Service

Workshop Manual
Sharan 2011 ➤
Sharan 2016 ➤
Running gear, axles, steering
Edition 02.2019

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
40 - Front suspension
42 - Rear suspension
43 - Self-levelling suspension
44 - Wheels, tyres, vehicle geometry
48 - Steering

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Checklist for evaluating running gear of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 Evaluating accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Raising wheel suspension to unladen position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Overview - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Assembly overview: subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Assembly overview: front left vehicle level sender G78 . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Removing and installing front left vehicle level sender G78 . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 Repairing thread in longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.4 Fixing position of subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.5 Lowering subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.6 Removing and installing subframe without steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.7 Removing and installing subframe with steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.8 Repairing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5 Assembly overview: front wheel suspension, suspension link . . . . . . . . . . . . . . . . . . . . . . 39
5.1 Checking swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.2 Removing and installing swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3 Removing and installing suspension link with mounting bracket . . . . . . . . . . . . . . . . . . . . 44
5.4 Removing and installing suspension link with mounting bracket (left side for vehicles with
DSG or automatic gearboxes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.5 Renewing bonded rubber bush for suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.6 Renewing mounting bracket with suspension link bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6 Assembly overview: wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.1 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7 Assembly overview: anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.1 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8 Assembly overview: suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.1 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.2 Repairing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9 Removing and installing drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
9.1 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft . . . . . . 84
9.2 Loosening and tightening twelve-point head bolt, without ribbing, securing drive shaft . . . . 85
9.3 Removing and installing drive shaft with constant velocity joint . . . . . . . . . . . . . . . . . . . . . . 87
9.4 Removing and installing left drive shaft with (push-on) constant velocity slip joint . . . . . . 90
9.5 Removing and installing right drive shaft with (push-on) constant velocity slip joint . . . . . . 96
9.6 Removing and installing drive shafts with triple roller joint AAR3300i . . . . . . . . . . . . . . . . 102
10 Repairing drive shaft - overview of drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
10.1 Heat shield for drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
11 Assembly overview: drive shaft with VL107 constant velocity joint . . . . . . . . . . . . . . . . . . 109
11.1 Dismantling and assembling drive shaft with VL107 constant velocity joint . . . . . . . . . . . . 111
11.2 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
11.3 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
12 Assembly overview: drive shaft with VL107 constant velocity slip joint . . . . . . . . . . . . . . . . 118
12.1 Dismantling and assembling drive shaft with VL107 constant velocity slip joint . . . . . . . . 120
12.2 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
13 Assembly overview: drive shaft with triple roller joint AAR3300i . . . . . . . . . . . . . . . . . . . . 125
13.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i . . . . . . . . . . . . . . 127

Contents i
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

1 Evaluating accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2 Rear axle in unladen position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3 Overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4 Assembly overview: subframe (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.1 Fixing position of subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.2 Lowering rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.3 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.4 Repairing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5 Assembly overview: transverse link, track rod (front-wheel drive) . . . . . . . . . . . . . . . . . . . . 154
5.1 Assembly overview: rear left vehicle level sender G76 , front-wheel drive . . . . . . . . . . . . 156
5.2 Removing and installing rear left vehicle level sender G76 . . . . . . . . . . . . . . . . . . . . . . . . 156
5.3 Removing and installing upper transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.4 Removing and installing lower transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5.5 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
6 Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) . . . . . . . . . . . . 164
6.1 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
6.2 Renewing bonded rubber bush for wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . 168
6.3 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
6.4 Removing and installing trailing arm with mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . 174
6.5 Repairing trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
7 Assembly overview: shock absorber, coil spring (front-wheel drive) . . . . . . . . . . . . . . . . . . 181
7.1 Converting to Nivomat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
7.2 Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
7.3 Removing and installing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
7.4 Repairing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
8 Assembly overview: anti-roll bar (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
8.1 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
9 Rear axle in unladen position (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
10 Overview of rear axle (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
11 Assembly overview: subframe, final drive (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . 195
11.1 Fixing position of subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
11.2 Lowering rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
11.3 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
11.4 Repairing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
12 Assembly overview: transverse link, track rod (four-wheel drive) . . . . . . . . . . . . . . . . . . . . 213
12.1 Assembly overview: rear left vehicle level sender G76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
12.2 Removing and installing rear left vehicle level sender G76 . . . . . . . . . . . . . . . . . . . . . . . . 216
12.3 Removing and installing upper transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
12.4 Removing and installing lower transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
12.5 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
13 Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) . . . . . . . . . . . . 225
13.1 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
13.2 Renewing bonded rubber bush for wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . 229
13.3 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
13.4 Removing and installing trailing arm with mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . 234
13.5 Repairing trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
14 Assembly overview: shock absorber, coil spring (four-wheel drive) . . . . . . . . . . . . . . . . . . 241
14.1 Converting to Nivomat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
14.2 Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
14.3 Removing and installing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
14.4 Repairing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

ii Contents
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

15 Assembly overview: anti-roll bar (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

15.1 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
16 Assembly overview: drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
16.1 Loosening and tightening twelve-point bolt for drive shaft connection . . . . . . . . . . . . . . . . 252
16.2 Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
16.3 Dismantling and assembling drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
16.4 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

43 - Self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

1 Evaluating accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
2 Components of adaptive chassis control DCC and fitting locations . . . . . . . . . . . . . . . . . . 263
2.1 Shock absorber damping adjustment button E387 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.2 Removing and installing front left and right body acceleration senders G341/G342 . . . . . . 264
2.3 Renewing bracket for front left/right body acceleration sender G341/G342 . . . . . . . . . . . . 265
2.4 Assembly overview: front left/right vehicle level sender G78/G289 for adaptive chassis control
DCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
2.5 Removing and installing front left/right vehicle level sender G78/G289 . . . . . . . . . . . . . . 268
2.6 Assembly overview: rear left vehicle level sender G76 for adaptive chassis control DCC
........................................................................ 269
2.7 Removing and installing rear left vehicle level sender G76 for adaptive chassis control DCC,
front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
2.8 Assembly overview: rear left vehicle level sender G76 for adaptive chassis control DCC, four-
wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
2.9 Removing and installing rear left vehicle level sender G76 for adaptive chassis control DCC,
four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
2.10 Removing and installing electronically controlled damping control unit J250 . . . . . . . . . . 273
2.11 Removing and installing retainer for electronically controlled damping control unit J250 . . 274
2.12 Basic setting of adaptive chassis control DCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
2.13 Cable routing left front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
2.14 Cable routing right front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
2.15 Cable routing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3 Assembly overview: suspension strut for adaptive chassis control DCC . . . . . . . . . . . . . . 278
3.1 Removing and installing suspension strut for adaptive chassis control DCC . . . . . . . . . . . . 280
4 Assembly overview: shock absorber for adaptive chassis control DCC . . . . . . . . . . . . . . . . 289
4.1 Removing and installing rear body acceleration sender G343 . . . . . . . . . . . . . . . . . . . . . . 290
4.2 Removing and installing shock absorber for adaptive chassis control DCC . . . . . . . . . . . . 291
4.3 Repairing shock absorber for adaptive chassis control DCC . . . . . . . . . . . . . . . . . . . . . . . . 293
5 Assembly overview: shock absorber for adaptive chassis control DCC (four-wheel drive)
........................................................................ 296
5.1 Removing and installing rear body acceleration sender G343 (four-wheel drive) . . . . . . . . 297
5.2 Removing and installing shock absorber for adaptive chassis control DCC (four-wheel
drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
5.3 Repairing shock absorber for adaptive chassis control DCC (four-wheel drive) . . . . . . . . 300

