Volkswagen Sharan 2011 Workshop Manual – PDF DOWNLOAD
FILE DETAILS:
Volkswagen Sharan 2011 Workshop Manual – PDF DOWNLOAD
Language : English
Pages : 10912
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Volkswagen Sharan 2011 Workshop Manual – PDF DOWNLOAD
00 – Technical data 1
1 Technical data 1
1 1 Engine number 1
1 2 Engine data 1
2 Safety information 3
2 1 Safety regulations for working on fuel supply 3
2 2 Safety measures when working on vehicles with a start/stop system 3
2 3 Safety precautions when using testers and measuring instruments during a road test 4
2 4 Safety precautions when working on the cooling system 4
2 5 Safety precautions when working on the SCR system 4
2 6 Safety precautions when working on exhaust system 5
10 – Removing and installing engine 7
1 Removing and installing engine 7
1 1 Removing and installing engine cover 7
1 2 Removing engine 7
1 3 Separating engine from gearbox 14
1 4 Separating engine from dual clutch gearbox 16
1 5 Securing engine to assembly stand 18
1 6 Installing engine 20
1 7 Assembly mountings 22
1 8 Adjusting assembly mountings 23
13 – Crankshaft group 27
1 Dismantling and assembling engine 27
1 1 Poly V-belt drive with tensioning element and air conditioner compressor 27
1 2 Poly V-belt drive with tensioning roller and air conditioner compressor 30
1 3 Poly V-belt drive without air conditioning compressor 34
1 4 Removing and installing bracket for ancillaries 35
1 5 Assembly overview – toothed belt drive 36
1 6 Removing and installing engine bracket 38
1 7 Assembly overview – crankcase 42
2 Removing and installing sealing flange and flywheel 44
2 1 Assembly overview – Sealing flange, belt pulley end 44
2 2 Renewing crankshaft oil seal – pulley end 45
2 3 Removing and installing sealing flange – pulley end 47
2 4 Assembly overview – Dual-mass flywheel and sealing flange 49
2 5 Removing and installing dual-mass flywheel 51
2 6 Renewing crankshaft sealing flange – flywheel end 52
2 7 Removing and installing engine speed sender G28 59
3 Pistons and conrods 61
3 1 Assembly overview – pistons and conrods 61
3 2 Piston and cylinder dimensions 64
3 3 Separating new conrods 64
3 4 Bearing shells – installation position 65
3 5 Piston and cylinder dimensions 65
3 6 Checking piston projection at TDC 65
3 7 Measuring radial clearance of conrods 67
4 Crankshaft 69
4 1 Assembly overview – crankshaft 69
4 2 Crankshaft dimensions 69
4 3 Renewing needle bearing in crankshaft 70
Sharan 2011 ➤
4-cylinder common rail engine (2 0 l, EA189 Gen II) – Edition 10 2018
Contents i
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Volkswagen AG Volkswagen AG does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by Volkswagen AG
15 – Cylinder head, valve gear 72
1 Cylinder head 72
1 1 Assembly overview – cylinder head cover 72
1 2 Removing and installing cylinder head cover 74
1 3 Removing, installing and tensioning toothed belt 77
1 4 Assembly overview – cylinder head 84
1 5 Removing and installing cylinder head 86
1 6 Removing and installing vacuum pump 95
1 7 Compression test 96
2 Valve gear 98
2 1 Assembly overview – valve gear 98
2 2 Removing and installing camshafts 101
2 3 Measuring axial clearance of camshaft 108
2 4 Measuring radial clearance of camshafts 109
2 5 Removing and installing camshaft oil seal 109
2 6 Checking hydraulic compensation elements 112
2 7 Renewing valve stem seals with cylinder head installed 112
2 8 Renewing valve stem seals with cylinder head removed 116
2 9 Valves 119
17 – Lubrication 121
1 Engine oil: 121
1 1 Oil capacities 121
1 2 Checking engine oil level 121
2 Parts of lubrication system 122
2 1 Assembly overview – oil pump, sump, balance shaft module 122
2 2 Removing and installing oil level and oil temperature sender G266 126
2 3 Removing and installing oil sump 126
2 4 Removing and installing oil pump 130
2 5 Removing balancer shaft module 131
2 6 Installing a new balancer shaft module 133
2 7 Installing a previously used balancer shaft module again 135
3 Oil filter bracket and engine oil cooler 137
3 1 Assembly overview – oil filter bracket and engine oil cooler 137
3 2 Removing and installing oil filter bracket with engine oil cooler 138
3 3 Removing and installing oil pressure switch F1 141
3 4 Checking oil pressure switch F1 142
3 5 Checking oil pressure 143
19 – Cooling 145
1 Parts of cooling system 145
1 1 Assembly overview – parts of cooling system, body side 145
1 2 Assembly overview – parts of cooling system, engine side 147
1 3 Assembly overview – coolant pump and thermostat 148
1 4 Coolant hose connection diagram 149
2 Repairing cooling system 150
2 1 Removing and installing cowling together with radiator fan V7 and radiator fan on right of
radiator V35 150
2 2 Removing and installing radiator 151
2 3 Removing and installing coolant pump 152
2 4 Removing and installing 4/2-way valve with thermostat 154
2 5 Draining and adding coolant 159
2 6 Coolant pipes, coolant temperature sender 163
2 7 Checking cooling system for leaks 174
Sharan 2011 ➤
4-cylinder common rail engine (2 0 l, EA189 Gen II) – Edition 10 2018
ii Contents
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Volkswagen AG Volkswagen AG does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by Volkswagen AG
