DOWNLOAD PDF Volkswagen Sharan 2011 Workshop Manual
Workshop Manual
Edition 10.2018
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List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system
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Technical information should always be available to the foremen and mechanics, because their carefulandconstantadherencetotheinstructionsisessentialtoensurevehicleroad-worthinessand safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.
rights reserved.
(Engine
3.2 Step 2 (Engine was not started with incorrect fuel)
3.3 Step 3
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
00 –Technical data
1Technical data
(VRL012336; Edition 10.2018)
⇒ “1.1 Engine number”, page 1
⇒ “1.2 Engine data”, page 1
1.1Engine number
The first 3 characters of the four-character engine code refer to the mechanical configuration of the engine. They are stamped onto the engine as before. The fourth digit shows the engine out‐put and varies according to engine control unit. The four-digit enginecodecanbefoundonthetypeplate,thevehicledatalabel and on the engine control unit.
The engine number (“engine code” and “serial number”) can be found at the joint between engine and gearbox -arrow-.
Inaddition,thereisastickeronthetoothedbeltguardwith“engine code” and “serial number”.
The engine codes can also be found on the vehicle data sticker.
Theenginenumberconsistsofupto9characters(alphanumeric). The first part (maximum 4 characters) makes up the “engine code”, and the second part (6 characters), the “serial number”. If more than 999,999 engines were produced with the same code letters, the first of the six digits is replaced by a letter.
1.2Engine data
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⇒ “2.1 Safety regulations for working on fuel supply”, page 3
⇒ “2.2 Safety measures when working on vehicles with a start/ stop system”, page 3
⇒ “2.3 Safety precautions when using testers and measuring in‐struments during a road test”, page 4
⇒ “2.4 Safety precautions when working on the cooling system”, page 4
⇒ “2.5 Safety precautions when working on the SCR system”, page 4
⇒ “2.6 Safety precautions when working on exhaust system”, page 5
2.1Safety regulations for working on fuel supply
Risk of injury from highly pressurised fuel.
The fuel system is pressurised. Injury from fuel spray possible.
Before opening the fuel system:
–Wear protective goggles.
–Wear protective gloves.
– Toreleasepressure,wrapacleanclotharoundtheconnection and carefully loosen the connection.
Danger of fire caused by escaping fuel
Whenthebatteryisconnectedandthedriverdooropens,thedoor contact switch activates the fuel pump. Escaping fuel can ignite and cause a fire.
–Disconnect voltage supply to fuel pump before opening the fuel system.
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2.2Safety measures when working on vehicles with a start/stop system
Risk of injury from engine starting unexpectedly
If the vehicle's start/stop system is activated, the engine could start unexpectedly. A message in the dash panel insert indicates whether the start/stop system is activated.
–Deactivate start/stop system by switching off the ignition.
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
2.3Safety precautions when using testers and measuring instruments during a road test
Risk of injury caused by unsecured testing and measuring instru‐ments
When the front passenger airbag is triggered in an accident, in‐sufficiently secured testing and measuring instruments become dangerous projectiles.
–Secure testing and measuring instruments on the rear seat.
Or
– Have a second person operate the test and measuring equip‐ment on the rear seat.
2.4Safety precautions when working on the cooling system
Danger of scalding by hot coolant
On a warm engine, the cooling system is under high pressure. Danger of scalding by steam and hot coolant.
–Wear protective gloves.
–Wear protective goggles.
–Reduce excess pressure by covering cap of coolant expan‐sion tank with cloths and opening it carefully.
2.5Safety precautions when working on the SCR system
Risk of injury due to reducing agent
The reducing agent may cause eye and skin irritations as well as injuries to the respiratory system and poisoning.
–Wear protective goggles.
–Wear protective gloves.
–Always wear protective clothes.
–Make sure that a sufficient amount of fresh air is supplied. In closed areas, switch on the exhaust gas extractor system.
Risk of damage caused by reducing agent
Ifreducingagentgetsontotrimpanelsandbodycomponents,the reducing agent may solidify after a while and thus damage the surface.
– Make sure that no reducing agent gets onto the trim panels or body components.
–If any reducing agent does get onto surfaces, remove it im‐mediately using water and a cloth.
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
When removing and installing components of the SCR system, note the following:
♦ The tank for reducing agent must be empty when working on theSCRsystem.Informationonwhenthereducingagenttank has to be emptied can be obtained from the respective de‐scription of work. Emptying tank for reduction agent ⇒ page 298
Automatic return of reducing agent
• After the ignition has been switched off, the reducing agent is returned from the metering line leading to the reducing agent injector - N474- back to the reducing agent tank.
• Before any work is done in this area, it is necessary to wait until all the reducing agent has been returned to the tank; this can take up to 10 minutes after the ignition is switched off.
• Similarly, it is not permissible to disconnect the battery until all the reducing agent has been returned to the tank, i.e. 10 mi‐nutes after the ignition is switched off ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
2.6Safety precautions when working on exhaust system
Risk of poisoning due to chemical substances
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Exhaust gas temperature senders may contain chemical sub‐stances. There is a risk of poisoning or injuries to respiratory system.
–Never open an exhaust gas temperature sender by cutting, sawing or any other means.
Risk of injury due to hot condensate and particles in the exhaust system.
The exhaust system could contain hot condensate and/or parti‐cles. There is a risk of injury to the eyes, skin and respiratory system, as well as poisoning.
–Always wear protective gloves and eye protection when cut‐ting the exhaust system.
–When cutting, use an extraction system or otherwise ensure sufficient ventilation.
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Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Pull engine cover panel upwards out of fasteners in areas of -arrows- and in sequence shown. To do this, grip as far be‐neath engine cover panel as possible.
–With ignition switched off, disconnect battery earth strap. ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and reconnect‐ing batteries.
–Remove air filter housing together with air mass meter and connecting pipe ⇒ page 263
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing and installing battery .
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Remove battery carrier, unscrew securing bolts -arrows- for this.
–Remove engine cover panel ⇒ page 7
–Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐tion .
–Drain coolant ⇒ page 159
– Extractairconditioningrefrigerant⇒ Heating,airconditioning; Rep. gr. 87 .
–Remove lock carrier ⇒ General body repairs, exterior; Rep. gr. 50 .
– Open clips -arrows- and pull coolant hoses off coolant expan‐sion tank.
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–Pull off vacuum hoses -1- and -2- for charge air control.