44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

1 Evaluating accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
2 Specified torque for fitting wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
3 Fitting wheel and tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3.2 Fittings instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
4 Self-sealing tyres “ContiSeal” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
4.1 Explanation for mobility tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
4.2 Handling mobility tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
5 Tyre pressure monitor display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
5.1 System fault in the ABS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

Contents iii
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

5.2 Perform basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

6 Vehicle alignment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
6.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
6.2 Conditions for testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
6.3 Test preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
6.4 Wheel alignment specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
6.5 Overview - wheel alignment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
6.6 Correcting front axle camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
6.7 Adjusting camber on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
6.8 Adjusting toe at rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
6.9 Adjusting front axle toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
6.10 Basic setting of steering angle sensor G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
6.11 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
7 Wheels, tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
7.1 Models with breakdown set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
7.2 Tyre sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
7.3 Removing a tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
7.4 Fitting a new tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
7.5 Tyre sealant disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
8 Instructions for changing or fitting wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
8.1 Fitting wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
9 Protecting wheel centring seat against corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
10 Vibration due to wheels/tyres - causes and rectification . . . . . . . . . . . . . . . . . . . . . . . . . . 328
10.1 Causes of rough running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
10.2 Balancing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
10.3 Conducting a road test before balancing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
10.4 Balancing wheels on stationary wheel balancing machine . . . . . . . . . . . . . . . . . . . . . . . . 329
10.5 Vibration control system VAS 6230 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
10.6 Finish balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
10.7 Radial and lateral runout of wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
10.8 Checking radial and lateral runout on wheels and tyres with tyre gauge V.A.G 1435 . . . . 333
10.9 Checking radial and lateral run-out on wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
10.10 Matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
10.11 Flat spots caused by storage or handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
11 Adaptive cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
11.1 Calibrating adaptive cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
12 Front camera for driver assist systems R242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
12.1 Adjusting front camera for driver assistance system R242 . . . . . . . . . . . . . . . . . . . . . . . . 344

48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
1 Evaluating accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
2.1 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
2.2 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
2.3 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
2.4 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
2.5 Guided fault-finding, vehicle self-diagnosis and test instruments . . . . . . . . . . . . . . . . . . . . 354
3 Assembly overview - airbag and steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
3.1 Removing and installing airbag and steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
4 Assembly overview: steering column, left-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
4.1 Removing and installing steering column, left-hand drive vehicle . . . . . . . . . . . . . . . . . . . . 358
4.2 Handling and transporting steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
4.3 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
5 Assembly overview: steering column, right-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369

iv Contents
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

5.1 Removing and installing steering column, right-hand drive vehicle . . . . . . . . . . . . . . . . . . 369
5.2 Handling and transporting steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
5.3 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
6 Electromechanical steering rack, LHD vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
6.1 Assembly overview - electromechanical steering rack for LHD vehicle . . . . . . . . . . . . . . . . 380
6.2 Removing and installing steering rack, left-hand drive vehicle . . . . . . . . . . . . . . . . . . . . . . 381
7 Electromechanical steering rack, RHD vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
7.1 Assembly overview - electromechanical steering rack for RHD vehicle . . . . . . . . . . . . . . . . 389
7.2 Removing and installing steering rack, RLD vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
8 Repairing electromechanical steering rack, LHD vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 398
8.1 Assembly overview: electromechanical steering rack, LHD vehicle . . . . . . . . . . . . . . . . . . 398
8.2 Renewing bonded rubber bushes for power-assisted steering rack . . . . . . . . . . . . . . . . . . 399
8.3 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
8.4 Removing and installing track rod ball joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
8.5 Removing and installing bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
8.6 Checking play, security and boots of track rod ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
8.7 Allocation of track rod ball joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
9 Repairing electromechanical steering rack, RHD vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 410
9.1 Assembly overview: electromechanical steering rack, RHD vehicle . . . . . . . . . . . . . . . . . . 410
9.2 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
9.3 Removing and installing track rod ball joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
9.4 Removing and installing bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
9.5 Checking play, security and boots of track rod ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
9.6 Allocation of track rod ball joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418

Contents v
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

vi Contents
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

00 – Technical data
1 Checklist for evaluating running gear
of accident vehicles
(VRL012734; Edition 02.2019)
Damage to running gear may go unnoticed during repairs to load-
bearing and suspension parts of accident vehicles. Under certain
circumstances, this undiscovered damage could lead to serious
consequential damage during later vehicle operation. Therefore,
the following parts of accident vehicles must be examined in the
manner and order described independent of wheel alignment
which may have to be performed. If no deviations from specifica‐
tions are measured during wheel alignment, there are no defor‐
mations of the running gear.
Visual and functional examination of steering system
♦ Visual examination for deformation and cracks
♦ Examination for play in track rod joints and steering rack
♦ Visual examination for tears in boots
♦ Examine electrical and hydraulic lines and hoses for chafing,
cuts and kinks.
♦ Check steering rack and lines for secure seating
♦ Check for flawless function from lock to lock by moving the
steering from stop to stop. In the process, the steering wheel
must turn with a constant force without resistance.
Visual inspection and functional check of running gear
• Adhere to the sequence of the following inspection steps!
♦ Check all components shown in the assembly overviews for
deformation, cracks and other damage.
♦ Renew damaged parts
♦ Align wheels on a Volkswagen AG-approved wheel alignment
stand
Visual and functional check of wheels and tyres
♦ Check for true running and imbalance ⇒ page 328 .
♦ Check tyres for cuts and impact damage in the tread and on
the flanks ⇒ page 328 .
♦ Check tyre inflation pressure; see tyre inflation pressure stick‐
er in fuel tank flap.
If rim of wheel and/or tyre is damaged, renew tyre. This also ap‐
plies if the circumstances of the accident and the damage to the
vehicle indicate possible damage which is not visible.
A further factor in the decision is the age of the tyre. Tyres should
not be older than 6 years.
If in doubt, the following always applies:
• Whenever a safety risk cannot be excluded, the tyre(s) must
be renewed.
Complete vehicle
Also check other vehicle systems such as:
♦ Brake system including ABS

1. Checklist for evaluating running gear of accident vehicles 1

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Visual and functional examination of exhaust system and pas‐

senger protection
Specifications for testing and adjusting can be found in the re‐
spective workshop manual in ELSA.
The accident vehicle check described here applies to the running
gear. This makes no claim to completeness for the overall vehicle.
Electronic vehicle systems
Safety-related systems such as ABS/EDL, airbags, electronically
regulated suspension systems, electromechanical or electrohy‐
draulic steering and other driver assist systems must be read with
the ⇒ Vehicle diagnostic tester for any event messages that may
be stored. If events are stored in the event memories of the above-
mentioned systems, repair them in accordance with the instruc‐
tions in the workshop manuals/ELSA. Following repairs, read
event memories of the affected systems again to ensure that
complete function has been restored.

