VW Touareg repair


+ 1. Operation and car maintenance
- 2. Engine
   + Preliminary checks on the car
   + Mechanical part (petrol engines 3,2L)
   + Mechanical part (petrol engines 4,2L)
   + Mechanical part (diesel engines 5,0L)
   - Removal and stretcher installation
      Removal and installation of pillows and engine support (right and left)
      Removal and installation of a conducted disk
      Removal and installation of a stage of support of a cranked shaft
      Forward sealing laying of a flange and damper of krutilny fluctuations
      Replacement of an epiploon of a cranked shaft on the party of a damper of krutilny fluctuations
      Replacement of an epiploon of a cranked shaft on the party of the mechanism of a gazoraspredeleniye of the engine
      Replacement of an epiploon of a shaft of a drive of the generator
      Installation of a cover of the distributive mechanism
      Removal and installation of a leading gear wheel of a camshaft
      Check of phases of a gazoraspredeleniye
      Adjustment of phases of a gazoraspredeleniye
      Removal and installation of heads of the block of cylinders
      Removal and installation of covers and laying of heads of the block of cylinders
      Repair of heads of the block of cylinders
   + pressurization System (diesel engines)
   + cooling System (petrol engines)
   + cooling System (diesel engines)
   + greasing System (petrol engines)
   + greasing System (diesel engines)
   + injection System (petrol engines)
   + injection System (diesel engines)
   + System of production of the fulfilled gases
   + System топливоподачи (beninovy engines)
   + Tables
+ 3. Transmission
+ 4. Running gear
+ 5. Steering mechanism
+ 6. Brake system
+ 7. Onboard electric equipment
+ 8. Body
+ electric equipment Schemes


Volkswagen Touareg / Touareg repair>> Engine>> Removal and stretcher installation>> Repair of heads of the block of cylinders

Fig. 2.207 . Components of the klapanny mechanism: 1–a bolt of 20 N · m + to tighten on 1/4 about. (90 °); 2–axis of roller levers; 3–bearing cover; 4–tarelchaty pusher; 5–conic cracker; 6–plate of a spring of the valve; 7–external spring of the valve; 8–internal spring of the valve; 9–sealant of a core of the valve; 10-a washer with a diamond covering; 11-plug; 12-head of the block of cylinders; 13-valves; 14-pump nozzle; 15-washer; 16-bearing loose leaf; 17-camshaft; 18-bearing loose leaf; 19-bolt of a head of the block of cylinders; 20-a bolt of 8 N · m + to tighten on 1/4 about. (90 °)


Verification of the provision of pistons in the top dead point
Measurement of a vystupaniye of the piston in conditions HUNDRED is impossible. Connection of a head of the block of cylinders with the aluminum block the cylinder is carried out by an anchor principle by means of anchor bolts. Thus it is reached such obzhaty the block of cylinders which cannot be reached at the dismantled head of the block of cylinders. On it at replacement of laying of a head of the block of cylinders it is necessary for reason to establish new laying of a head of the block of cylinders with identical index marking.

Fig. 2.208 . Piston and rod: 1–a rod bolt, 30 N · m + to tighten on 1/4 about. (90 °); 2–rod cover; 3–support loose leaf; 4–rod; 5–lock ring; 6–piston; 7–piston finger; 8–piston rings


Sizes of pistons and cylinders

NOTE
Repair standard sizes are not provided.

Check of a thermal gap of piston rings

Fig. 2.209 . Check of a thermal gap of piston rings


Drive a piston ring from above, at right angle to a cylinder wall, to the bottom opening of the cylinder, at distance about 15 mm from its edge (fig. 2.209) .


Check of a gap of piston rings on height

Fig. 2.210 . Check of a gap of piston rings on height


Before check clear a ring flute (fig. 2.210) .


Check of diameter of the cylinder

Fig. 2.211 . Scheme of check of diameter of the cylinder


Measure in three places by a cross cross-section distance And and longitudinal In (fig. 2.211) .
The tolerance from the nominal size is maximum: 0,05 mm.
Piston: assembly situation and belonging to the piston / cylinder.
Marking is put on a bottom of the piston:
– pistons 1-5 for a number of cylinders 1;
– pistons 6-10 for a number of cylinders 2.
Arrangement: the arrow at the bottom of the piston shows on the absorption party.

Check of axial shift of a cam-shaft

Fig. 2.212 . Check of axial shift of a cam-shaft


Check at the dismantled tarelchaty pushers and the established covers of a support (fig. 2.212) .
First row of cylinders:
– covers of bearings 2, 4 and 6 are established
Second row of cylinders:
– covers of bearings 9, 11, and 13 are established
Limiting wear: Max. 0,15 mm
Put hermetic on landing surfaces of external covers of bearings.

