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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
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Repair of the cylinder head



Springs of valves and valve guides
Valve springs must not have cracks and must be sufficiently elastic. To take full control of the valve spring, use a special tool to check the springs. If it is not, then set the spring in a row on a smooth surface so that knurling was closed at the bottom. Put next to a spring steel bracket and measure the gap between the top of the spring and the area. The gap must not be greater than 2.0 mm. Otherwise skewed spring.
Valve guides
Check the valve guide using the following procedure:
- Clean the carbon deposits from the valve guide, which drag a rag soaked in gasoline through the sleeve back and forth;
- Thoroughly clean the valve stem, and in order to insert the valve guides;

Control beating the valve stem inside the guide sleeve using a measuring device VW387
Fig. 113. Control beating the valve stem inside the guide sleeve using a measuring device VW387





- Check the run-out of the valve stem inside the guide sleeve using a measuring device VW387 (Fig. 113), as follows:
- Set Meter VW387 with the corresponding bracket on the top honor of the cylinder head;
- Pull the valve out of the hole so that the end of the valve stem was finally stopped by the guide sleeve;
- Shake the valve plate at the top of from side to side and check the meter reading. If the received value is greater than 1.0 mm on the inlet valves or 1.3 mm on the exhaust valves, the valve guide to be replaced.
Check and general condition of the cylinder head. It can be used after grinding the cylinder head. If it has abrasion between the valve seats or between the valve seat and the first threaded holes for spark plugs, provided that scratches no wider than 0.5 mm, the cylinder head can be reground and reused.

Measuring the height of the cylinder head
Fig. 114. Measuring the height of the cylinder head





After regrinding of the cylinder head, and the value (Fig. 114) should not be less than 132.60 mm. Measurements should be carried out either caliper or measuring ruler, placing the cylinder head on a flat surface.
Pressing off the sleeves of the cylinder head spend in the following order:
- Inspect installed guides. If replacement guides are not yet carried out, the valve guides are not fastened and can be pressed out of the cylinder head from the camshaft. If you already had a replacement guides, the hub will have a bond that can be seen from the camshaft. In this case, the old guide tube should is extruded from the combustion chamber;

Pressing off the valve guide. New bushings are pressed with the same hand
Fig. 115. pressing off the valve guide. New bushings are pressed with the same hand





- Guide sleeve is extruded from the cylinder head with a punch. To facilitate the pressing off the cylinder head can be heated. On the punch you need to tie a pin that fits the size of the inside of the valve guide. Pulling out of the original guide sleeve, wherein the replacement is not yet performed is shown in (Fig. 115);
- When replacing the valve guide, with her changing and the valve itself. Then it is necessary to grind the valve seats.
Pressing guides in the cylinder head using the following procedure:
- New guides before installing the engine oil and grease Press fit them on the part of the camshaft in the cold cylinder head so that the shoulder of the valve guide entered the cylinder head. Wherein the pressing pressure should not be more than 1 m, since otherwise the collar may be cut. The cylinder head must lie on a completely flat surface;
- After pressing the valve guide sleeve should be treated with a special scan 3120. If there is a sweep, you can use an adjustable sweep at 8.0 mm, which must be lubricated regularly so-called coolant to the hole after it left little chipping - traces of "fragmentation."

Note
If the guide sleeve has been replaced, it is necessary to perform grinding of the valve seat that it is concentrically aligned with the new guide bush.

Valve seats
Check valve seat performed as follows:

Saddles of valves: a - the diameter of the valve seat (see. Table adjustments and control); b - the maximum permissible value of the processing; c - the width of the valve seat
Fig. 116. Valve seats: a - the diameter of the valve seat (see. Table adjustments and control); b - the maximum permissible value of the processing; c - the width of the valve seat: intake valve - 2.0 mm, the outlet valve - 2.4 mm; z - the bottom edge of the cylinder head; 30 ?� - the upper correction angle; 45 ?� - chamfer angle of the valve seat





- Check all valve seats for wear and scratches. On working facet saddles (area of contact with the valves) should be no pinholes, corrosion and damage. Minor damage can be eliminated by grinding mill under the seats of 45 ?�. Thus as little as possible remove the metal. Sand can be both manually and using grinder. If the seat is strongly worn, they must be milled again. The shape of facets of saddles of valves is shown in (Fig. 116); The angles are suitable for exhaust and intake valves. The value of the diameter of the valve seat and should be taken of their adjustments and the control table. This is especially important for the intake valves, as they are not the same for some engines;
- To determine the size of the processing valve seat, perform the following measurements:
- Insert the valve in its guide sleeve and press on the saddle (flat head) valve;

Depth measurement during further processing valve seats. Dimension a is measured between the arrows
Fig. 117. The measurement of depth during further processing valve seats. Dimension a is measured between the arrows





