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>> Dismantling of a head of the block of cylinders
Dismantling of a head of the block of cylinders carry out in the following order:

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





- remove all remained details located on a head of the block of cylinders (see fig. 28 );
- clamp a head of the block of cylinders a collar fastened to the adjusting screw of the inlet pipeline;
- remove camshafts (it can be made and on not removed engine), for what:

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





- remove directing wires of spark plugs (see fig. 27 );
- remove the top part of the inlet pipeline. Close open inlet channels a pure rag in order that foreign matters inside did not get;
- turn a cranked shaft so that the piston of the first cylinder appeared in the top dead point (VMT). If the engine is not removed, it is possible to raise slightly a forward wheel, to include the fifth transfer and, rotating a wheel, to establish the piston in situation VMT. If the engine is removed, put on a nut of a flywheel of a cranked shaft a cap wrench and turn a shaft so that both cams of a camshaft for valves of the first cylinder looked the round party up;
- remove the ignition coil;
- if the engine is not removed, uncover heads of the block of cylinders;
- remove a protective casing of asterisks of a drive of camshafts;

Fig. 31. Components of camshafts together with covers of bearings and asterisks: 1 — a cover of the bearing of a camshaft; 2 — a nut, 20 N · m; 3 — camshafts; 4 — asterisks of camshafts; 5 — the driving mechanism of the sensor of the Hall; 6 — bolts, 100 N · m





- turn out bolts 6 (fig. 31) of asterisks 4 drives of camshafts;

Fig. 32. Fixing of camshafts. Shooters showed the shestigrannik intended for fixing of camshafts





- fix camshafts in a motionless condition. For this purpose on everyone to a shaft there is a shestigrannik ( fig. 32 , it is shown by an arrow) on whom put on a rozhkovy key «24 mm» and hold a camshaft.
- turn out a natyazhitel 21 (see fig. 28 ) chains from a head of the block of cylinders;

Fig. 33. Places for marking of chains of a drive of camshafts before removal are shown by shooters





- remove asterisks of a drive of camshafts. If the chain of a drive of a camshaft is not removed yet, it should be noted the direction of installation of a chain (fig. 33) in order that it was possible to establish it correctly;

Fig. 34. Numbering of covers of bearings of camshafts. On each cover there is an arrow showing the direction of installation





- at first remove a camshaft of a number of cylinders 1, 3 and 5 (fig. 34) . For this purpose weaken fastening of both covers of extreme bearings (number 1 and 7), and then, having unscrewed them completely, remove covers;
- evenly to unload springs of valves, alternately cross-wise weaken nuts of covers of bearings (number 3 and 5) so that covers of bearings did not test pressure from springs;
- remove both covers of bearings;
- take out a camshaft from support of a head of cylinders;
- remove a camshaft of a number of cylinders 2, 4 and 6 (see fig. 34 ). For this purpose alternately cross-wise weaken nuts of a cover of the bearing number 4, and uncover the bearing;
- similarly remove covers of bearings number 2 and number 6;
- take out the second camshaft;

Fig. 35. Marking of hydraulic pushers





- put risks scratches on inside of pushers, i.e. the first pusher — one risk, the second pusher — the 2nd risks etc. (fig. 35) as it is impossible to confuse them (counting begin with the party of a drive of units of the engine) and take out pushers. Do not put pushers, and put the contact plane down;

Note
Pushers are supplied with the hydraulic elements regulating a gap in the valve a drive and consequently it is necessary to handle with care with pushers.


Fig. 36. Removal of valves by means of the special adaptation of Volkswagen firm





- the standard tool for removal and installation of valves is the tool at number 2036 (fig. 36) . It fastens to a head of the block of cylinders. Release the valve 8 (fig. 37) from half of a rod of the valve (crackers) 2, compressing springs the 4th adaptation 2036;

Fig. 37. Details of the mechanism of a drive of valves: 1 — a hydraulic pusher; 2 — half of a core of the valve (crackers); 3 — the top plate of a spring of the valve; 4 — valve springs; 5 — a maslootrazhatelny cap; 6 — the directing plug of the valve; 7 — a head of the block of cylinders; 8 — valves; a — height of a head of the block of cylinders





- for removal of valves it is possible to use also a piece of a pipe which is put on the top plate of a spring. Under a plate of the valve on the other hand it is necessary to enclose something to fix it. Shortly strike with a hammer on a pipe so that there were half of a rod of the valve. They remain in a pipe;
- take out the top plate 3 (see fig. 37 ) with springs 4, turn a head of cylinders 7 and take out from the bottom party the valve 8;
- remove a maslootrazhatelny cap 5 from the directing plug 6;

Note
Maslootrazhatelnye caps always replace new.

- if at the car big run or works are carried out on the second-hand car, about which a little that is known before establishing into place the block of cylinders it is necessary to measure height of a head of the block of cylinders — size a (see fig. 37 ).