–Separate connectors for exhaust temperature sender 1G235- -1-, for Lambda probe - G39- -3- and for exhaust temperature sender 3 - G495- -2- and exhaust temperature sender 4 - G648- -4-.
–Cut cable ties of cables.
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– Guide lines out of retainers on plenum chamber bulkhead and on turbocharger. Sharan 2011 ➤
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Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Bolt drive shafts to gearbox ⇒ Running gear, axles, steering; Rep. gr. 40 ; Repairing drive shaft; Removing and installing drive shafts .
–Install heat shield for drive shaft (right-side) -arrows-.
Vehicles with manual gearbox:
Specified torque ⇒ 6-speed manual gearbox; Rep. gr. 34
Vehicles with dual clutch gearbox:
Specified torque ⇒ 6-speed dual clutch gearbox; Rep. gr. 34
Continued for all vehicles:
–Install lock carrier ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Lock carrier; Removing and installing lock carrier with add-on parts .
–Secure refrigerant lines free of stress to air conditioner com‐pressor and to condenser ⇒ Heating, air conditioning; Rep. gr. 87 .
–Charge air conditioning system ⇒ Heating, air conditioning; Rep. gr. 87 .
– Installbatteryandbatterycarrier⇒ Electricalsystem;Rep.gr. 27 ; Removing and installing battery .
–Observe notes after connecting battery ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and reconnecting battery.
–Fill coolant system with coolant ⇒ page 159
–Filling fuel system ⇒ page 235
–Read the event memories of all control units. Clear all fault entries which may have occurred during installation ⇒ Vehicle diagnostic tester “Vehicle self-diagnosis”.
– Check headlight adjustment and correct if necessary ⇒ Main‐tenance ; Booklet 20.1 .
Specified torques Bolted
1) Specified torque for M12 collar bolts: 75 Nm
1.7Assembly mountings
Engine mounting
A 1) = 40 Nm + turn 90° further
B 1) = 60 Nm + 90° further
C 1) = 20 Nm + 90° further
1) Renew
Gearbox mounting
1 1) = 40 Nm + 90° further
2 1) = 60 Nm + 90° further
1) Renew
Pendulum support
A 1) = 40 Nm + turn 90° further
B 1) = 60 Nm + 90° further
C 1) = 100 Nm + 90° further
1) Renew
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
1.8Adjusting assembly mountings
Special tools and workshop equipment required
♦ Support - 10-222 A-
♦ Adapter - 10-222 A/3Sharan 2011 ➤
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Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
♦ Adapter - 10-222 A/8-
♦ Torque wrench - V.A.G 1331-
♦ Pliers for spring-type clips - VAS 6362Procedure
⇒ “1.1.2 Removing and installing poly-V belt”, page 28
⇒ “1.1.3 Removing and installing poly V-belt tensioner”, page 29
1.1.1Assembly overview - poly V-belt drive
Sharan 2011 ➤ 4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
1 - Belt pulley and vibration damper
❑Offset holes make as‐sembly possible in one position only
2 - 25 Nm
3 - Alternator
4 - Bracket
❑For ancillaries
❑ Removing and installing ⇒ page 35
5 - 20 Nm + turn 90° further
6 - Poly V-belt tensioning ele‐ment
7 - Air conditioner compressor
8 - 25 Nm
9 - Dowel sleeves
10 - Poly V-belt
❑Mark direction of rota‐tion before removing
❑Check for wear
❑Do not kink
❑ Removing and installing ⇒ page 28
1.1.2Removing and installing poly-V belt
Special tools and workshop equipment required
♦ Locking pin - T10060 A-
Removing
–Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front, Assembly overview - noise insula‐tion .
–Mark poly V-belt direction of rotation.
Sharan 2011 ➤ 4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
– Swing tensioning element in direction of arrow to remove ten‐sion from poly V-belt.
–Align holes -arrows- and lock tensioning element in position with locking pin - T10060 A- .
–Remove poly V-belt.
Installing
–Install in reverse order of removal.
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1.1.3 Removing and installing poly V-belt ten‐sioner
Removing
–Remove poly V-belt ⇒ page 28
–Loosen clamp -2-, raise retaining clip -1- and remove con‐necting hose on »cold side«.
–Remove cowling together with radiator fan - V7- and radiator fan on right of radiator - V35- ⇒ page 150
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
– Removesecuringbolts-arrows-fromchargeairpipeandsep‐arate connector -1- from charge air pressure sender - G31- .
–Open clamp -2-, lay coolant hose -3- to side and remove charge air pipe.
–Unscrew securing bolt -2- and remove poly V-belt tensioner -1-.
Installing
Install in reverse order of removal. When doing this, observe the following:
♦ Specified torques ⇒ page 27
♦ Install poly V-belt ⇒ page 28 .
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1.2Poly V-belt drive with tensioning roller and air conditioner compressor
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Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Unscrew bolts -6 … 1- and remove bracket for ancillaries.
Installing
Install in reverse order of removal. When doing this, observe the following:
♦ Take note of any dowel sleeves in ancillary bracket and re‐place missing ones if necessary.
♦ Renew all bolts that must be tightened with turning further an‐gle.
Ancillary bracket - specified torques and tightening sequence
–Insert securing bolts for ancillary bracket as follows:
♦ Bolts -1- and -2- M10 x 52.
♦ Bolts -5- and -6- M10 x 60.
♦ Bolts -3- and -4- M10 x 30.
–Tighten securing bolts for ancillary bracket in sequence -1 … 6- in 2 stages as follows:
1.Screw all bolts in to stop by hand.
2.Tighten all bolts to 40 Nm.
3.Turn bolts -3- and -4- 45° further.
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4.Turn bolts -1, 2, 5 and 6- 90° further.
–Install alternator ⇒ Electrical system; Rep. gr. 27 .
–Install high-pressure pump ⇒ page 232
–Install front bolt of engine bracket ⇒ Item 32 (page 38) .
1.5Assembly overview - toothed belt drive
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1 - Toothed belt
❑Mark direction of rota‐tion before removing
❑Check for wear
❑Do not kink
❑Removing, installing and tensioning ⇒ page 77
2 - 180 Nm + turn 135° further
❑Renew
❑ Use counterhold - 3415to loosen and tighten.
❑ Do not additionally oil or grease thread and shoulder.
❑The continued turn may be made in several steps, e.g. 90° + 45°
1.) Mounting seal with sender wheel on assembly tool - T10134-
–Screw in hexagon nut -B- to just before clamping surface -Aof threaded spindle.
