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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Sharan (from 1995 to 2000, the year of issue)

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Volkswagen Sharan
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Volkswagen
Sharan
Introduction
VR6 engine
Removing and installing
Disassembly and assembly
Cylinder head and valves
Removing the cylinder head
Dismantling the cylinder head
Repair of the cylinder head
Assembling the cylinder head
Installing the cylinder head
Hydraulic tappet
The pistons and connecting rods
Cylinder block
Crankshaft and main bearings
Drive timing
Countershaft
Compression check in engine cylinders
Exhaust
The two-liter engine (ADY)
Engine oil
Cooling
A fuel injection system VR6 engine
The system Simos injection 2.0-liter engine
The ignition system
Coupling
Manual 5-speed gearbox
The drive shafts
Power steering
Front suspension
Rear suspension
Brakes
Electrical
Diesel engine
The lubrication system of the diesel engine
The cooling system of the diesel engine
The power supply system of the diesel engine and turbocharger
Map service.
Applications
Wiring
 


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Removing the cylinder head



Details top of the cylinder head
Fig. 26. Details of the upper part of the cylinder head: 1 - screws (5 Nm); 2 - the central cover (above the upper part of the inlet pipeline); 3 - bolts (25 Nm); 4 - holders spark plug wires; 5 - the holder of the throttle cable; 6 - rear left bracket upper portion of the inlet pipe; 7 - tube neck for Gulf oil; 8 - gasket; 9 - crankcase ventilation valve; 10 - ring to the cylinder head cover; 11 - a nut (10 Nm); 12 - the cylinder head cover; 13 - gasket cylinder head cover; 14 - holders of the fuel; 15 - a bolt (10 Nm); 16 - a vacuum hose; 17 - gasket top of the intake manifold; 18 - the top of the intake manifold; 19 - rear right arm upper part of the inlet pipeline





The details that you want to take to dismantle the cylinder head from the cylinder block shown in Fig. 26.
Cylinder head removed from the engine to the car, if corrective action is not required to disassemble the whole engine. Removing the cylinder head in the following order:
- Disconnect terminal "-" of the AB;
- Remove the upper part of the air filter;
- Disconnect connectors throttle switch, heating element, the air flow sensor and the intake air temperature sensor;
- Remove the crankcase ventilation valve 9 (see. Fig. 26) from the cylinder head cover 12;
- Disconnect from the top of the intake manifold vacuum hose 16, 18 of activated carbon. At the same time, make sure that the hose does not touch other parts;
- Remove the air guide hose with mass air flow sensor to the throttle body;
- Remove the high voltage (HV) from spark plugs;

The upper part of the intake manifold
Fig. 27. The upper part of the intake manifold 1, 3, 4 - high voltage rails; 2 - the central cover





- Remove the rails 1, 3 and 4 (Fig. 27) HV wires and unscrew bolts 1 shown in Fig. 26 and remove the central part of the top cover 2 intake manifold;
- Remove the accelerator cable along with its support for undoing the support and remove the cable end. Do not remove the clip that holds the throttle cable in the support, as in this case will be necessary tension adjustment throttle cable;
- Open the lid of the expansion tank of the cooling system to remove any excess of pressure and drain the coolant;
- Mark attached to the throttle body coolant hoses and remove them from unions;
- Disconnect the vacuum hose to the intake valve of the secondary air supply system;
- Disconnect the vacuum hose from the brake servo intake manifold. Place of compound 16 (see. Fig. 26);
- Remove the fuel (fuel supply and removal) of the holders 14 in the cylinder head and carefully remove the fuel hoses. Before removing the hoses, wrap a thick cloth around the connection, as the fuel system is under pressure;
- Unscrew the oil dipstick guide tube at the bottom of the intake manifold;
- Unscrew and remove the rear left 6 (see. Fig. 26) and right brackets 19 between the top of the intake manifold and the cylinder head;
- Remove the upper part of the intake manifold 18 with throttle body. Be careful not to have jumped handling sleeve. The inlets are now open, so close to their respective means, for example, plugged clean cloth;
- Remove the bolts 15 and remove the cylinder head cover 12 with a gasket 13;
- The side of the cylinder head cover, disconnect electrical cable holder and valve EGR (valve EGR);

Partially disassembled cylinder head (were dropped on the top of the head part)
Fig. 28. The partially disassembled cylinder head (were dropped on the top of the head parts): 1 - a bolt, 25 Nm; 2 - belt tensioner; 3 - Fuel distributor; 4 - gasket bottom of the intake manifold; 5 - the lower part of the intake manifold; 6 - Lifting ear; 7 - bolt 25 Nm; 8 - a bolt of fastening of the cylinder head; 9 - cylinder head; 10 - cylinder head gasket; 11 - a bolt, 25 Nm; 12 - O-ring seal; 13 - the thermostat; 14 - bolt 10 Nm; 15 - cable holder; 16 - bolt 10 Nm; 17 - the ignition coil; 18 - bolts 10 Nm; 19 - the holder; 20 - a sealing ring; 21 - chain tensioner, 30 Nm; 22 - bolt 10 Nm; 23 - Hall sensor; 24 - spacer ring; 25 - the O-shaped sealing ring; 26 - spacer ring; 27 - a cover of the camshaft; 28 - The O-ring seal





- Then remove the holder 19 (Fig. 28), which fixes the plug connector with 42 pins, as well as an additional coolant pump, designed to protect a stopped motor from overheating;
- Disconnect the connector coolant temperature sensor;
- Remove the V-belt drive system of the engine;
- Disconnect a reception pipe with catalytic converter from the exhaust manifold;

Location ignition coils
Fig. 29. Location of the ignition coil 1 - wire fixation; 2 - plug connector; 3 - the bolt





- Unscrew the screws 3 (Fig. 29) and disconnect the ignition coil 17 (see. Figure 28) from the cylinder head;
- Remove the steering drive (see. Sect. 12.1) in such a way to release the top-row chain of asterisks of camshafts;
- Turn the tensioner bottom-row chain drive the intermediate shaft on the side of the cylinder head;
- Remove the cover 27 of camshafts. When installing the cover must be covered with a sealant (AMV188 001,002). If you have only removed the cylinder head cover, and the engine block is not removed, the seal of the cylinder head should be prepared to cover the installation in accordance with the guidelines given below;
- Disconnect from the cylinder head all the electrical wires;

The sequence of the bolts fastening the cylinder head. Otvertyvanie bolts in reverse order
Fig. 30. The sequence of the bolts fastening the cylinder head. Otvertyvanie bolts in reverse order





- In several stages unscrew in sequence, return shown on (Fig. 30), the bolts of the cylinder head;
- Remove the cylinder head. If she become attached, then it can be hit several times with a plastic or rubber mallet to facilitate removal;
- If further disassembly of the cylinder head, remove the lower part of the intake manifold, belt tensioner, distributor Fuel and other mounted on the cylinder head, detail.




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Dismantling the cylinder head

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