2 Rep. gr.00 - Technical data

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

2 General information
Information concerning wheels, tyres and snow chains can be
found in “Wheel and Tyre Guide” ⇒ Wheels, tyres, wheel align‐
ment; Rep. gr. 44 .
Information for conversion of rear axle to Nivomat ⇒ page 182 .

2. General information 3
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

40 – Front suspension
1 Evaluating accident vehicles
A check list for evaluating running gear of accident vehicles can
be found under ⇒ page 1 .

4 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

2 Raising wheel suspension to unladen position

Special tools and workshop

equipment required

♦ Engine and gearbox jack - V.A.G 1383 A-

♦ Tensioning strap - T10038-
♦ Support - T10149-

Caution

All bolts on running gear components with bonded rubber

bushes may be tightened only when the component is in the
unladen position (normal position).
Bonded rubber bushes can be twisted only to a limited extent.
Axle components with bonded rubber bushes must therefore
be brought to a position equivalent to the unladen (normal) po‐
sition before being tightened.
Otherwise, the bonded rubber bush would be subject to torsion
loading, shortening its service life.

2. Raising wheel suspension to unladen position 5

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

To simulate this position on the lifting platform, raise the respec‐

tive wheel suspension with the engine and gearbox jack - V.A.G
1383 A- and support - T10149- .
Before the respective wheel suspension is raised, the vehicle
must be strapped to the lifting platform arms on both sides with
tensioning straps - T10038- .

WARNING

If the vehicle is not strapped down, there is a danger that the

vehicle will slip off the lifting platform!

– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- to wheel hub using wheel bolt.
Respective nuts and bolts may be tightened only when dimension
-a- between the centre of wheel hub and edge of wheel housing
has been attained.
The dimension -a- depends on the ride height of the installed run‐
ning gear:

Running gear 1) Ride height -a- in mm

Standard running gear (G02) 408 ± 10 mm
Standard running gear with 398 ± 10 mm
adaptive chassis control DCC
(G40)
Sports running gear (G03) 393 ± 10 mm
Blue Motion (G40) 398 ± 10 mm
Fully automatic ride height set‐ 408 ± 10 mm
ting (G02+1JH)
Lowered standard running gear 400 ± 10 mm
Mobile service 398 ± 10 mm
ADAC 398 ± 10 mm
1)The type of running gear fitted to the vehicle is recorded on the
vehicle data sticker. The running gear is identified by the PR
number. Which PR No. is allocated to which running gear can be
found here ⇒ page 314 .
– Raise wheel bearing housing using engine and gearbox jack
- V.A.G 1383 A- until dimension -a- is attained.

WARNING

♦ Never raise or lower the vehicle while the engine and

gearbox jack is positioned beneath the vehicle.
♦ Do not leave engine and gearbox jack - V.A.G 1383 A-
under vehicle longer than necessary.

– Tighten respective nuts and bolts.

– Lower wheel bearing housing.
– Pull engine and gearbox jack - V.A.G 1383 A- out from under
vehicle.
– Detach support - T10149- .

6 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

3 Overview - front axle

Note

♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

♦ Always renew self-locking nuts.
♦ Always renew corroded nuts and bolts.
♦ Bonded rubber bushes can be twisted only to a limited extent. Therefore, tighten the bolted connections of
components with bonded rubber bushes only when the wheel bearing housing has been raised (unladen
state) ⇒ page 5 .

I - Assembly overview: sub‐

frame ⇒ page 9
II - Assembly overview: front
wheel suspension, suspension
link ⇒ page 39
III - Assembly overview: wheel
bearing ⇒ page 58

3. Overview - front axle 7

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

IV - Assembly overview: anti-

roll bar ⇒ page 67
V - Assembly overview: sus‐
pension strut ⇒ page 73
V - Assembly overview: sus‐
pension strut for adaptive
chassis control DCC
⇒ page 278

“Removing and installing drive shafts” ⇒ page 84

“Repairing drive shaft” ⇒ page 107

8 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

4 Assembly overview: subframe

Caution

♦ It is not permitted to weld or straighten load-bearing or

wheel-guiding components of the suspension.
♦ Always renew self-locking nuts.
♦ Always renew corroded nuts and bolts.

1 - Subframe
❑ Fixing position
⇒ page 13
❑ Lowering ⇒ page 15
❑ Removing and installing
without steering rack
⇒ page 19
❑ Removing and installing
with steering rack
⇒ page 24
❑ Various versions
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
2 - Intermediate plate
3 - Mounting bracket
❑ Fixing position
⇒ page 15
❑ With bonded rubber
bush
4 - Bolt
❑ M10 x 70
❑ 50 Nm + 90° further
❑ Renew after each re‐
moval
5 - Front left vehicle level send‐
er - G78-
❑ Removing and installing
⇒ page 12
❑ Can be tested in guided
fault finding using ⇒ Ve‐
hicle diagnostic tester
6 - Bolt
❑ 9 Nm
7 - Bolt
❑ M12 x 1.5 x 100: 70 Nm + 180° further
❑ Renew after each removal
8 - Suspension link
❑ If damaged, also renew swivel joint.
❑ Removing and installing ⇒ page 44
❑ Renew mounting ⇒ page 53
❑ Different versions of suspension links are possible (cast steel, sheet steel, aluminium).

4. Assembly overview: subframe 9

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019
❑ Allocation ⇒ Electronic parts catalogue “ETKA”

Note

A mixed installation of suspension

links of different types or made of
different materials is not permissi‐
ble.

