Disassembling the cylinder head (VW Sharan 1)

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

• remove all remaining parts located on the cylinder head (Fig. 28);
• clamp the cylinder head with a clamp screwed to the intake manifold set screw;
• remove the camshafts (this can be done even on an un-removed engine), for what:

Fig. 27. Upper part of the intake manifold: 1, 3, 4 - high voltage wire guides; 2 - central cover

• remove the spark plug wire guides (Fig. 27);
• remove the upper part of the intake manifold. Cover the open intake ports with a clean cloth to prevent foreign bodies from getting inside;
• turn the crankshaft so that the piston of the first cylinder is at the top dead center (TDC). If the engine is not removed, you can slightly lift the front wheel, engage fifth gear and, rotating the wheel, set the piston to the TDC position. If the engine is removed, put an open-end wrench on the crankshaft flywheel nut and turn the shaft so that both camshaft lobes for the valves of the first cylinder are facing the round side up;
• remove the ignition coil;
• if the engine is not removed, remove the cylinder head cover;
• remove the protective cover of the camshaft drive sprockets;

Fig. 31. Components of camshafts together with bearing caps and sprockets: 1 - camshaft bearing cap; 2 - nut, 20 Nm; 3 - camshafts; 4 - camshaft sprockets; 5 - Hall sensor drive mechanism; 6 - bolts, 100 Nm

• unscrew bolts 6 (Fig. 31) of sprockets 4 of the camshaft drive;

Fig. 32. Fixing the camshafts. The arrows show the hexagons used to fix the camshafts

• fix the camshafts in a stationary position. For this purpose, there is a hexagon on each shaft (fig. 32, shown by arrow), onto which place a 24 mm open-end wrench and hold the camshaft.
• unscrew the tensioner 21 (Fig. 28) of the chain from the cylinder head side;

Fig. 33. The locations for marking the camshaft drive chains before removal are shown by arrows

• remove the camshaft drive sprockets. If the camshaft drive chain has not yet been removed, the direction of installation of the chain must be marked (Fig. 33) so that it can be installed correctly;

Fig. 34. Numbering of camshaft bearing caps. Each cap has an arrow indicating the direction of installation

• first remove the camshaft of cylinder banks 1, 3 and 5 (Fig. 34). To do this, loosen the fastening of both outer bearing caps (numbers 1 and 7), and then, having unscrewed them completely, remove the covers;
• to evenly relieve the valve springs, alternately loosen the bearing cap nuts in a crisscross pattern (number 3 and 5) so that the bearing caps are not subject to pressure from the springs;
• remove both bearing caps;
• remove the camshaft from the cylinder head supports;
• remove the camshaft of cylinder banks 2, 4 and 6 (Fig. 34). To do this, alternately crosswise loosen the nuts of bearing cap number 4, and remove the bearing cap;
• similarly remove bearing caps number 2 and number 6;
• remove the second camshaft;

Fig. 35. Marking of hydraulic tappets

• apply scratch marks on the inner side of the pushers, i.e. the first pusher - one mark, the second pusher - 2 marks, etc. (Fig. 35), since they cannot be confused (start counting from the engine drive side) and remove the pushers. Do not fold the pushers, but place them with the contact surface facing down;

Note: The tappets are equipped with hydraulic elements that adjust the valve clearance and therefore the tappets must be handled with care.

Fig. 36. Removing valves using a special device from the company "Volkswagen"

• the standard tool for removing and installing valves is tool number 2036 (Fig. 36). It is attached to the cylinder head. Release valve 8 (Fig. 37) from valve stem halves (crackers) 2, compressing springs 4 with tool 2036;

Fig. 37. Valve drive mechanism parts: 1 - hydraulic pusher; 2 - valve stem halves (crackers); 3 - upper valve spring plate; 4 - valve springs; 5 - oil deflector cap; 6 - valve guide bushing; 7 - cylinder head; 8 - valves; a - cylinder head height

• to remove the valves, you can also use a piece of pipe that fits over the upper spring plate. You need to put something under the valve plate on the other side to fix it. Hit the pipe briefly with a hammer so that the halves of the valve stem come out. They will remain inside the pipe;
• remove the upper plate 3 (Fig. 37) with springs 4, turn the cylinder head 7 and remove valve 8 from the bottom;
• remove the oil deflector cap 5 from the guide sleeve 6;

Note: Always replace the valve stem seals with new ones.

• if the car has a high mileage or the work is being carried out on a used car about which little is known, then before installing the cylinder block in place, the height of the cylinder head should be measured - the value a (Fig. 37).