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–Clamp assembly device - T10134- in a vice on clamping sur‐face -A- of threaded spindle.
–Press assembly housing -C- downwards until it lies on hexa‐gon nut -B- -arrow-.
–Screw hexagon nut onto threaded spindle until inner part of assembly device and assembly housing are at same height.
–Remove securing clip -arrow- from new sealing flange.
Note
Donotremovethesenderwheelfromthesealingflangeorturn it.
– Locatinghole-A-onsenderwheel-C-mustalignwithmarking -B- on sealing flange.
– Place sealing flange with front side downwards on a clean flat surface.
–Upper edge of sender wheel and front edge of sealing flange must align -arrows-. Sharan 2011 ➤ 4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
AG Volkswagen
isnotpermittedunlessauthorisedbyVolkswagen
– Push sealing lip support ring -A- downwards in direction of ar‐row until it lies on flat surface.
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Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
– Placesealingflangewithfrontsideonassemblytool-T10134so that locating pin -B- can be inserted in sender wheel hole -A-.
Note
Ensuresealingflangeliesflatonassemblytool.
– Pushsealingflangeandsupportringforsealinglip-B-against surface of assembly tool - T10134- whilst tightening the 3 knurled screws -A- so that locating pin cannot slide out of sender wheel hole.
– Push assembly housing -C- by hand in direction of arrow until sealing lip support ring -B- contacts crankshaft flange -A-.
– Push guide pin for diesel engines (black knob) -D- into hole in crankshaft. This ensures that the sender wheel reaches its fi‐nal installation position.
5.) Checking sender wheel installation position on crankshaft
–Screw hexagon nut -E- to end of threaded spindle.
–Remove the two bolts -A- from cylinder block.
–Screw the three knurled screws -B- out of sealing flange.
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Unscrew Allen head bolts -A- and remove assembly toolT10134- .
–Remove sealing lip support ring.
AGdoesnotguaranteeoracceptanyliab
–The sender wheel is in the correct installation position on the crankshaft if a gap -a- = 0.5 mm exists between crankshaft flange -A- and sender wheel -B-.
–Set vernier gauge on crankshaft flange.
–Measure distance -a- between crankshaft flange and sender wheel.
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If dimension -a- is too small:
–Re-press sender wheel ⇒ page 58
If dimension -a- is attained:
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–Tighten new securing bolts for sealing flange to 15 Nm using alternate and diagonal sequence.
–Install engine speed sender - G28- -arrow-, and tighten se‐curing bolt to 5 Nm.
–Install sump ⇒ page 126
–Install intermediate plate.
–Install flywheel using new bolts. Tighten securing bolts to 60 Nm + 90 .
6.) Re-pressing sender wheel
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Secure assembly tool - T10134- to crankshaft flange using hexagon socket head bolts -A-.
–Hand tighten both hexagon socket head bolts.
–Push assembly tool - T10134- by hand to sealing flange.
–Screw hexagon nut -E- onto threaded spindle by hand until it lies on assembly housing -C-.
– Tighten hexagon nut of assembly tool - T10134- to 40 Nm us‐ingtorquewrench-V.A.G1331-andtoolinsert,24mm-V.A.G 1332/11- .
–Check installation position of sender wheel on crankshaft again ⇒ page 57
If dimension -a- is still too small:
–Tighten hexagon nut for assembly tool - T10134- to 45 Nm.
–Check installation position of sender wheel on crankshaft again ⇒ page 57 .
2.7Removing and installing engine speed
sender - G28-
Removing
–Remove noise insulation. ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐tion .
–Clamp off coolant hoses from oil cooler with hose clips, up to 25 mm in diameter - 3094- .
– Loosen spring-type clips -arrows- using spring-type clip pliers - VAS 6362- .
Note
Collectescapingcoolantwithdriptray-VAS6208-.
–Pull coolant hoses off oil cooler.
–Remove oil filter bracket ⇒ page 137
AG. V
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Loosen securing bolt -arrow- ( socket AF 4 mm - T10370- ) and pull out speed sender.
Installing
Install in reverse order of removal, observing the following.
• Specified torques for oil filter bracket ⇒ page 137 –Check coolant level, replenish coolant if necessary ⇒ page 159
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Sharan 2011 ➤
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
3Pistons and conrods
⇒ “3.1 Assembly overview - pistons and conrods”, page 61
⇒ “3.3 Separating new conrods”, page 64
⇒ “3.5 Piston and cylinder dimensions”, page 65
⇒ “3.6 Checking piston projection at TDC”, page 65
3.1Assembly overview - pistons and conrods
1 - Piston rings
❑Offset gaps by 120°
❑Use piston ring pliers to remove and install.
❑“TOP” faces towards piston crown.
❑Checking ring gap ⇒ page 62
❑ Checkingring-to-groove clearance ⇒ page 63
❑Top and centre: Com‐pression rings.
❑ Bottom:Oilscraperring.
2 - Piston
❑With combustion cham‐ber.
❑Mark installation posi‐tion and cylinder num‐ber.
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❑Installation position and allocation of piston to cylinder ⇒ page 64
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❑Arrow on piston crown pointstobeltpulleyend.
❑Install using piston ring clamp.
❑ If piston skirt is cracked, renew piston.
❑Checking piston projec‐tion at TDC ⇒ page 65
3 - Piston pin
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❑If difficult to remove, heat piston to 60°C.
❑Remove and install using drift - VW 222- .
4 - Retaining ring
5 - Connecting rod
❑Mark cylinder allocation -A- with coloured pen.
❑Installation position: Marking -B- faces towards pulley end.
❑With industrially cracked conrod cap.
❑Separate new conrod ⇒ page 64
6 - Bearing shell
❑Note installation position ⇒ page 65
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
❑Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi‐cation: Black line on bearing surface in area of joint.
❑Do not interchange used bearing shells.
❑Insert bearing shells centrally.
❑Ensure firm seating
❑Axial clearance, wear limit: 0.37 mm
❑Check radial clearance with Plastigage; wear limit: 0.08 mm.
❑Do not rotate crankshaft when checking radial clearance.
7 - Cylinder block
❑Checking cylinder bores ⇒ page 63 .
❑Piston and cylinder dimensions ⇒ page 65
8 - Conrod bearing cap
❑Observe installation position
❑The caps only fit in one position and only on the appropriate conrod due to the breaking procedure (cracking) separating the cap from the conrod.
