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>> Assembly of a head of the block of cylinders
Assembly of a head of the block of cylinders carry out in sequence, return dismantling, observing the following recommendations:
- plentifully grease cores of valves with engine oil and insert them into the corresponding directing plugs;

Fig. 49. Installation of a maslootrazhatelny cap: 1 — a plastic sleeve; 2 — a maslootrazhatelny cap; 3 — the special tool 3129





- using the special tool 3 (fig. 49) , establish maslootrazhatelny caps 2, for what:
- get a plastic sleeve of 1 special tool 3129 on an acting part of the directing plug of the valve;
- well grease with engine oil a maslootrazhatelny cap and put on it a plastic sleeve;
- put on the special tool 3129 a maslootrazhatelny cap and carefully press on directing plug;

Note
At installation of maslootrazhatelny caps without use of the special tool 3129 they can be damaged that will lead to the increased consumption of oil.

- if grinding in of valves was made, each valve should be established in that saddle to which it was ground in;

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





- establish in openings of a head of the block of cylinders on one internal and external spring 4 (see fig. 37 ) for the corresponding valve (if old springs are established);

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





- put on the top plate of 3 springs of the valve. Establish a stripper of valves (see fig. 36 ) to squeeze springs. If the end of a core of the valve acts from the top plate of a spring of the valve, it is necessary to establish both half of a core of the valve 2 (see fig. 37 ) in a nest of a core and smoothly to press a stripper of valves;
- insert hydraulic pushers according to the risks put earlier into openings, previously having greased them with engine oil;
- plentifully grease with engine oil of a neck (the location of bearings) camshafts;
- lay camshafts in support of a head of cylinders and several times them turn. Soriyentiruyte camshafts so that both cams of the first cylinder on two shaft looked up;
- mount both camshafts in a head of the block of cylinders as follows.
Assembling of a camshaft of a number of cylinders 1, 3 and 5

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




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




Fig. 50. Numbering of covers of bearings of camshafts




Plentifully grease inside of covers of bearings with engine oil and establish on a head of the block of cylinders of a cover of bearings 3 and 5 (see fig. 34 ), and covers of bearings 1 (see fig. 31 ) a camshaft according to fig. 50 :

Note
Figures on the established covers of bearings should be read from an exhaust pipe, and shooters on the established covers should specify towards a flywheel of a cranked shaft.

- tighten four nuts alternately, cross-wise in stages and tighten them the moment of 20 N · m. Thanks to a uniform inhaling of a spring of valves will be slowly compressed, and thus it will be possible to avoid a camshaft distortion;
- similarly establish covers of bearings 1 and 7;
- turn a camshaft several times to be convinced that it is not clamped anywhere.
Assembling of a camshaft of a number of cylinders 2, 4 and 6
Plentifully grease inside of covers of bearings with engine oil and establish on a head of the block of cylinders of a cover of bearings 2 and 6 (see fig. 34 ), and covers of bearings 1 (see fig. 31 ) a camshaft, according to fig. 50 :

Note
Figures on the established covers of bearings should be read from an exhaust pipe, and shooters on the established covers should specify towards a flywheel of a cranked shaft.

- tighten four nuts alternately, cross-wise, in stages and tighten them the moment of 20 N · m. Thanks to a uniform inhaling of a spring of valves will be slowly compressed, and thus it will be possible to avoid a camshaft distortion;
- similarly establish a bearing 4 cover;
- turn the second camshaft several times to be convinced that it is not clamped anywhere;
- put on asterisks camshafts. Asterisks should be established on those shaft on which stood before dismantling. Cледите that asterisks were fixed by stoppers;
- on one of camshafts establish a lead of the driving mechanism of the sensor of the Hall 5 (see fig. 31 );
- establish on camshafts of an asterisk 4 (see fig. 31 ) a drive. Adjoining surfaces of a lead and an asterisk of a drive should be dry;


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




- twirl bolts 6 (see fig. 31 ) fastenings of asterisks, fix camshafts in motionless situation with the help of shestigrannik (see fig. 32 ) and tighten both bolts of fastening of asterisks the moment of an inhaling of 100 N · m. After that unblock camshafts;
- clear a surface of a cover of camshafts and put on it AMV 188 002 02 hermetic;
- establish a cover. At first tighten in turn bolts by hand then tighten them around with the moment of an inhaling of 10 N · m. Whether check from the interior of a cover the About-shaped ring which should be in a cover is inserted;

Fig. 51. Cleaning of openings. The arrow showed places of cleaning of openings in diameter of 3 mm





- if both camshafts (or only one camshaft) were removed at the established engine before establishing a cover of camshafts, it is necessary to smooth out both three-millimetric openings ( fig. 51 , are shown by shooters) in a cover of a head of the block of cylinders and to grease with AMV 188 002 02 hermetic;
- establish the ignition coil;
- establish on a head of the block of cylinders everything removed before a detail which quantity depends on volume of carried-out repair work. Except for details which are established at installation of a head of the block of cylinders not to do one work twice.