- Measure the interval and (Fig. 117) between the top of the valve stem and upper edge of cylinder head. To do this, put on a plane cylinder head measuring range;
- Calculate the maximum and minimum allowable value after milling as measured value. On the intake valve, it should be 33.8 mm for the exhaust - 34.1 mm;
- If the measured value subtracted by the minimum distance, there will be a permissible value b is obtained (see. Fig. 116). This is necessary to avoid too strong to bore the valve seat in the cylinder head. Milling is carried out in the valve seat when installed new bushings. To do this:
- Treat the mill slightly at an angle of 45 ?�, and then the cutter at an angle of 30 ?� top edge of the valve seat to reduce the width of the seat from the valve and bring it to a value of 2.0 mm to 2.4 mm intake and exhaust valves. Treatment should be discontinued as soon as the size of the valve seat is reached these values. Saddles and exhaust valves have a diameter of the restrictors. During the treatment, take care not to damage these constraints;
- In order not to squander the valve seats in the cylinder head too much, be sure to calculate the value of b;

Ointments valve using suction cups. Suckers should be rotated back and forth in the direction of the arrows
Fig. 118. ointments valve using suction cups. Suckers should be rotated back and forth in the direction of the arrows





- Sand the machined valve seats. To do this, apply a small amount of the valve seat lapping compound and install valves in the saddle. Attach the suction cup onto the valve and turn the valve with the help of back and forth in the direction of the arrows (Fig. 118). In order to get a good lap the valve seat, it is necessary to periodically remove the suction cup mount, turn the valve a quarter turn, and then continue grinding;
- After grinding thoroughly clean all parts of the mud and lapping compound;
- Check valve seat in place of the valve head and a sealing ring. Must be seen uninterrupted, matte ring on both parts;
- Apply a pencil a few dashes on the ring on the valve head. Dashes have to be drawn around the ring with an interval of about 1 mm. Then carefully insert the valve into directing plug, lower it into the seat and turn in a circle of 90 ?�, applying light pressure to the valve;
- Remove the valve and check if you still have inflicted pencil lines with sealing ring;
- If the valve seat width of these size ranges, the cylinder head can be installed. Otherwise, the valve seat must be treated again, or at the very least install a new cylinder head.
Valves
All that is written on the engine valve VR6 (see. P. 2.3.3) is true for the 2.0 liter engine. Valve dimensions indicated in Table adjustments and control.
Cylinder Head
Wash the cylinder head and clean the oil channels. Remove the carbon deposits from the combustion chamber and the exhaust ports from the surface with a wire brush. Carefully clean the contact surfaces of the cylinder head and cylinder block. Inspect the cylinder head. On the neck a support under the camshaft and in the holes under the tappets should be scuffing or damage. Cracks in any area of the cylinder head are not allowed.

Checking cylinder head for distortion using a ruler and measuring probe
Fig. 119. Checking cylinder head for distortion using a ruler and measuring probe





Check the surface of the cylinder head on the deformation (Fig. 119).
To do this, place the cylinder head and the measuring range using probe check the clearance along, across and diagonally. If it is less than 0.10 mm, the cylinder head can be sanded. If the gap in any place more, the cylinder head must be replaced, since the removal of more metal layer can adversely affect the engine compression.
The cylinder head can be sanded until its minimum height a (see. Fig. 114) is not less than 132.60 mm.
Camshaft

Places Marking the camshaft. The letters and numbers stamped on the locations indicated by the arrows
Fig. 120. Places of drawing marks on the camshaft. The letters and numbers stamped on the locations indicated by the arrows





Camshaft engine ADY labeled in a certain way. At the place indicated by the arrow A (Fig. 120) is stamped letter (B), in place of B - number (037). Since camshafts for other types of engines have other markings, it is recommended when buying a new camshaft to bring old.
The diameter of the cam A (see. Fig. 120) on the number of engines that constructive reduced to 34.0 mm.
When viewed from the camshaft, pay attention to the surface of the bearing journals (bearing location), the cams, which should be well polished and undamaged. If you find traces of seizing or profound risks, the camshaft must be replaced. Before installing camshaft perform the following steps:

Measure radial runout of the camshaft
Fig. 47. The measurement of the radial runout of the camshaft





- Establish a camshaft extreme tails into two prisms, or hold between the jaws of the lathe and set the measuring device (see. Fig. 47) at the middle bearing (neck) of a camshaft;
- Slowly rotate the camshaft and watch the meter readings. If the readings on the instrument runout exceeds 0.01 mm, the camshaft must be replaced because it is deformed;

Measurement of an axial backlash of a camshaft
Fig. 121. Measurement of an axial backlash of a camshaft





- To measure the axial clearance of the camshaft, put it in a cylinder head (without pushers), secure the extreme bearing and install the cylinder head on a flat surface. Set meter VW387 (Fig. 121) from the end face of the cylinder head and the shaft rocking back and forth in the longitudinal direction (Fig. 121 is shown by arrows).
The axial clearance must not exceed 0.15 mm. Otherwise worn working surface of the bearing cap.




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Assembling the cylinder head

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