9 - Oil spray jet
❑For piston cooling
10 - 25 Nm
❑Insert without sealant.
11 - Conrod bolt, 30 Nm + 90° further
❑Renew
❑Oil threads and contact surface
❑Use old bolt for measuring radial clearance.
Checking piston ring gap
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Special tools and workshop equipment required
♦ Feeler gauge
– Push piston ring squarely from above down to approx. 15 mm from bottom end of cylinder.
Piston ring dimensions in mm New (mm) Wear limit (mm)
1st compression ring 0.20 … 0.40 1.00
2nd compression ring 0.20 … 0.40 1.00
Oil scraper ring 0.25 … 0.50 1.00
2011 ➤ 4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
Checking ring-to-groove clearance
Special tools and workshop equipment required
♦ Feeler gauge
–Clean ring groove before checking.
Piston ring dimensions in mm
Checking cylinder bores
isnotpermittedunlessauthorisedbyVolkswag
Special tools and workshop equipment required
♦ Cylinder gauge 50 …100 mm
– Take measurements at 3 positions in both transverse -A- and longitudinal -B- directions, as illustrated. Difference between actual and nominal diameter max. 0.10 mm.
Sharan
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
♦ Measuring plate -VW 385/17- from universal measuring toolVW 385-
♦ Dial gauge - VAS 6079-
Test sequence
–Secure dial gauge - VAS 6079- with measuring bridgeVW 382/7- and measuring plate -VW 385/17- to cylinder block as shown in the illustration.
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
– Measuretheprojectionofeachpistonatthetwopointsmarked with -arrows- (at the rear side and front side of the piston seen in the longitudinal direction of the engine).
Piston projection at TDC must be measured when new pistons or a short engine is installed. Install the appropriate cylinder head gasket depending upon piston projection, according to following table:
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
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Sharan 2011 ➤ 4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
4Crankshaft
⇒ “4.1 Assembly overview - crankshaft”, page 69
⇒ “4.2 Crankshaft dimensions”, page 69
⇒ “4.3 Renewing needle bearing in crankshaft”, page 70
4.1Assembly overview - crankshaft
1 - Bearing shell
❑ For bearings 1, 2, 4 and 5.
❑Do not interchange used bearing shells (mark).
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2 - 65 Nm + turn 90° further
❑Renew
❑ Tomeasureradialclear‐ance, tighten to 65 Nm but not further.
3 - Bearing cap
❑Bearing cap 1: belt pul‐ley end.
❑Bearing cap 3 with re‐cesses for thrust wash‐ers
❑Bearing shell retaining lugs in cylinder block and bearing caps must align.
4 - Thrust washer
❑For bearing cap 3
❑ Note fixing arrangement
5 - Needle bearing
❑Only vehicles with dual clutch gearbox.
❑ Removing and installing ⇒ page 70
6 - Crankshaft
❑Axial clearance new: 0.07 to 0.17 mm; wear limit: 0.37 mm
❑Check radial clearance with Plastigage
❑New: 0.03 … 0.08 mm; Wear limit 0.17 mm
❑Do not rotate crankshaft when checking radial clearance
❑Crankshaft dimensions ⇒ page 69 .
7 - Thrust washer
❑For cylinder block, bearing 3
4.2Crankshaft dimensions
(Dimensions in mm)
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
4.3Renewing needle bearing in crankshaft
Only vehicles with a dual clutch gearbox
Special tools and workshop equipment required
♦ Counter support, e.g. KUKKO 22-1 - VAS 251 621-
♦ Internal puller - VAS 251 635-
♦ Drift - VW 207 C-
Condition:
• The front edges of the inner puller must be free of chips.
• Gearbox has been removed.
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4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
Pulling out needle roller bearing
– Pull out needle bearing -1- with internal puller - VAS 251 635-A- and counter support, e.g. KUKKO 22-1 - VAS 251 621-B- from crankshaft -2-.
AGdoesnotguaranteeoracce
– The internal puller must be positioned behind the needle-andcage assembly -arrow-.
Installing
–Clean bearing seat in crankshaft and apply as thin coating of grease.
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Sharan 2011 ➤ 4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Pull connector off radiator outlet coolant temperature sender - G83- , open clips -arrows- and remove toothed belt guard.
–Remove front right wheel housing liner ⇒ General body re‐pairs, exterior; Rep. gr. 66 ; Wheel housing liner .
–Remove poly V-belt ⇒ page 27
–Remove vibration damper ⇒ Item 29 (page 38)
– Remove lower and centre toothed belt guard -arrows- and un‐screw securing nut of coolant pipe -1-.
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–Position crankshaft at TDC and lock crankshaft toothed belt pulley with crankshaft stop - T10050- . To do this, push crank‐shaft stop into teeth of belt pulley from face side. Depending on the production version, either the toothed segment or the arrow on the camshaft toothed belt pulley must be at »12 o'clock«.
–Lock hub of high-pressure pump with locking pin - 3359- . To do this, slide locking pin into adjustment hole outside toothed belt pulley.
–Turn camshaft toothed belt pulley and toothed belt pulley of high-pressurepumpintheirelongatedholesclockwisetostop.
–Fit toothed belt to crankshaft pulley, tensioning roller, cam‐shaft pulley, toothed belt pulley of coolant pump and toothed belt pulley of high-pressure pump.
–Finally, fit toothed belt to idler pulley.
– Loosen tensioning roller securing nut and pull out locking tool - T10265- .
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Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Screw eccentric of tensioning roller clockwise carefully using angled screwdriver - T10264- . Indicator -2- must be roughly past the centre of the gap in the base plate (corrects itself dur‐ing pretensioning).
Ensure that securing nut -1- does not turn as well.
–Hold tensioning roller in this position and tighten securing nut for tensioning roller as follows: 20 Nm and 45° further.
AG Volkswagen
–Apply counterhold - T10172- as shown. Press counterholdT10172- in direction of arrow, keeping camshaft toothed belt pulley under tension.
– In this position, first tighten securing bolts -1- of camshaft pul‐ley and of toothed belt pulley for high pressure pump by hand and then tighten to 20 Nm.
–With ignition switched off, disconnect battery earth strap. ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and reconnect‐ing batteries.
–Remove engine cover panel ⇒ page 7
–Remove air filter housing ⇒ page 263
– Removebatteryandbatterytray⇒ Electricalsystem;Rep.gr. 27 ; Removing and installing battery .