9 - Nut
❑ 9 Nm
10 - Bolt
❑ M12 x 1.5 x 90
❑ 70 Nm + 180° further
❑ Renew after each removal
11 - Bolt
❑ M14 x 1.5 x 70
❑ 100 Nm + 90° further
❑ Do not tighten until pendulum support is bolted to gearbox.
❑ Renew after each removal
12 - Bolt
❑ M10 x 75: 50 Nm + 90° further
❑ M12 x 1.5 x 85: 60 Nm + 90°further
❑ Renew after each removal
13 - Bolt
❑ M10 x 35: 50 Nm + 90° further
❑ M12 x 1.5 x 50: 60 Nm + 90° further
❑ Renew after each removal
14 - Lower bonded rubber bush for pendulum support
❑ Pressing out and in ⇒ page 30
❑ Different versions ⇒ page 11 .
15 - Pendulum support
❑ Bolt first to gearbox and then to subframe
❑ Various versions
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
16 - Upper bonded rubber bush for pendulum support
❑ Pressing out and in ⇒ page 30
❑ Different versions ⇒ page 11 .
17 - Bolt
❑ M12 x 1.5 x 110
❑ 70 Nm + 180° further
❑ Renew after each removal
❑ Tighten only in unladen state ⇒ page 5
18 - Bolt
❑ M12 x 1.5 x 100
❑ 70 Nm + 180° further
❑ Renew after each removal

10 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Distinguishing characteristics of bonded rubber bushes for pen‐

dulum support

Note

♦ There are 2 different types of bonded rubber bushes for pen‐

dulum supports: the T version -I- and the V version -II-.
♦ They are allocated by means of the ⇒ Electronic parts cata‐
logue “ETKA” .

I - The corners of the inner core -1- point towards the opening for
pendulum support -arrow- (T version)
II - The corners of the inner core -2- point away from the opening
for pendulum support -arrow- (V version)

4.1 Assembly overview: front left vehicle level sender - G78-

Note

♦ Assembly overview: front left/right vehicle level sender - G78/G289- for adaptive chassis control DCC
⇒ page 267
♦ The front left vehicle level sender - G78/- is only available as a replacement part complete with coupling rod
and upper and lower retaining plates.
♦ Replace with subframe installed.

4. Assembly overview: subframe 11

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

1 - Subframe
2 - Bolt
❑ M6 x 16
❑ 9 Nm
3 - Front left vehicle level send‐
er - G78- and front right vehicle
level sender - G289-
❑ Complete with attach‐
ments
❑ Lever -arrow- must face
outwards
❑ Removing and installing
⇒ page 12
❑ Following renewal, ba‐
sic settings for headlight
must be performed.
Basic setting of headlights
⇒ Vehicle diagnostic tester

4 - Suspension link
5 - Nut
❑ 9 Nm
❑ Self-locking
❑ Renew after each re‐
moval

4.2 Removing and installing front left vehicle

level sender - G78-
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

12 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Perform the following steps:

Removing

Note

To remove front left vehicle level sender - G78- , steering must

be turned to right lock to ensure clearance between suspension
link and anti-roll bar.

– Detach connector.
– Remove bolt and nut.
– Take out vehicle level sender.
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:

Note

♦ The lever of the vehicle level sender must point towards the
outside of the vehicle.
♦ Thread of vehicle level sender must be screwed into front hole
in suspension link. The retaining lug of the vehicle level sender
must engage in the rear hole in order to ensure the correct
installation position.

– Carry out basic setting of headlights ⇒ Vehicle diagnostic test‐

er

Specified torques
Component Specified torque
Bolt to subframe 9 Nm
Nut 9 Nm
♦ Use new bolts

4.3 Repairing thread in longitudinal member

Repairing the thread in captive nuts in the longitudinal member is
possible only under certain conditions ⇒ Body Repairs; Rep. gr.
50 .

4.4 Fixing position of subframe

Special tools and workshop equipment required

4. Assembly overview: subframe 13

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Locating pins - T10096-

♦ Engine and gearbox jack - V.A.G 1383 A-

Perform the following steps:

Installing locating pins - T10096-
To fix position of subframe, locating pins - T10096- must be
screwed one after the other into positions -1-, -2-, -3- and -4-.

Caution

The locating pins - T10096- may be tightened only to a maxi‐

mum of 20 Nm; otherwise the threads of the locating pins may
be damaged.

14 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Fixing position of mounting bracket

– Replace securing bolts on mounting bracket with locating pins
- T10096- one after the other on both sides of the vehicle and
tighten to 20 Nm.

Fixing position of subframe

– Replace the front bolts on subframe one after the other with
locating pins - T10096- and tighten them to 20 Nm.
The position of the front axle is now fixed.
Continue with removal of anti-roll bar ⇒ page 69 .
Continue with removal of steering rack, left-hand drive
⇒ page 384 .
Continue with removal of subframe without steering rack
⇒ page 22 .
Continue with removal of subframe with steering rack
⇒ page 27 .
Removing locating pins - T10096-
Remove in reverse order. Ensure that the locating pins - T10096-
are replaced one after the other with new bolts.

Specified torques, subframe to body

Bolt Specified torque
M12 x 1.5 x 90 70 Nm + 180° further
♦ Use new bolts

M12 x 1.5 x 100 70 Nm + 180° further

♦ Use new bolts

4.5 Lowering subframe

Special tools and workshop equipment required
♦ Locating pins - T10096-

4. Assembly overview: subframe 15

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Engine and gearbox jack - V.A.G 1383 A-

Perform the following steps:

Removing
– Turn steering wheel to straight-ahead position and remove ig‐
nition key so that the electronic steering column lock engages.
Vehicles with keyless entry and start system “Keyless Access”
– Switch off ignition and open driver’s door so that the steering
lock engages.
Continued for all vehicles
– Remove nuts -arrows- and remove footwell trim -1-.

– Unscrew bolt -arrow- from universal joint -1- and pull off uni‐
versal joint in -direction of arrow-.

Caution

The following work must not be performed while the universal

joint is separated from the steering rack:
♦ Switch on ignition
♦ Turn steering mechanism
♦ Turn steering column
These points must absolutely be heeded because otherwise,
irreparable damage may be caused.

– Remove lower noise insulation ⇒ General body repairs, ex‐

terior; Rep. gr. 50 ; Assembly overview - noise insulation .

16 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Detach exhaust system bracket from subframe -arrows-.

– Disconnect pendulum support from gearbox by removing bolts

-14-.

– Remove hexagon nut -1- from coupling rod -3- (left and right
sides).
– Pull coupling rod -3- out of anti-roll bar -2- on left and right side.
– Fix position of subframe ⇒ page 13 .

– Position engine and gearbox jack - V.A.G 1383 A- under sub‐

frame.
– Place, for example, a wooden block -1- between engine and
gearbox jack - V.A.G 1383 A- and subframe.

4. Assembly overview: subframe 17

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove bolts -9- and -10- and lower subframe a maximum of

10 cm.

Note

Be sure to observe electrical wires to avoid overstretching them.

Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:

– Renew seal -1-.

– Slide seal -1- over collar of steering rack -2- so that rubber lip
makes contacts with collar all round -arrows-.
– Make sure that seal -1- is firmly seated.
– Coat seal with lubricant e.g. soft soap from above.

