VW Sharan repair

. Diesel engines: 1,9 l of TDI.
+ 1. Introduction
+ 2. VR6 engine
- 3. Two-liter engine (ADY)
   3.1. Removal and installation
   + 3.2. Dismantling and assembly
   - 3.3. Head of the block of cylinders and valves
      3.3.1. Removal of a head of the block of cylinders
      3.3.2. Dismantling of a head of the block of cylinders
      3.3.3. Repair of a head of the block of cylinders
      3.3.4. Assembly of a head of the block of cylinders
      3.3.5. Installation of a head of the block of cylinders
      3.3.6. Hydraulic pusher
      3.3.7. Replacement of an epiploon of a camshaft
   + 3.4. Pistons and rods
   3.5. Block of cylinders
   + 3.6. Cranked shaft and radical bearings
   + 3.7. Drive of the mechanism of a gazoraspredeleniye
   3.8. Adjustment of a tension of a driving belt of units of the engine
   3.9. Intermediate shaft
   3.10. Compression check in engine cylinders
   3.11. System of production of the fulfilled gases
   3.12. Cleaning system with absorbent carbon application
   3.13. System of a retsirkulyatsiya of the fulfilled gases
+ 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>> Two-liter engine (ADY)>> 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. 112. Removal of the bottom plate of springs of the valve by means of special nippers 3047





- by means of special nippers 3047 (see fig. 112 ) establish the bottom plates of valves;

Fig. 122. Installation of a maslootrazhatelny cap: 1 — a plastic sleeve; 2 — a maslootrazhatelny cap; 3 — the special tool 3129





- using the special tool 3 (fig. 122) , establish maslootrazhatelny caps 2, for what:
- get a plastic sleeve 1 by means of the special tool 3129 on an acting part of the directing plug of the valve;
- well grease with engine oil a maslootrazhatelny cap 2 and put on it a plastic sleeve;
- put on the special tool 3129 a maslosjemny cap and carefully get it in directing plug;

Note
Installation of maslootrazhatelny caps without use of the special tool 3129 can damage them that will lead to the increased consumption of oil.

- after carrying out grinding in of valves each valve should be established in that saddle to which it was ground in;
- establish in openings of a head of the block of cylinders on one internal and external spring for the corresponding valve (if old springs are established);

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




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




- put on the top plate of a spring 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 (crackers) 2 (see fig. 37 ) in cylindrical flutes of a core and smoothly to press a stripper of valves;
- with a plastic hammer strike by the top part of a core of the valve. Thus incorrectly established crackers will take off from a cylindrical flute;

Fig. 109. Marking of hydraulic pushers





- insert hydraulic pushers according to the risks put earlier (see fig. 109 ) into openings (previously having greased them with engine oil);

Note
Before final installation of pushers read indications of rather hydraulic pushers (see item 3.3.6) to avoid engine damage at his first ambassador of work start.

- plentifully grease with engine oil of a neck (the location of bearings) camshaft;
- lay a camshaft in support of a head of cylinders and several times them turn. Establish a camshaft so that both cams of the first cylinder on a shaft looked up;

Fig. 108. Camshaft details: 1 — a bearing No. 5 cover; 2 — a bearing No. 4 cover; 3 — a bearing No. 3 cover; 4 — a bearing No. 2 cover; 5 — a nut, 20 N · m; 6 — a bearing No. 1 cover; 7 — a camshaft; 8 — a segment shponka; 9 — a bolt with a washer, 80 N · m; 10 — a camshaft cogwheel





- put on covers of bearings No. 2 and 4 (see fig. 108 ) and by hand screw nuts;

Fig. 123. Installation of a cover of the bearing of a camshaft on a head of the block of cylinders





- check, that covers of the bearing were correctly established, as is shown in fig. 123 , and only after that wrap fastening 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 No. 5, 1 and 3;
- turn a camshaft several times to be convinced that it is not clamped anywhere;
- at installation of an epiploon grease with engine oil a sealing surface (it is necessary to grease and a surface of a kacheniye of a camshaft) and look, that the epiploon party on which the spring is located, it was directed in a head of the block of the cylinder. For installation of an epiploon it is possible to use a pipe which should correspond to the size of an external part of an epiploon completely. Put an epiploon directly (without distortions) and впрессовывайте it until its external surface will not come completely inside. To establish an epiploon it is possible in the way described in item 3.6.4 for a new forward epiploon of a cranked shaft;
- establish inlet and final collectors on a head of the block of cylinders (thus surely use new laying).