–Remove cowling together with radiator fan - V7- and radiator fan on right of radiator - V35- ⇒ page 150
–Remove connecting hose on »cold side« ⇒ Item 4 (page 219) from charge air cooler.
–Remove cylinder head cover ⇒ page 74
–Pull connector off throttle valve module - J338- -2-.
–Remove bolt from oil dipstick attachment -4-.
–Disconnect vacuum line from vacuum pump.
–Unscrew bolts -2, 5- and -arrows-.
– Free electrical wiring and hoses on left air pipe using removal lever - 80 - 200- .
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–Release hose clip -3- and remove left air pipe.
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Unscrew bolts -arrows- and remove pulsation damper -2-.
–Remove noise insulation ⇒ General body repairs, exterior; Rep.gr. 50;Body-front;Assemblyoverview-noiseinsulation
–Drain coolant ⇒ page 159
–Disconnect electrical connector -4- on coolant temperature sender - G62- .
– Pullcoolanthosesoffconnection.Todothis,loosenhoseclips -1- and -2-.
–Disconnect electrical connector -1- on oil pressure switchF1- .
–Remove bolt -arrow-.
–Pull off vacuum hose -2-.
– Disconnect connectors for exhaust gas temperature sender 1 - G235- -1-.
–Free electrical lines on turbocharger.
isnotpermittedunlessauthorisedbyVolkswagen
–Remove radiator cowl together with radiator fans ⇒ page 150
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
– Unscrew securing bolts -arrows- from charge air pipe and dis‐connect connector from charge air pressure sender - G31-1-.
AG Volkswag
–Open clamp -2-, lay coolant hose -3- to side and remove charge air pipe.
– Do not use any other means rather than the contour blade set - VAS 852 005- or a commercially available CERAN surface scraper to remove the sealant residue from the cylinder head and cylinder block.
• The sealing surfaces must not be damaged.
• There must be no oil or coolant in the bolt pockets.
• Do not remove new cylinder head gasket from packaging until it is ready to be fitted.
• If a new cylinder head is installed, contact surfaces between roller rocker fingers and running surface of cam must be oiled.
• Handle the cylinder head gasket very carefully to prevent damage to the silicone coating or the indented area of the gasket.
• Turn the crankshaft carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.
• When the cylinder head or cylinder head gasket is renewed, the entire coolant and the engine oil must be changed.
–Remove any loose remains using a lint-free cloth.
–Before fitting cylinder head, remove crankshaft stopT10050- , and turn crankshaft in opposite direction of engine rotation until all pistons are nearly uniformly below TDC.
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–Cylinder head gasket must lie with identification facing up‐wards.
– To centre, screw guide pins - 3070- into outer threaded holes on intake side.
⇒ “2.2 Removing and installing camshafts”, page 101
⇒ “2.5 Removing and installing camshaft oil seal”, page 109
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⇒ “2.7 Renewing valve stem seals with cylinder head installed”, page 112
⇒ “2.8 Renewing valve stem seals with cylinder head removed”, page 116
⇒ “2.9 Valves”, page 119
2.1Assembly overview - valve gear
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
1 - Valve
❑Do not rework; only grinding-in is permissi‐ble
❑Mark installation posi‐tion for re-installation.
❑Checking ⇒ page 120
❑Valve dimensions
⇒ page 119
❑Checking valve guides
⇒ page 119
2 - Cylinder head
3 - Valve stem seal
❑Renewing with cylinder head installed
⇒ page 112
❑Renewing with cylinder head removed
⇒ page 116
4 - Valve springs
5 - Valve spring plate
6 - Valve cotters
7 - Cap
❑Renew
❑Removing: With retain‐ing frame installed, pierce one side of cap with an awl and pry out.
❑Installing: Drive in with‐out sealant using an ap‐propriate thrust piece.
❑ Driveindepth1to2mm
8 - Oil seal
❑Renewing ⇒ page 109
9 - Exhaust camshaft
❑Removing and installing ⇒ page 101
❑Measuring axial clearance ⇒ page 108
❑Measuring radial clearance ⇒ page 109
10 - Bolt
❑Specified torque and tightening sequence ⇒ page 100
11 - Ladder frame
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❑With integrated camshaft bearings.
❑Specified torque and tightening sequence ⇒ page 100
12 - Inlet camshaft
❑Removing and installing ⇒ page 101
❑Measuring axial clearance ⇒ page 108
❑Measuring radial clearance ⇒ page 109
13 - Roller rocker fingers
❑Mark installation position for re-installation.
❑Check roller bearing for ease of movement.
❑Lubricate contact surfaces before installing.
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
14 - Retaining clip
❑For hydraulic compensation element.
15 - Hydraulic compensation element
❑Mark installation position for re-installation.
❑Lubricate contact surfaces before installing.
Retaining frame - specified torques and installation sequence
–Tighten bolts in 2 stages in the sequence shown:
Stage Bolts Specified torque
1) -1 … 24- Screw in by hand as far as stop
• The retaining frame must make contactwiththecylinderheadover the entire contact surface.
2) -1 … 24- 10 Nm
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2.2Removing and installing camshafts
Special tools and workshop equipment required
♦ Diesel injection pump locking pin - 3359-
♦ Counter-hold tool - T10051-
♦ Puller - T10052-
♦ Camshaft fitting tool - T40094-
♦ Camshaft clamping tool - T40095-
♦ Camshaft fitting tool - T40096-
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
♦ Torque wrench - V.A.G 1331/-
♦ Torque wrench - V.A.G 1332/-
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♦ Silicone adhesive sealant - D 176501 A1-
2.2.1Removing
–Remove engine cover panel ⇒ page 7
–Remove fuel filter ⇒ page 195 .
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–Take toothed belt off camshaft and high-pressure pump ⇒ page 77 .
–Remove cylinder head cover ⇒ page 74
–Remove securing bolts for camshaft toothed belt pulley -1-.
–Detach camshaft pulley from hub.
Sharan 2011 ➤ 4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Counterhold hub with counterhold - T10051- and loosen se‐curing bolt -1- of hub.
–Loosen hub securing bolt about 2 turns.
–Fit puller - T10052- and align it with holes in hub.
–Tighten securing bolts -1-.
–Apply tension to hub by evenly tightening puller -2- until hub separates from taper of camshaft.
Note
Whendoingthis,holdpullerwith30mmspanner.
