Repair VW Sharan

. Diesel engines: 1,9 l TDI.
+ 1. Introduction
+ 2. Engine VR6
- 3. The two-litre engine (ADY)
   3.1. Removal and installation
   + 3.2. Dismantling and assemblage
   - 3.3. A 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. Assemblage of a head of the block of cylinders
      3.3.5. Installation of a head of the block of cylinders
      3.3.6. A hydraulic pusher
      3.3.7. Replacement of an epiploon of a camshaft
   + 3.4. Pistons and rods
   3.5. The block of cylinders
   + 3.6. A cranked shaft and radical bearings
   + 3.7. A mechanism drive газораспределения
   3.8. Tension adjustment приводного a belt of units of the engine
   3.9. An intermediate shaft
   3.10. Compression check in engine cylinders
   3.11. System of release of the fulfilled gases
   3.12. System of clearing with application of the activated coal
   3.13. System рециркуляции the fulfilled gases
+ 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>> The two-litre engine (ADY)>> 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. 112. Removal of the bottom plate of springs of the valve by means of special nippers 3047





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

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





- Using the special tool 3 (fig. 122), establish маслоотражательные caps 2, for what:
- Spread 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 маслоотражательный a cap 2 and put on it a plastic sleeve;
- Put on the special tool 3129 on маслосъемный a cap and cautiously spread it in directing plug;

The note
Installation маслоотражательных caps without application of the special tool 3129 can damage them that will lead to the increased expense of oil.

- After carrying out of grinding in of valves each valve should be established in that saddle to which it has been ground in;
- Establish in apertures 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 firm "Volkswagen"




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




- Put on the top plate of a spring 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 (crackers) 2 (see fig. 37) in cylindrical flutes of a core and smoothly to press a stripper of valves;
- 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. Marks of hydraulic pushers





- Insert hydraulic pushers according to the risks put earlier (fig. 109 see) into apertures (preliminary having greased with their engine oil);

The note
Before definitive installation of pushers read instructions concerning hydraulic pushers (item 3.3.6 see) to avoid engine damage at its first ambassador of work start.

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

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





- Put on covers of bearings № 2 and 4 (fig. 108 see) 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 up, that bearing covers have been correctly established, as is shown in fig. 123, and only after that wrap fastening 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 № 5, 1 and 3;
- Turn a camshaft some times to be convinced that it is not clamped anywhere;
- At epiploon installation grease with engine oil a sealing surface (it is necessary to grease and a surface качения a camshaft) and look, that the epiploon party on which the spring is located, has been directed in a head of the block of the cylinder. For epiploon installation 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 warps) 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 necessarily use new linings).