Repair VW Sharan

. Diesel engines: 1,9 l TDI.
+ 1. Introduction
- 2. Engine VR6
   + 2.1. Cнятие and installation
   + 2.2. Dismantling and assemblage
   - 2.3. A 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. Assemblage of a head of the block of cylinders
      2.3.5. Installation of a head of the block of cylinders
      2.3.6. A hydraulic pusher
   + 2.4. Pistons and rods
   2.5. The block of cylinders
   + 2.6. A cranked shaft and radical bearings
   + 2.7. A mechanism drive газораспределения
   2.8. An intermediate shaft
   2.9. Compression check in engine cylinders
   + 2.10. System of release of the fulfilled gases
+ 3. The two-litre engine (ADY)
+ 4. System of greasing of the engine
+ 5. Cooling system
+ 6. System of injection of fuel of engine VR6
+ 7. System Simos of injection of fuel of the 2,0-litre engine
+ 8. Ignition system
+ 9. Coupling
+ 10. A mechanical 5-step transmission
+ 11. Shaft of a drive of wheels
+ 12. The steering hydraulic booster
+ 13. A forward suspension bracket
+ 14. A back suspension bracket
+ 15. Brake system
+ 16. An electric equipment
+ 17. The diesel engine
+ 18. System of greasing of the diesel engine
+ 19. System of cooling of the diesel engine
+ 20. The power supply system of the diesel engine and turbocharger
+ Maintenance service card
+ Specifications and characteristics
+ Electroschemes




Folksvagen Sharan/Sharan repair>> Engine VR6>> Head of the block of cylinders and valves>> Assemblage of a head of the block of cylinders
Assemblage of a head of the block of cylinders spend in sequence, return dismantling, observing following recommendations:
- Plentifully grease cores of valves with engine oil and insert them into corresponding directing plugs;

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





- Using the special tool 3 (fig. 49), establish маслоотражательные caps 2, for what:
- Spread a plastic sleeve of 1 special tool 3129 on an acting part of the directing plug of the valve;
- Well grease with engine oil маслоотражательный a cap and put on it a plastic sleeve;
- Put on the special tool 3129 on маслоотражательный a cap and cautiously press on directing plug;

The note
At installation маслоотражательных caps without application of the special tool of 3129 them it is possible to damage that will lead to the increased expense of oil.

- If grinding in of valves each valve should be established in that saddle to which it has been ground in has been made;

Fig. 37. Details of the mechanism of a drive of valves: 1 — a hydraulic pusher; 2 — half of core of the valve (crackers); 3 — the top plate of a spring of the valve; 4 — valve springs; 5 — маслоотражательный a 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 apertures of a head of the block of cylinders on one internal and external spring 4 (fig. 37 see) for the corresponding valve (if old springs are established);

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





- Put on the top plate of 3 springs of the valve. Establish a stripper of valves (fig. 36 see) 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 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 apertures, preliminary having greased with their engine oil;
- Plentifully grease with neck engine oil (the location of bearings) camshafts;
- Lay camshafts in support of a head of cylinders and some times them turn. Сориентируйте camshafts so that both cams of the first cylinder on two shaft looked upwards;
- Mount both camshafts in a head of the block of cylinders as follows.
Assembling of a camshaft of some 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 Нм; 3 — camshafts; 4 — asterisks of camshafts; 5 — приводной the mechanism of the gauge of the Hall; 6 — bolts, 100 Нм




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




Fig. 50. Numbering of covers of bearings of camshafts




Plentifully grease an 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 (fig. 34 see), and covers of bearings 1 (fig. 31 see) camshaft according to fig. 50:

The note
Figures on the established covers of bearings should be read from outside an exhaust pipe, and arrows on the established covers should specify towards a flywheel of a cranked shaft.

- Tighten four nuts alternately, cross-wise in stages and tighten their moment 20 Нм. Thanks to a uniform inhaling of a spring of valves will be slowly compressed, and thus it will be possible to avoid a camshaft warp;
- Similarly establish covers of bearings 1 and 7;
- Turn a camshaft some times to be convinced that it is not clamped anywhere.
Assembling of a camshaft of some cylinders 2, 4 and 6
Plentifully grease an 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 (fig. 34 see), and covers of bearings 1 (fig. 31 see) camshaft, according to fig. 50:

The note
Figures on the established covers of bearings should be read from outside an exhaust pipe, and arrows on the established covers should specify towards a flywheel of a cranked shaft.

- Tighten four nuts alternately, cross-wise, in stages and tighten their moment 20 Нм. Thanks to a uniform inhaling of a spring of valves will be slowly compressed, and thus it will be possible to avoid a camshaft warp;
- Similarly establish a cover of the bearing 4;
- Turn the second camshaft some 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 have been fixed by stoppers;
- On one of camshafts establish a lead приводного the mechanism of the gauge of the Hall 5 (fig. 31 see);
- Establish on camshafts of an asterisk 4 (fig. 31 see) drive. Adjoining surfaces of a lead and a drive asterisk should be dry;


Fig. 32. Fixing of camshafts. By arrows are shown шестигранники, intended for fixing of camshafts




- Twirl bolts 6 (fig. 31 see) fastenings of asterisks, fix camshafts in motionless position with the help шестигранников (fig. 32 see) and tighten both bolts of fastening of asterisks the moment of an inhaling 100 Нм. After that unblock camshafts;
- Clear a surface of a cover of camshafts and put on it hermetic АМV 188 002 02;
- Establish a cover. At first tighten by turns bolts by hand then tighten them on a circle with the moment of an inhaling 10 Нм. Whether check up from the interior of a cover the O-shaped sealing ring which should be in a cover is inserted;

Fig. 51. Cleaning of apertures. By an arrow places of cleaning of apertures in diameter of 3 mm are shown





- If both camshafts (or only one camshaft) have been removed at the established engine before to establish a cover of camshafts, it is necessary to smooth out both three-millimetric apertures (fig. 51, are shown by arrows) in a cover of a head of the block of cylinders and to grease with hermetic АМV 188 002 02;
- Establish the ignition coil;
- Establish on a head of the block of cylinders all removed before a detail which quantity depends on volume of spent repair work. Except for details which are established at installation of a head of the block of cylinders not to do one work twice.