–Remove hub from taper of camshaft.
–Remove vacuum pump ⇒ page 95 .
–Remove securing bolts of retaining frame in sequence -24 … 1-.
–Remove retaining frame.
–Carefully take out camshafts.
2.2.2Installing
Note
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– Handtightensecuringbolts-1-tocamshafttoothedbeltpulley so that there is no play.
–Lock hub using locking pin - 3359- .
–Install toothed belt and adjust valve timing ⇒ page 77 .
–Install vacuum pump ⇒ page 95
–Install cylinder head cover ⇒ page 74
–Install fuel filter.
2.3Measuring axial clearance of camshaft
Special tools and workshop equipment required
♦ Universal dial gauge holder - VW 387-
♦ Dial gauge - VAS 6079-
isnotpermittedunlessauthorisedbyVolkswagen AG Volkswa
Procedure
–Remove retaining frame ⇒ page 101 .
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Sharan 2011 ➤ 4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
– Fasten dial gauge - VAS 6079- to cylinder head with universal dial gauge bracket - VW 387- as shown in the illustration.
–Press camshaft against dial gauge by hand.
–Set dial gauge to “0”.
–Press camshaft away from dial gauge and read off value:
Axial clearance of inlet and outlet camshafts:
• Specification: 0.048 to 0.118 mm.
• Wear limit: 0.17 mm
2.4Measuring radial clearance of cam‐shafts
Special tools and workshop equipment required
♦ Plastigage
Procedure
–Remove roller rocker finger.
–Remove bearing cap and clean crankshaft journal.
– Place a length of Plastigage corresponding to the width of the bearing on the journal to be measured or into the bearings.
• The Plastigage must lie in the middle of the bearing.
–Fit retaining frame and tighten to 10 Nm ⇒ page 100 without twisting crankshafts.
–Remove retaining frame.
–Compare width of Plastigage with the measurement scale.
• Radial clearance: 0.035 to 0.085 mm.
2.5Removing and installing camshaft oil seal
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GAnegawskloVybthgirypoC.tnemucodsihtninoitamrof
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
Special tools and workshop equipment required
♦ Fitting tool - V.A.G 10-203-
♦ Seal puller - 3240-
♦ Torque wrench - V.A.G 1331/-
♦ Torque wrench - V.A.G 1332/-
♦ Bolt M12 x 1.5 x 75
Removing
–Take toothed belt off camshaft and high-pressure pump ⇒ page 77 .
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Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
1 - Seal
❑Permanently attached to drain plug
2 - Oil drain plug, 30 Nm
3 - Sump
❑ Removing and installing ⇒ page 126
4 - 9 Nm
5 - Suction line
❑Clean strainer if soiled
6 - O-ring
❑Renew
7 - Oil pump
❑ Removing and installing ⇒ page 130
❑Before installing, check that the two dowel sleeves for centring oil pump on balancer shaft module are fitted.
8 - Input shaft
❑For oil pump.
9 - Retaining ring
❑Must lie in base of groove.
❑Renew damaged or over-tensioned circlip.
10 - Spur gear
❑For balancer shaft.
11 - 20 Nm + turn 90° further
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❑Renew
12 - Thrust washer
❑For intermediate gear wheel.
❑Renew
❑Fitting position ⇒ page 125
❑To install intermediate gear wheel, secure to balancer shaft module with grease.
13 - Intermediate gear
❑Renew
❑A coating is applied to the new intermediate gear wheel which sets the correct tooth backlash through wear.
❑Installation position: Part number must be visible.
❑Make sure thrust washer is seated correctly ⇒ page 125
14 - 90 Nm + 90°
❑With washer
❑Renew
15 - Hub
❑For intermediate gear wheel.
❑Renew
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
16 - Crankshaft sprocket
17 - Balancer shaft module
❑Removing ⇒ page 131
❑Reinstalling previously run balancer shaft module ⇒ page 135
❑Installing new balancer shaft module ⇒ page 133
❑ Before installing, check that the two dowel sleeves for centring balancer shaft module on cylinder block are fitted.
18 - Bolt
❑Renew
❑Specified torque and tightening sequence ⇒ page 130
19 - Dowel sleeves
20 - 9 Nm
21 - Oil extraction pipe
22 - 9 Nm
23 - Seal
❑Renew
24 - Oil level and oil temperature sender - G266-
❑Removing and installing ⇒ page 126
25 - 9 Nm
❑Self-locking
❑Renew
26 - Bolt
❑Renew
❑Specified torque and tightening sequence ⇒ page 124
Sump - specified torque and tightening sequence
Note
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GAnegaw
Renewoilsumpbolts.
–Tighten bolts in 3 stages:
Stage Bolts Specified torque
1) -1 … 20- In diagonal sequence to 5 Nm
2) -Arrows- 40 Nm
3) -1 … 20- Diagonally in stages; final torque 15 Nm
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4-cylinder common rail engine (2.0 l, EA189 Gen II) -
2011 ➤ 4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
Removing
–Drain engine oil ⇒ Maintenance ; Booklet .
– Remove air hose; loosen hose clip -2- and raise retaining clip -1- for this.
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–Unscrew bolts -arrows-.
–Free coolant hose -3-.
–Release hose clip -2-.
– Disconnectelectricalconnector-1-onchargepressuresender - G31- and remove right air pipe.
–Unscrew bolt -arrow- and push coolant circulation pump 2V178- to the side.
GAnegawskloVybthgirypoC.tnemucodsihtninoitamrof
Sharan
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Unscrew bolt -arrow- on left air pipe.
–Disconnect electrical connector -arrow- on oil level and oil temperature sender - G266- .
–Open fasteners -arrows- and remove noise insulation -1- for sump.
–Unscrew bolts -arrows- of sump to gearbox connection.
–Slacken bolts -1 … 20- in diagonal sequence and remove.
–Release sump carefully from adhesive.
Installing
Caution
Dangerofsoilinglubricationsystemandbearings.
♦ Coveropenpartsofengine.
WARNING
Riskofeyeinjury.
♦ Wearsafetygoggles.
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
– Remove sealant residues from sump and cylinder block using rotating plastic brush or similar.
–Clean sealing surfaces; they must be oil and grease free.
Note
Checktheexpirydateofthesealant.
–Cut off nozzle on tube at front marking (∅ of nozzle approx. 2 mm).
Install in reverse order of removal, observing the following.
Note
♦ RenewO-ring.