– Always make sure that intermediate plate -1- is inserted be‐

tween subframe -2- and body.
– Install lower noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Assembly overview - noise insulation .

Note

Ensure that boot is not damaged or twisted.

Specified torques
Component Specified torque
Anti-roll bar to coupling rod 65 Nm
♦ Use new bolts
♦ Counterhold on multi-point socket of joint pin

18 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Component Specified torque

Universal joint to steering rack 30 Nm
♦ Use new bolt

Exhaust system bracket to subframe

⇒ Engine; Rep. gr. 26

Specified torques, subframe to body

Bolt Specified torque
M12 x 1.5 x 90 70 Nm + 180° further
♦ Use new bolts

M12 x 1.5 x 100 70 Nm + 180° further

♦ Use new bolts

Specified torques for pendulum support to gearbox

Bolt Specified torque
M10 × 35 50 Nm + 90° further
♦ Use new bolt

M10 × 75 50 Nm + 90° further

♦ Use new bolt

M12 x 1.5 x 85 ; M12 x 1.5 x 50 60 Nm + 90° further

♦ Use new bolt

Volkswagen Technical Site: http://vwts.ru http://vwts.info

4.6 Removing and installing subframe with‐

out steering rack
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

4. Assembly overview: subframe 19

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Torque wrench - V.A.G 1332-

Perform the following steps:

Removing

Note

The subframe is removed together with the suspension links.

– Loosen wheel bolts.

– Raise vehicle.
– Remove wheels.
– Remove lower noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Assembly overview - noise insulation .
– Remove nuts -arrows- on left and right sides of vehicle.
– Remove nuts -arrows- on left and right sides of vehicle.

Vehicles with vehicle level sender.

– Disconnect connector -1- on front left vehicle level sender -
G78- and/or front right vehicle level sender - G289- , as
applicable.
– Pull swivel joint out of suspension link.

20 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Detach exhaust system bracket from subframe -arrows-.

– Remove hexagon nut -1- from coupling rod -3- (left and right
sides).
– Pull coupling rod -3- out of anti-roll bar -2- on left and right side.

– Disconnect pendulum support from gearbox by removing bolts

-14-.
– Fix position of subframe ⇒ page 13 .

4. Assembly overview: subframe 21

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove bolts -5- and -6- for steering rack.

– Remove bolts -7- and -8- for anti-roll bar.

– Remove bolts -9- and -10- for subframe.

– Lower subframe with engine and gearbox jack - V.A.G 1383
A- .

22 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove cable guide from subframe -arrow-.

– Secure steering rack to body.
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:

– Always make sure that intermediate plate -1- is inserted be‐

tween subframe -2- and body.
– Fit wheels, torque setting ⇒ page 304 .
– Install noise insulation and tighten, specified torques ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 50 ; Overview - noise
insulation .

Specified torques
Component Specified torque
Anti-roll bar to subframe 20 Nm + 90°
♦ Use new bolts

Anti-roll bar to coupling rod 65 Nm

♦ Use new bolts
♦ Counterhold on multi-point socket of joint pin

Steering box to subframe 50 Nm + 90°

♦ Use new bolts

Swivel joint to cast steel suspension link 60 Nm

♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Exhaust system bracket to subframe

⇒ Engine; Rep. gr. 26

Specified torques, subframe to body

Bolt Specified torque
M12 x 1.5 x 90 70 Nm + 180° further
♦ Use new bolts

4. Assembly overview: subframe 23

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Bolt Specified torque

M12 x 1.5 x 100 70 Nm + 180° further
♦ Use new bolts

Specified torques for pendulum support to gearbox

Bolt Specified torque
M10 × 35 50 Nm + 90° further
♦ Use new bolt

M10 × 75 50 Nm + 90° further

♦ Use new bolt

M12 x 1.5 x 85 ; M12 x 1.5 x 50 60 Nm + 90° further

♦ Use new bolt

4.7 Removing and installing subframe with

steering rack
Special tools and workshop equipment required
♦ Ball joint puller - T10187-

♦ Torque wrench - V.A.G 1332-

Perform the following steps:

Removing
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .

24 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Disconnect cable -1- from electronics box.

– Disconnect connector -1-.

– Unscrew cap nut -arrow- and remove earth cable.
– Remove wiring harness from bracket on longitudinal member
so that it can be removed together with the steering rack.

– Remove footwell trim by unscrewing nuts -arrows-.

4. Assembly overview: subframe 25

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unscrew bolt -arrow- from universal joint -1- and pull off uni‐
versal joint in -direction of arrow-.

Caution

The following work must not be performed while the universal

joint is separated from the steering rack:
♦ Switch on ignition
♦ Turn steering mechanism
♦ Turn steering column
These points must absolutely be heeded because otherwise,
irreparable damage may be caused.

– Loosen wheel bolts.

– Raise vehicle.
– Remove front wheels.
– Remove lower noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Assembly overview - noise insulation .
– Pull connector off oil level and temperature sender - G266- on
sump and pull wiring off subframe.

– Detach exhaust system bracket from subframe -arrows-.

– Remove hexagon nut -1- from coupling rod -3- (left and right
sides).
– Pull coupling rod -3- out of anti-roll bar -2- on left and right side.

26 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove nuts -arrows-

– Pull swivel joint out of suspension link.

– Loosen nut on track rod ball joint but do not remove complete‐
ly.

Caution

To protect thread, leave nut screwed a few turns onto joint pin.

– Push track rod ball joint off wheel bearing housing and remove
nut.
1- Ball joint puller - T10187-

– Disconnect pendulum support from gearbox by removing bolts

-14-.
– Fix position of subframe with brackets. ⇒ page 13

– Position engine and gearbox jack - V.A.G 1383 A- under sub‐

frame.
– Place, for example, a wooden block -1- between engine and
gearbox jack - V.A.G 1383 A- and subframe.

4. Assembly overview: subframe 27

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove bolts -9- and -10- and lower subframe with engine
and gearbox jack - V.A.G 1383 A- .

– Secure subframe to engine and gearbox jack - V.A.G 1383 A-

with the appropriate strap.
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:

– Renew seal -1-.

– Slide seal -1- over collar of steering rack -2- so that rubber lip
makes contacts with collar all round -arrows-.
– Make sure that seal -1- is firmly seated.
– Coat seal with lubricant e.g. soft soap from above.

28 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Always make sure that intermediate plate -1- is inserted be‐

tween subframe -2- and body.
– Install battery tray and battery⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery .
– Install noise insulation and tighten, specified torques ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 50 ; Overview - noise
insulation .

