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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
The two-liter engine (ADY)
Refitting
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
Replacing the oil seal Camshaft
The pistons and connecting rods
Cylinder block
Crankshaft and main bearings
Drive timing
Adjust the belt tension engine units
Countershaft
Compression check in engine cylinders
Exhaust
Cleaning system with activated carbon
Exhaust gas recirculation
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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Assembling the cylinder head



The assembly of the cylinder head spend in the sequence, return dismantling, observing the following guidelines:
- Generously grease the valve stems with engine oil and insert them in the appropriate guides;

Removal of the bottom plate of the valve springs using special tongs 3047
Fig. 112. Removal of the bottom plate of the valve springs using special tongs 3047





- With special forceps 3047 (see. Fig. 112) set the lower valve plates;

Installing the valve stem seals
Fig. 122. Setting the valve stem cap: 1 - plastic sleeve; 2 - stem seal; 3 - special tool 3129





- Using a special tool 3 (Fig. 122), install the valve stem seals 2, as follows:
- Push the plastic sleeve 1 with a special tool 3129 at the protruding portion of the valve guide;
- Well, lubricate with engine oil valve stem seal 2 and put it into a plastic sleeve;
- Put on the special tool 3129 to the valve stem seal and carefully plant them in the guide sleeve;

Note
Installing the valve stem seals without the use of a special tool 3129 may damage them, resulting in increased oil consumption.

- After lapping valves each valve must be installed in the seat to which he had been lapped;
- Set the opening of the cylinder head, one inner and outer coils for the respective valve (if installed the old spring);

Removing the valve with the help of a special device company ?«Volkswagen?»
Fig. 36. Removing the valves using a special device company ?�Volkswagen?�




Details of the mechanism of the valve
Fig. 37. Details of the mechanism of the valve: 1 - hydraulic pusher; 2 - half of the valve stem (biscuits); 3 - the top plate of the valve spring; 4 - valve spring; 5 - stem seal; 6 - Valve Guides; 7 - cylinder head; 8 - valves; a - the height of the cylinder head




- Put on the top plate of the valve spring. Set puller valves (see. Fig. 36) to compress the spring. If the end of the valve stem protrudes from the top plate of the valve spring, you need to install the two halves of the valve stem (crackers) 2 (see. Fig. 37) in the cylindrical groove of the rod and gently press the valve remover;
- Plastic mallet, hit the top of the valve stem. This improperly installed crumbs fly out of the cylindrical groove;

Marking the hydraulic tappets
Fig. 109. Marking of hydraulic pushers





- Insert the hydraulic tappets in accordance with the previously deposited risk (see. Fig. 109) into the holes (after brushing their engine oil);

Note
Before final installation of pushers read the instructions on the hydraulic tappets (see. P. 3.3.6), in order to avoid damage to the engine when it is first after the start of work.

- Generously grease the engine oil cervix (the location of the bearing) of a camshaft;
- Position the camshaft bearings in the cylinder head several times and rotate them. Install the camshaft so that both cams of the first cylinder on the shaft looked up;

Details of the camshaft
Fig. 108. Details of the camshaft 1 - bearing cover number 5; 2 - bearing cover number 4; 3 - bearing cover number 3; 4 - a cover of the bearing number 2; 5 - nut 20 Nm; 6 - bearing cover number 1; 7 - camshaft; 8 - Woodruff; 9 - a bolt with a washer 80 Nm; 10 - a cogwheel of a camshaft





- Put the cap bearing number 2 and 4 (see. Fig. 108) and from the hand screw nuts;

Install the camshaft bearing cap in the cylinder head
Fig. 123. Installing the camshaft bearing cap in the cylinder head





- Check that the bearing caps are correctly installed, as shown in Fig. 123, and only then tighten the nuts alternately crosswise in several stages, and tighten them to a torque of 20 Nm. Due to the uniform tightening the valve springs will slowly shrink, and thus be able to avoid misalignment of the camshaft;
- In the same way, set the number bearing caps 5, 1 and 3;
- Turn the camshaft several times to make sure it is not pinched anywhere;
- When installing the gland lubricate the engine oil seal surface (must be lubricated and the rolling surface of the camshaft) and see that side of the gland, which is located a spring, it was sent into the cylinder head. Seal installer can use a pipe, which must fully comply with the size of the outer part of the gland. Place the stuffing box directly (without bias) and pressed into it as long as its outer surface not go all the way in. Install the gland can be the method described in Sec. 3.6.4 for the new front oil seal of the crankshaft;
- Install the intake and exhaust manifolds to the cylinder head (in this case, always use new gaskets).




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Installing the cylinder head

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