♦ Renewdamagedoroverstretchedcirclip.
♦ Theretainingringmustseatinthebaseofthegroove.
–Insert dowel sleeves if oil pump has no dowel sleeves -arrows-.
–Insert dowel sleeves if balancer shaft module has no dowel sleeves for centring oil pump.
–Install sump ⇒ page 126
2.5Removing balancer shaft module
Special tools and workshop equipment required
♦ Crankshaft stop - T10050-
Procedure
–Pull out oil dipstick.
–Remove vibration damper ⇒ page 30
Sharan
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
Caution
Riskofdestructionduetotoothedbeltjumping.
♦ Onlyturncrankshaftinenginedirectionofrotation.
–Turn crankshaft at bolt for toothed belt pulley until crankshaft is at “TDC”.
–Lock crankshaft in position with crankshaft stop - T10050- .
• Themarkingsonthetoothedbeltpulley-2-andthecrankshaft stop -1- must align -arrow-. When doing this, the pin of the crankshaft stop must engage in the drilling of sealing flange.
–Press intermediate gear wheel -3- forcefully (with assistance of a wooden rod if necessary) in -direction of arrow- into spur gear teeth -2- and balance shaft gear wheel -1-.
⇒ “3.2 Removing and installing oil filter bracket with engine oil cooler”, page 138
⇒ “3.3 Removing and installing oil pressure switch F1 ”, page 141
⇒ “3.4 Checking oil pressure switch F1 ”, page 142
⇒ “3.5 Checking oil pressure”, page 143
3.1Assembly overview - oil filter bracket and engine oil cooler
1 - Cap
❑25 Nm
2 - O-ring
❑Renew
3 - O-ring
❑Renew
4 - O-ring
❑Renew
5 - Oil filter element
❑Observe notes
⇒ page 122
❑ Removing and installing
⇒ Maintenance ; Book‐let 808
6 - Engine oil cooler
❑Observe notes
⇒ page 122
❑Connection diagram for coolant hoses
⇒ page 149
❑ Removing and installing
⇒ page 138
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❑Renew coolant after re‐placing
7 - 11 Nm
8 - Seals
❑Renew
9 - Bolt
❑Renew
❑Specified torque and tightening sequence
⇒ page 138
10 - Oil filter bracket
❑With integrated oil retention valve.
❑Removing and installing
⇒ “3.2 Removing and installing oil filter bracket with engine oil cooler”, page 138
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
11 - Seals
❑Renew
Oil filter bracket - specified torques and sequence
Note
Renewoilfilterbracketbolts.
–First tighten upper left and lower right bolts.
–Tighten bolts in 2 stages:
Stage Bolts Specified torque/turning further angle
1) -Arrows- In diagonal sequence to 14 Nm 2) -Arrows- turn 90° further diagonally
3.2 Removing and installing oil filter bracket with engine oil cooler
Special tools and workshop equipment required
♦ Release lever - 80 - 200-
♦ Used oil collector and extractor - V.A.G 1782-
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Sharan 2011 ➤ 4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
♦ Drip tray for workshop hoist - VAS 6208-
♦ Spring-type clip pliers - VAS 6362-
Removing
–Drain coolant ⇒ page 159
–Remove radiator cowl ⇒ page 150 .
–Remove air filter housing ⇒ page 263
–Remove oil filter element ⇒ Maintenance ; Booklet .
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4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Unscrew bolts -arrows-.
–Free off coolant hose -3-.
–Release hose clip -2-.
– Disconnectelectricalconnector-1-onchargepressuresender -G31-/intakeairtemperaturesender-G42-andremoveright air pipe.
–Pull out oil dipstick slightly, unscrew bolt -1-.
–Press off clip -2- using removal lever - 80 - 200- .
– Pulloildipstickguidetubeoffcylinderblockupwardsandpush to side.
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AGdoesnotguaranteeoracceptanyliabilitywi
Sharan 2011 ➤
Sharan 2011 ➤ 4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Place drip tray for workshop hoist - VAS 6208- under point of separation.
–Remove coolant hoses. To do this, loosen hose clips -1-.
– Place used oil collection and extraction unit - V.A.G 1782- un‐der engine.
–Unscrew bolts -arrows- and remove oil filter bracket with en‐gine oil cooler.
Install in reverse order of removal, observing the following.
Note
Renewtheseal.
–Install vacuum line to exhaust gas recirculation cooler
⇒ page 224
–Install intake pipe ⇒ page 205
3.4Checking oil pressure switch - F1-
Special tools and workshop equipment required
♦ Oil pressure tester - V.A.G 1342-
♦ Voltage tester - V.A.G 1527B-
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♦ Adapter set - V.A.G 1594C-
Sharan 2011 ➤ 4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
Procedure
• Oil level OK.
• Engine oil temperature approx. 80°C.
–Remove oil pressure switch - F1- ⇒ page 141
–Connect oil pressure tester - V.A.G 1342- to hole for oil pres‐sure switch.
–Connect brown line -1- of oil pressure tester to earth (–).
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–Connect voltage tester - V.A.G 1527B- with auxiliary cables from auxiliary measuring set - V.A.G 1594C- to oil pressure switch - F1- and battery positive (+).
• LED should not light up.
Note IfLEDlightsupnow,renewoilpressureswitch-F1-.
–Start engine.
Note
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Test for leaks in cooling system using cooling system testerV.A.G1274/-andadapterforexpansiontank-V.A.G1274/8-and adapter for sealing cap - V.A.G 1274/9- .
Volkswagen
⇒ “1.1 Assembly overview - parts of cooling system, body side”, page 145
2011 ➤ 4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
♦ 10 mm jointed spanner - 3185-
♦ Refractometer - T10007-
♦ Torx bit - T10058-
♦ Torque wrench - V.A.G 1331/-
♦ Drip tray for workshop hoist - VAS 6208-
♦ Hose clamp pliers - VAS 6340-
Removing
Note Renewgasketsandseals.
–Drain coolant ⇒ page 159
–Remove engine cover panel ⇒ page 7 .
–Remove air filter housing together with air mass meter and connecting pipe ⇒ page 263
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing and installing battery .
Sharan
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Remove battery carrier, unscrew securing bolts -arrows- for this.
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– Remove crankcase breather hose -1- from cylinder head cov‐er. Press release tabs to do this.
–Free vacuum hoses -arrows- at air pipe.