Specified torques
Component Specified torque
Anti-roll bar to coupling rod 65 Nm
♦ Use new bolts
♦ Counterhold on multi-point socket of joint pin

Track rod ball joint to wheel bearing housing Tighten to 100 Nm, then loosen (turn back) 180°
♦ Use new bolts and retighten to 100 Nm

Swivel joint to cast steel suspension link 60 Nm

♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Universal joint to steering rack 30 Nm

♦ Use new bolt

Exhaust system bracket to subframe

⇒ Engine; Rep. gr. 26

Specified torques, subframe to body

Bolt Specified torque
M12 x 1.5 x 90 70 Nm + 180° further
♦ Use new bolts

M12 x 1.5 x 100 70 Nm + 180° further

♦ Use new bolts

Specified torques for pendulum support to gearbox

Bolt Specified torque
M10 × 35 50 Nm + 90° further
♦ Use new bolt

M10 × 75 50 Nm + 90° further

♦ Use new bolt

Volkswagen Technical Site: http://vwts.ru http://vwts.info

4. Assembly overview: subframe 29

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Bolt Specified torque

M12 x 1.5 x 85 ; M12 x 1.5 x 50 60 Nm + 90° further
♦ Use new bolt

4.8 Repairing subframe

Special tools and workshop

equipment required

♦ Assembly tool - T10205-

♦ Torque wrench - V.A.G 1332-
♦ Hydraulic cylinder - VAS 6178-
♦ Foot pump - VAS 6179-
♦ Assembly tool - VAS 6779-

30 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Thrust plate - VW 401-

♦ Press tool - VW 412-

Renewing bonded rubber bushes for pendulum support

– Remove front noise insulation ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Noise insulation; Assembly overview - noise
insulation .
– Remove hexagon nut -1- from coupling rod -3- (left and right
sides).
– Pull coupling rod -3- out of anti-roll bar -2- on left and right side.

4. Assembly overview: subframe 31

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove bolts -7- and -8- for anti-roll bar.

• Leave the anti-roll bar in its installation position in the vehicle.

– Unscrew bolt -1-.

– Unscrew bolts -2- and -3-.
– Remove pendulum support.

Pressing out bonded rubber bush

– Fit assembly tool - VAS 6779- to subframe as shown in illus‐
tration.
– Place thrust piece for removal - VAS 6779-1- -1- on bonded
rubber bush so that flattened side -arrow- faces to direction of
travel.

32 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

1 - Thrust piece for removal - VAS 6779/1-

2 - Tube - VAS 6779/4- with small outside diameter facing sub‐
frame
3 - Thrust piece - VAS 6779/5-
4 - Hydraulic press - VAS 6178- with thrust piece - T10205/13-
5 - Hexagon nut - VAS 6779/3-
6 - Threaded spindle - VAS 6779/2-

4. Assembly overview: subframe 33

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Press out both bonded rubber bushes until upper bonded rub‐
ber bush -2- is visible in pendulum support opening -arrow- in
subframe.
– Carry out visual check of outer ring of upper bonded rubber
bush -2-.
• If outer ring of upper bonded rubber bush -2- is deformed, de‐
stroy it through opening of pendulum support -arrow- in pen‐
dulum support.
– Using a chisel or similar -1-, create a break in the outer ring of
the upper bonded rubber bush -2-.

Note

This process is necessary to prevent the canting of the outer ring

of the upper bonded rubber bush in the area of the opening of the
pendulum support in the subframe.

– Press out both bonded rubber bushes together.

Preparing bonded rubber bush for pressing in

Note

♦ There are two different types of bonded rubber bushes for

pendulum supports: the T version -I- and the V version -II-.
♦ They are allocated by means of the ⇒ Electronic parts cata‐
logue “ETKA” .

I - The corners of the inner core -1- point towards the opening for
pendulum support -arrow- (T version)
II - The corners of the inner core -2- point away from the opening
for pendulum support -arrow- (V version)

– Place both bonded rubber bushes -1- and -2- together so that
the cut-outs -arrows- line up precisely.
– Bolt bonded rubber bushes -1- and -2- hand-tight together us‐
ing original bolt -3-.

34 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Insert bonded rubber bushes -1- into larger diameter of tube -

VAS 6779/6- -2- with bolt head facing upwards.
– Align bonded rubber bushes -1- in tube - VAS 6779/6- -2-. The
cut-out in the bonded rubber bush must align exactly with the
recess -arrow- in the tube - VAS 6779/6- -2-.

– Press in bonded rubber bush -3- in tube - VAS 6779/6- to stop,

as illustrated.
1- Press tool - VW 412-
2- Thrust piece - VAS 6779/5- , the side with the lettering »A«
must face upwards.
3- Bonded rubber bush
4- Funnel - VAS 6779/6-
5- Tube - VAS 6779/4-
6- Pressure plate - VW 401-
– Remove bolt from bonded rubber bush.

– Fit counterhold - VAS 6779/7- -1- from the left in

-direction of arrow- on subframe -2-.

4. Assembly overview: subframe 35

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Insert counterhold attachment - VAS 6779/7-1A- -1- into pen‐

dulum support opening in subframe.
– Bolt insert - VAS 6779/7-1A- to counterhold - VAS 6779/7-
-2- using bolt -arrow-.
– Ensure that the insert - VAS 6779/7-1A- -1- is correctly seated
in the pendulum support opening of the subframe -arrow-.

Pressing in bonded rubber bush

– Screw threaded spindle - VAS 6779/2- -7- into counterhold -
VAS 6779/7- -1-
– Fit assembly tool - VAS 6779- to subframe as shown in illus‐
tration.

36 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

1 - Counter-hold tool - VAS 6779/7-

2 - Tube - VAS 6779/6- , -arrow mark- on tube must align centrally
between both bolts -arrow-.
3 - Thrust piece - VAS 6779/9-
4 - Stepped ring - VAS 6779/8- : the mark -III- on stepped ring
must face towards lug -arrow B- on thrust piece - VAS 6779/9- .
5 - Hydraulic press - VAS 6178- with thrust piece - T10205/13-
6 - Hexagon nut - VAS 6779/3-
7 - Threaded spindle - VAS 6779/2-
– Press in both bonded rubber bushes together.
– Remove assembly tool - VAS 6779- from subframe and check
pressed-in bonded rubber bushes are properly seated.
– Bolt anti-roll bar to subframe and coupling rods.

4. Assembly overview: subframe 37

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Insert pendulum support.

– Screw in bolts -2- and -3- and tighten.
– Screw in and tighten bolt -1-.
– Install front noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation; Assembly overview - noise in‐
sulation .