Works order

Fig. 2.213 . Scheme of drawing of hermetic


To put AMV 176 501 hermetic on surfaces with a thin uniform layer 1 (fig. 2.213) .
First row of cylinders:
Put hermetic – AMV 176 501 on landing surfaces of covers of bearings 1 and 7
Second row of cylinders:
Put AMV 176 501 hermetic on landing surfaces of covers of bearings 8 and 14

Sizes of valves

Fig. 2.214 . Sizes of the valve



NOTE
Valves are forbidden to be processed. Grinding in is allowed only.

Camshaft marking (gazoraspredeleniye phase)
Main circle of a klapanny cam: a= mm

Fig. 2.215 . Camshaft marking (gazoraspredeleniye phases from a drive)


Marking is put in the form of the stamped figures and letters on a face surface of the party of a drive of a camshaft (fig. 2.215) .
Drive party
First row of cylinders: 07Z G.
Second row of cylinders: 07Z H.

Gazoraspredeleniye phases at a valve stroke 1мм

Processing of saddles of valves

NOTE
At repair of engines with leaky valves to process or replace saddles of valves and valves it is not enough. Especially in engines with long service life it is necessary to check directing plugs of valves on wear.
Saddles of valves should be processed only so to reach a faultless type of a working surface. Before processing it is necessary to calculate the most admissible allowance on processing. At allowance excess on processing function of hydraulic regulation of a gap in a drive of valves (hydrojacks) that will cause GBTs replacement can be broken.

Count the most admissible allowance on processing as follows:
– insert the valve in directing and densely press it to a saddle;

NOTE
If the valve at repair is replaced, at measurements it is necessary to use the new valve.


Fig. 2.216 . Distance And between the end of a core of the valve and the upper edge of a head of the block of cylinders


– measure distance And between the end of a core of the valve and the upper edge of a head of the block of cylinders (fig. 2.216) ;
– calculate the most admissible allowance on processing on the basis of the measured distance And and minimum admissible size.
Minimum sizes:
The inlet valve – 43,4 mm
The final valve – 43,2 mm
The measured distance a minus the minimum size = the most admissible allowance on processing.
Example:
The measured distance – 44,1 mm
The minimum size – 43,4 mm
The most admissible allowance on processing of 44,1-43,4=0,7 mm

Processing of a saddle of the inlet valve

Fig. 2.217 . Scheme of processing of a saddle of the inlet valve


a–Ж35,7 mm
b–1,6 mm
45 ° – the Corner of a basic surface of the valve

NOTE
Frezerovka at an angle in 30 ° saddles of the valve is necessary because of a ratio of streams in the inlet channel.

Processing of a saddle of the final valve

Fig. 2.218 . Scheme of processing of a saddle of the final valve


a–Ж31,4 mm
b–2,7 mm
45 ° – the Corner of a basic surface of the valve

Check of directing plugs of valves
Insert the new valve into directing plug. The end of a core of the valve should be blocked by the directing plug. Because of various diameter of a core use the inlet valve only in the directing plug of the inlet valve and the final valve in the directing plug of the final valve.

Fig. 2.219 . Definition люфта


Define люфт when rocking valve (fig. 2.219) .
Limiting wear: Max. 1,3 mm.
At values люфта exceeding limits of wear – to replace a head of the block of cylinders.

Replacement of sealants of cores of valves (at the established head of the block of cylinders)
Dismantle a camshaft.
Take tarelchaty pushers of valves and put them a working surface down. Do not interchange the position of tarelchaty pushers.
Transfer the piston of the corresponding cylinder to situation VMT.

Fig. 2.220 . Adaptation installation for dismantle of springs of valves


Establish the assembly adaptation for valves 2036 and establish a support by means of rasporny bolts (fig. 2.220) .
Dismantle springs of valves by means of the lever for dismantle of springs of VW valves of 541/1 A and VW 541/5 opravka.

NOTE
Thus valves lean on a piston bottom.


Fig. 2.221 . Removal of sealants


Pull together a sealant of cores of valves by means of a stripper of 3047 A (fig. 2.221) .

Installation

Fig. 2.222 . Installation of a new sealant


Put on the corresponding core of the valve entering in ремкомплект a plastic cover And (fig. 2.222) . It helps to avoid damages of a new sealant of a core of the valve B.
Establish a new sealant of a core of the valve in an opravka 3129.
Grease a working edge of a sealant of a core of the valve and carefully establish on directing plug of the valve.
Establish a camshaft.


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