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–Unscrew bolt -2-, swing air pipe with inlet connection to rear and remove from turbocharger.
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–Unclip wiring harness from bracket -arrow-.
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
– Free wiring harnesses -arrows- and electrical connector -1- at bracket.
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–Unscrew bolts -2, 5- and -arrows-.
–Free electrical lines and hoses on left air pipe using removal lever - 80 - 200- .
–Release hose clip -3- and remove left air pipe.
–Pull off coolant hoses. To do this, open hose clips -1-.
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–Remove electrical connector -1- for Hall sender - G40- from bracket.
– Unscrewbolts-arrows-andpullfrontcoolantpipetosideaway from 4/2-way valve. Sharan 2011 ➤
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Pull coolant pipe out of connection -C- for 4/2-way valve. Leave in its installation position.
–Unscrew bolts -arrows-.
–Free coolant hose -3-.
–Release hose clip -2-.
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– Disconnectelectricalconnector-1-onchargepressuresender -G31-/intakeairtemperaturesender-G42-andremoveright air pipe.
–Remove alternator ⇒ starter, current supply, CCS; Rep. gr. 27 ; Removing and installing alternator .
–Unscrew bolt -1-.
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–Press off clip -2- using removal lever - 80 - 200- .
–Pull oil dipstick guide tube upwards out of cylinder block and press aside.
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Sharan 2011 ➤ 4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Pull coolant hoses off connections -A, B and D-.
–Remove securing bolts -3- for 4/2-way valve -2-.
–Pull valve out from cylinder block.
2.5Draining and adding coolant
Special tools and workshop equipment required
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♦ Refractometer - T10007-
♦ Drip tray for workshop hoist - VAS 6208-
♦ Hose clamp pliers - VAS 6340-
♦ Coolant system charge unit - VAS 6096-
♦ Adapter for cooling system tester - V.A.G 1274/8-
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
Remove noise insulation: ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insulation –Pull coolant hoses -1- off coolant circulation pump 2 - V178-2-.
–Remove air hose. Release hose clips -1- and -2- for this.
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–Pull off lower coolant hose retaining clip -arrow- and remove coolant hose from quick-release connection of radiator.
2011 ➤ 4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–To drain coolant from engine, also remove coolant hose from engine oil cooler -arrow-.
Note
Pleaseobservedisposalinstructions!
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Recommended mixing ratios (use only distilled water for mixing):
1) The quantity of coolant can vary depending on the vehicle equipment. Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Install lower coolant hose and secure with retaining clip -arrow-.
– Connect coolant hoses to engine oil cooler and coolant circu‐lation pump 2 - V178- .
– Installnoiseinsulation:⇒ Generalbodyrepairs,exterior;Rep. gr. 50 ; Body - front; Assembly overview - sound insulation .
With cooling system charge unit - VAS 6096- :
– Screw adapter for cooling system tester - V.A.G 1274/8- onto expansion tank.
–Fill coolant circuit using cooling system charge unitVAS6096-⇒ Operatinginstructionsforcoolingsystemcharge unit VAS 6096.
Without cooling system charge unit - VAS 6096- :
–Slowly fill coolant to upper marking of shaded field on expan‐sion tank.
–Fit expansion tank cap.
– Startengineandmaintainanenginespeedofabout2,000rpm for about 3 minutes.
–Then run engine at idling speed until radiator fan cuts in.
– Check coolant level and top up as needed. When engine is at normaloperatingtemperature,thecoolantlevelmustbeatthe upper mark; when engine is cold, in the middle of the shaded field.
–Remove battery ⇒ Electrical system; Rep. gr. 27 .
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4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
– Unscrew bolts -arrows- and remove battery mounting bracket -1-.
– Remove crankcase breather hose -1- from cylinder head cov‐er. Press release tabs to do this.
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Volkswagen
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–Free vacuum hoses -arrows- at air pipe.
–Unscrew bolt -2-, swing air pipe with inlet connection to rear and pull from turbocharger.
–Unclip wiring harness from bracket -arrow-.
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Vehicles with dual clutch gearbox:
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–Clamp off coolant hoses using hose clamps -3094- and pull from gearbox oil cooler. To do this, open hose clips -arrows-.
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
Continued for all vehicles:
– Free wiring harnesses -arrows- and electrical connector -1- at bracket.
–Remove air hose. Release hose clips -1- and -2- for this.
–Unscrew bolts -2, 5- and -arrows-.
– Free electrical wiring and hoses on left air pipe using removal lever - 80 - 200- .
–Release hose clip -3- and remove left air pipe.
–Release hose clips -1- and pull coolant hoses off.
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Sharan 2011 ➤
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Remove electrical connector -1- for Hall sender - G40- from bracket.
–Remove bracket from front from coolant pipe.
–Open hose clips -2- and -3-, and pull coolant hoses off.
–Unscrew bolts -arrows- and pull front coolant pipe out of 4/2way valve.
Installing
• Specified torques ⇒ page 147
Install in reverse order of removal, observing the following.
–Check coolant level and top up if necessary ⇒ page 159 .
2.6.6Removing and installing radiator outlet coolant temperature sender - G83-
Removing • Engine cold.
–Briefly open filler cap for coolant expansion tank in order to reduce pressure in cooling system.
–Remove engine cover panel ⇒ page 7 .
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Sharan 2011 ➤ 4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
–Unscrew bolts and nuts -arrows-.
–Move fuel filter clear to one side (fuel hoses remain connec‐ted).
When removing and installing fuel gauge sender or fuel pump (fuel delivery unit) from a full or partly full fuel tank, observe the following:
♦ Place the suction hose of an activated exhaust gas extraction system close to the assembly opening of the fuel tank to ex‐tract any fuel vapours that are released. If no exhaust gas extractionsystemisavailable,aradialfanwithadisplacement greater than 15 m3/h can be used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
Sharan 2011 ➤
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 10.2018
2Rules for cleanliness
Whenworkingonthefuelsupply/injectionsystem,carefullyfollow the “6 rules” below:
♦ Thoroughly clean all joints and surrounding areas before dis‐mantling.
♦ Place removed parts on a clean surface and cover them over. Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs cannot be carried out immediately.
♦ Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have been kept unpackaged (for example in toolboxes).
♦ If system is open, do not work with compressed air. Do not move the vehicle.
♦ Also ensure that no diesel fuel comes into contact with the coolant hoses. Should this occur, the hoses must be cleaned immediately. Damaged hoses must be renewed.
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