Specified torques
Bolt Specified torque
Pendulum support to gearbox M10 x 35 50 Nm + 90° further
♦ Use new bolt

Pendulum support to gearbox M10 x 75 50 Nm + 90° further

♦ Use new bolt

Pendulum support to gearbox M12 x 1.5 x 50 60 Nm + 90° further

♦ Use new bolt

Pendulum support to gearbox M12 x 1.5 x 85 60 Nm + 90° further

♦ Use new bolt

Pendulum support to subframe M14 x 1.5 x 70 100 Nm + 90° further

♦ Use new bolt
♦ Do not tighten until pendulum support is bolted to gear‐
box

Anti-roll bar to coupling rod 65 Nm

♦ Use new bolts
♦ Counterhold on multi-point socket of joint pin

Anti-roll bar to subframe 20 Nm + 90°

♦ Use new bolts

38 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

5 Assembly overview: front wheel suspension, suspension link

Note

♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

♦ Always renew self-locking nuts.
♦ Always renew corroded nuts and bolts.
♦ Bonded rubber bushes can be twisted only to a limited extent. Therefore, tighten the bolted connections of
components with bonded rubber bushes only when the wheel bearing housing has been raised (unladen
state) ⇒ page 5 .

1 - Bolt
❑ 20 Nm + 90°
❑ Renew after each re‐
moval
2 - Body - front
3 - Suspension strut
❑ Removing and installing
⇒ page 74
4 - Nut
❑ 65 Nm
5 - Multi-point socket head bolt
❑ Tip of bolt must point in
direction of travel
6 - Nut
❑ 70 Nm + 90° further
❑ Renew after each re‐
moval
7 - Swivel joint
❑ Checking ⇒ page 40
❑ Removing and installing
⇒ page 41
❑ Renew together with
suspension link if sus‐
pension link is damaged
8 - Wheel bearing housing
❑ Removing and installing
⇒ page 62
❑ If wheel bearing housing
is renewed, wheels
must be aligned
⇒ page 311
❑ Various versions
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
9 - Nut
❑ For cast steel suspension link: 60 Nm
❑ For sheet steel and forged aluminium suspension link: 100 Nm
❑ Self-locking
❑ Renew after each removal
❑ Tighten only in unladen state ⇒ page 5

5. Assembly overview: front wheel suspension, suspension link 39

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

10 - Suspension link
❑ If damaged, also renew swivel joint.
❑ Removing and installing ⇒ page 44
❑ Renew mounting ⇒ page 53
❑ Different versions of suspension links are possible (cast steel, sheet steel, aluminium).
❑ Allocation ⇒ Electronic parts catalogue “ETKA”

Note

A mixed installation of suspension

links of different types or made of
different materials is not permissi‐
ble.

11 - Bonded rubber bush

❑ Removing and installing ⇒ page 53
12 - Nut
❑ 20 Nm + 90° further
❑ Self-locking
❑ Renew after each removal
13 - Mounting bracket
❑ Fixing position ⇒ page 15
❑ With bonded rubber bush
14 - Coupling rod

5.1 Checking swivel joint

Checking axial play
– Firmly pull suspension link down in -direction of arrow- and
press up again.
Checking radial play

– Press lower part of wheel forcefully inwards and outwards in

-direction of arrow-.

Note

♦ There should be no palpable or visible “play” during both tests.

♦ Observe swivel joint while performing tests.
♦ Take into account possible existing wheel bearing play or
“play” in upper suspension strut mounting.
♦ Check rubber boot for damage and renew swivel joint if nec‐
essary.

40 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

5.2 Removing and installing swivel joint

Special tools and workshop

equipment required

♦ Ball joint puller - 3287A-

♦ Torque wrench - V.A.G 1332-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Torque angle wrench - V.A.G 1756-

♦ Ejector - T10520-

5. Assembly overview: front wheel suspension, suspension link 41

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Perform the following steps:

Removing
– Loosen drive shaft bolt at wheel hub ⇒ page 84 .

Caution

Wheel bearings must not be subjected to load after bolt secur‐

ing drive shaft to wheel hub has been loosened.
If wheel bearings are loaded with weight of vehicle, bearing will
be damaged. This reduces the service life of the wheel bearing.
It is not permissible to loosen drive shaft bolt more than 90° if
vehicle is standing on its wheels.
Do not attempt to move the vehicle without the drive shafts
fitted as this would damage the wheel bearing. If a vehicle must
nevertheless be moved, comply with the following:
♦ Install an outer joint instead of the drive shaft.
♦ Tighten outer joint to 120 Nm.

– Loosen wheel bolts.

– Raise vehicle.
– Remove wheel.
– Remove nuts -arrows-
– Pull drive shaft slightly out of wheel hub.
If the drive shaft cannot be pulled out of the wheel bearing by
hand, use ejector - T10520- .

Before using press tool - T10520- ensure that thrust piece -1- is
inserted.

42 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Using ejector - T10520- :

– To press out drive shaft -3-, secure ejector - T10520- -1- to
wheel hub using 3 wheel bolts -2-.

– It is essential to follow specified sequence.

I - Tighten knurled nut -1- hand-tight.
II - Turn only bolt -2- using a spanner in order to press out drive
shaft with ejector - T10520- .

Note

At the end of the procedure or for pressing out drive shaft further,
the spindle must be moved to its original position in order to apply
the hydraulic force.

– Pull swivel bearing out of suspension link.

– Bend suspension link downwards as far as necessary.

– Loosen nut on swivel joint but do not remove completely.

Caution

To protect thread, leave nut screwed a few turns onto joint pin.

– Apply ball joint splitter - 3287A- as shown in figure and press

out swivel joint.

Note

Place engine and gearbox jack - V.A.G 1383 A- or similar under‐

neath (danger of accident through falling parts when pressing out
the swivel joint).

Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:
– Fit swivel joint in wheel bearing housing.
– Fit drive shaft in wheel hub.
– Screw on new self-locking nut and counterhold with Torx key
- T40- .

5. Assembly overview: front wheel suspension, suspension link 43

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Tighten nuts -arrows-.

Note

Ensure that boot is not damaged or twisted.

– Attach wheel and tighten; specified torque ⇒ page 304 .

– Tighten drive shaft bolt at wheel hub ⇒ page 84 .

Note

During this step, vehicle must not be standing on its wheels or

wheel bearing will be damaged.

Specified torques
Component Specified torque
Swivel joint to cast steel suspension link 60 Nm
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Swivel joint to wheel bearing housing 20 Nm + 90°

♦ Use new bolts

Drive shaft to hub 70 Nm + 90°

♦ Use new bolt

5.3 Removing and installing suspension link

with mounting bracket
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

44 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Locating pins - T10096-

Perform the following steps:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove lower noise insulation ⇒ Rep. gr. 50 ; Assembly
overview - noise insulation .
– If present, unscrew coupling rod of front left vehicle level send‐
er - G78- from suspension link.
– Unscrew nuts -arrows-.
– Pull suspension link out of swivel joint and turn wheel bearing
housing outwards to relieve suspension link.
– Fix position of mounting bracket ⇒ page 15 .

– Replace bolt for left side -1- or for right side -2- with locating
pins - T10096- and tighten locating pins to 20 Nm.

Caution

The locating pins - T10096- may be tightened only to a maxi‐

mum of 20 Nm; otherwise the threads of the locating pins may
be damaged.