20 – Fuel supply system 178
1 Safety regulations for working on fuel supply 178
2 Rules for cleanliness 179
3 Repair instructions if tank has been filled with incorrect fuel 180
3 1 Step 1 (Engine was started with incorrect fuel) 180
3 2 Step 2 (Engine was not started with incorrect fuel) 181
3 3 Step 3 (There are filings in fuel delivery unit and fuel tank) 182
3 4 Step 4 (There are no filings in fuel delivery unit and fuel tank) 182
3 5 Step 5 (There are filings in high-pressure pump) 183
3 6 Step 6 (There are no filings in high-pressure pump) 183
4 Parts of fuel supply system 184
4 1 Assembly overview – fuel tank 184
4 2 Assembly overview – fuel delivery unit, fuel gauge sender and suction jet pump 185
4 3 Removing and installing fuel delivery unit 186
4 4 Removing and installing fuel gauge sender G 188
4 5 Emptying fuel tank 189
4 6 Removing and installing fuel tank 192
5 Repairing fuel supply 194
5 1 Assembly overview – fuel filter 194
5 2 Removing and installing fuel filter 195
5 3 Checking fuel system pressurisation pump G6 196
5 4 Assembly overview – accelerator mechanism 200
5 5 Removing and installing accelerator pedal module 201
21 – Turbocharging/supercharging 204
1 Exhaust turbocharger 204
1 1 Safety precautions 204
1 2 Rules for cleanliness 204
1 3 Assembly overview – turbocharger 205
1 4 Removing and installing turbocharger 207
1 5 Replacing vacuum unit with position sender for charge pressure positioner G581 211
2 Charge air system 217
2 1 Installing hose connections with plug-in connectors 217
2 2 Installing hose connections with corrugated pipe connection 218
2 3 Assembly overview – parts of charge air cooling 218
2 4 Removing and installing charge air cooler 219
2 5 Checking charge air system for leaks 220
2 6 Vacuum hose connection diagram 224
2 7 Checking vacuum system 224
23 – Mixture preparation – injection 228
1 Diesel direct injection system 228
1 1 Safety precautions 228
1 2 Rules for cleanliness 228
1 3 System layout 229
2 High-pressure pump 231
2 1 Assembly overview – high-pressure pump 231
2 2 Removing and installing high-pressure pump 232
2 3 Filling/bleeding fuel system 235
2 4 Checking for leaks in the fuel system 236
3 Injectors 237
3 1 Assembly overview – injectors 237
3 2 Carrying out adaptation for injector delivery calibration 240
3 3 Checking for injectors sticking open 241
Sharan 2011 ➤
4-cylinder common rail engine (2 0 l, EA189 Gen II) – Edition 10 2018
Contents iii
Protected by copyright Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Volkswagen AG Volkswagen AG does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by Volkswagen AG
3 4 Removing and installing injectors 242
3 5 Installing high-pressure lines 246
3 6 Checking fuel pressure regulating valve N276 247
3 7 Removing and installing fuel pressure regulating valve N276 249
3 8 Removing and installing fuel pressure sender G247 250
3 9 Removing and installing fuel rail 252
4 Intake manifold 256
4 1 Assembly overview – intake manifold with attachments 256
4 2 Removing and installing throttle valve module J338 257
4 3 Removing and installing intake manifold 258
5 Air filter 262
5 1 Assembly overview – air filter 262
5 2 Removing and installing air filter housing 263
5 3 Removing and installing air mass meter G70 265
6 Lambda probe and pressure differential sender 266
6 1 Removing and installing Lambda probe G39 with Lambda probe heater Z19 266
6 2 Removing and installing pressure differential sender G505 267
7 Engine (motor) control unit 269
7 1 Removing and installing engine (motor) control unit J623 269
7 2 Removing and installing anti-theft engine control unit J623 270
26 – Exhaust system 272
1 Front exhaust pipe with particulate filter 272
1 1 Assembly overview – front exhaust pipe with particulate filter 272
1 2 Removing and installing particulate filter 274
2 Silencer 282
2 1 Assembly overview – silencers 282
2 2 Aligning exhaust system free of stress 283
2 3 Installation position and specified torque of clamp 283
3 Exhaust gas temperature regulation 285
3 1 Assembly overview – exhaust gas temperature regulation 285
3 2 Removing and installing exhaust gas temperature sender 1 G235 286
3 3 Removing and installing exhaust gas temperature sender 3 G495 287
3 4 Removing and installing exhaust gas temperature sender 4 G648 289
4 SCR system (selective catalytic reduction) 290
4 1 Assembly overview – reduction catalytic converter 290
4 2 Assembly overview – tank for reducing agent 292
4 3 Removing and installing heater element (heater cup) 293
4 4 Removing and installing injector for reduction agent N474 297
4 5 Draining reducing agent tank 298
4 6 Removing and installing reducing agent tank 300
5 Exhaust gas recirculation system 304
5 1 Assembly overview – exhaust gas recirculation 304
5 2 Checking changeover for exhaust gas recirculation cooler 305
5 3 Removing and installing exhaust gas recirculation cooler 305
5 4 Checking exhaust gas recirculation cooler for leaks 308
5 5 Cleaning exhaust gas recirculation system 312
28 – Glow plug system 318
1 Checking glow plug system 318
1 1 Removing and installing glow plugs 318
1 2 Removing and installing automatic glow period control unit J179 320
S.V 03/02/2025