jump out. Inlet openings are open now, therefore close them in the corresponding way, for example, having stopped up with pure rags;
- unscrew bolts of fastening 15 and uncover heads of the block of cylinders 12 together with sealing laying 13;
- sideways from a cover of a head of the block of cylinders disconnect the holder of an electric cable and the EGR valve (the valve of system of a retsirkulyatsiya of the fulfilled gases);

Fig. 28. Partially disassembled head of the block of cylinders (the heads of a detail located on the top part were removed): 1 — a bolt, 25 N · m; 2 — a natyazhitel of a belt; 3 — the distributor of supply of fuel; 4 — sealing laying of the lower part of an inlet collector; 5 — the lower part of an inlet collector; 6 — an ear for lifting; 7 — a bolt, 25 N · m; 8 — a bolt of fastening of a head of the block of cylinders; 9 — a head of the block of cylinders; 10 — laying of a head of the block of cylinders; 11 — a bolt, 25 N · m; 12 — the About-shaped ring; 13 — the thermostat case; 14 — a bolt, 10 N · m; 15 — the holder of a cable; 16 — a bolt, 10 N · m; 17 — the ignition coil; 18 — bolts, 10 N · m; 19 — the holder; 20 — a sealing ring; 21 — a natyazhitel of a chain, 30 N · m; 22 — a bolt, 10 N · m; 23 — the Hall sensor; 24 — a rasporny ring; 25 — the About-shaped ring; 26 — a rasporny ring; 27 — a cover of camshafts; 28 — the About-shaped ring





- then unscrew the holder 19 (fig. 28) which fixes a shtekerny block with 42 contacts, and also the additional pump of system of the cooling intended for protection of the stopped engine from an overheat;
- disconnect the shtekerny socket of the sensor of temperature of cooling liquid;
- remove maple a belt of a drive of units of the engine;
- disconnect a reception pipe with the catalyst from a final collector;

Fig. 29. Arrangement of the coil of ignition: 1 — wire fastening; 2 — a shtekerny block; 3 — a fastening bolt





- unscrew bolts of fastening 3 (fig. 29) and disconnect the coil of ignition 17 (see rice 28 ) from a head of the block of cylinders;
- remove a steering drive (see подразд. 12.1) so that the top dvukhryadny chain of asterisks of camshafts was liberated;
- turn out a natyazhitel of the bottom single-row chain of a drive of the intermediate shaft, located sideways on a head of the block of cylinders;
- uncover 27 camshafts. At installation the cover should be covered with hermetic (AMV188 001 002). If the cover of a head of the block of cylinders was removed only, and the block of cylinders did not act in film, sealing laying of a head of the block of cylinders should be prepared for cover installation according to the recommendations provided further;
- disconnect from a head of the block of cylinders all electric wires;

Fig. 30. Sequence of an inhaling of bolts of fastening of a head of the block of cylinders. Otvertyvaniye of bolts is carried out in return sequence





- in stages turn on in sequence, return specified (fig. 30) , bolts of fastening of a head of the block of cylinders;
- remove a head of the block of cylinders. If it became attached, on it it is possible to strike several times with a plastic or rubber hammer for simplification of removal;
- if further dismantling of a head of the block of cylinders is necessary, it is necessary to remove the lower part of an inlet collector, a natyazhitel of a belt, the distributor of supply of fuel and others, established on a head of the block of cylinders, a detail.