– Now remove bolt -11- for left side and bolt -12- for right side.
– If present, unscrew coupling rod of front left vehicle level send‐
er - G78- from suspension link.

5. Assembly overview: front wheel suspension, suspension link 45

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove bolts -1-.

– Remove suspension link with mounting bracket.
Installing
– Insert suspension link with mounting bracket into subframe.

– Start bolts -11- and -12- but do not tighten.

– Start bolt -1- and tighten.

– Replace locating pins - T10096- by a new bolt and tighten this.

– Bolt suspension link to swivel joint and tighten -arrows-.

46 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Bolt transverse link to subframe -11- and -12- in unladen state

⇒ page 5 .
Continue installation in reverse order of removal.
– Attach lower noise insulation ⇒ Rep. gr. 50 ; Assembly over‐
view - noise insulation .
– Attach wheel and tighten; specified torque ⇒ page 304 .

Specified torques
Component Specified torque
Mounting bracket to body 70 Nm + 180°
♦ Use new bolts

Mounting bracket to subframe 50 Nm + 90°

♦ Use new bolts

Swivel joint to cast steel suspension link 60 Nm

♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Suspension link to subframe 70 Nm + 180°

♦ Use new bolt
♦ Tighten bolt in unladen state

Coupling rod for front left vehicle level sender - G78- to 9 Nm

suspension link

5.4 Removing and installing suspension link

with mounting bracket (left side for ve‐
hicles with DSG or automatic gearbox‐
es)
Special tools and workshop equipment required

5. Assembly overview: front wheel suspension, suspension link 47

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Locating pins - T10096-

♦ Engine and gearbox jack - V.A.G 1383 A-

Perform the following steps:

Removing
– Turn steering wheel to straight-ahead position and remove ig‐
nition key so that the steering lock engages.
Vehicles with keyless entry and start system “Keyless Access”
– Switch off ignition and open driver’s door so that the steering
lock engages.
Continued for all vehicles
– Remove footwell trim by unscrewing nuts -arrows-.

48 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unscrew bolt -arrow- from universal joint -1- and pull off uni‐
versal joint in -direction of arrow-.

Caution

The following work must not be performed while the universal

joint is separated from the steering rack:
♦ Switch on ignition
♦ Turn steering mechanism
♦ Turn steering column
These points must absolutely be heeded because otherwise,
irreparable damage may be caused.

– Loosen wheel bolts.

– Raise vehicle.
– Remove front left wheel.
– Remove lower noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Assembly overview - noise insulation .

– Detach exhaust system bracket from subframe -arrows-.

– Disconnect pendulum support from gearbox by removing bolts

-14-.
– If present, unscrew coupling rod of front left vehicle level send‐
er - G78- from suspension link.

5. Assembly overview: front wheel suspension, suspension link 49

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove nuts -arrows-

– Remove hexagon nut -1- from coupling rod -3- (left and right
sides).

– Loosen bolt -12-.

– Fix position of subframe ⇒ page 13 .

– Position engine and gearbox jack - V.A.G 1383 A- under sub‐

frame.
– Place, for example, a wooden block -1- between engine and
gearbox jack - V.A.G 1383 A- and subframe.

50 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unscrew bolts -13-.

– Remove bolts -9- and -10- and lower subframe as far as nec‐
essary.

Note

Be sure to observe electrical wiring.

– Remove bolt -12- and remove suspension link from subframe.

Installing
Install in reverse order. During this step, observe the following:

5. Assembly overview: front wheel suspension, suspension link 51

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Always make sure that intermediate plate -1- is inserted be‐

tween subframe -2- and body.

Note

♦ Ensure proper seating of dowel sleeves for steering rack in

suspension bracket.
♦ Ensure that boot is not damaged or twisted.

– Install lower noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Assembly overview - noise insulation .
– Attach wheel and tighten; specified torque ⇒ page 304 .

Specified torques
Component Specified torque
Suspension link to subframe 70 Nm + 180°
♦ Use new bolts

Swivel joint to cast steel suspension link 60 Nm

♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Mounting bracket to body 70 Nm + 180°

♦ Use new bolts

Mounting bracket to subframe 50 Nm + 90°

♦ Use new bolts

Anti-roll bar to subframe 20 Nm + 90°

♦ Use new bolts

Universal joint to steering rack 30 Nm

♦ Use new bolt

Steering box to subframe 50 Nm + 90°

♦ Use new bolts

Exhaust system bracket to subframe

⇒ Engine; Rep. gr. 26

Specified torques, subframe to body

Bolt Specified torque
M12 x 1.5 x 90 70 Nm + 180° further
♦ Use new bolts

M12 x 1.5 x 100 70 Nm + 180° further

♦ Use new bolts

52 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Specified torques for pendulum support to gearbox

Bolt Specified torque
M10 × 35 50 Nm + 90° further
♦ Use new bolt

M10 × 75 50 Nm + 90° further

♦ Use new bolt

M12 x 1.5 x 85 ; M12 x 1.5 x 50 60 Nm + 90° further

♦ Use new bolt

5.5 Renewing bonded rubber bush for suspension link

Special tools and workshop

equipment required

♦ Tube - T10219/1-
♦ Pin - T10219/2-
♦ Thrust plate - VW 402-
♦ Press tool - VW 411-

5. Assembly overview: front wheel suspension, suspension link 53

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Press tool - VW 412-

Perform the following steps:

Pressing out bonded rubber bush
– Press out bonded rubber bush as illustrated.
1- Press tool - VW 411-
2- Tube - T10219/1-
3- Pressure plate - VW 402-
Pressing in bonded rubber bush
Start the bonded rubber bush at an angle to prevent damage
when pressing in. The bonded rubber bush will then straighten up
as it is pressed in.
– Moisten outer surface of bonded rubber bush with assembly
oil - G 294 421 A1- .

– Position bonded rubber bush tilted (towards suspension link)

so lip -arrow- slides into hole as illustrated.
1- Pin - T10219/2-
2- Tube - T10219/1-
3- Pressure plate - VW 402-

54 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Press in bonded rubber bush until core of bush -1- and hole in
suspension link -2- are flush.

– Press bush back slightly in the suspension link.

1- Tube - T10219/1-
2- Pressure plate - VW 402-

The dimensions -a- and -b- must be the same.

5.6 Renewing mounting bracket with suspension link bush

5. Assembly overview: front wheel suspension, suspension link 55

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Special tools and workshop

equipment required

♦ Guide - VW 439-
♦ Thrust plate - VW 401-
♦ Thrust plate - VW 402-

♦ Tube - VW 426-

Perform the following steps:

Pressing mounting bracket with bush off suspension link
The bonded rubber bush is available as a replacement part only
in conjunction with the mounting bracket.

56 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Press mounting bracket with bonded rubber bush off suspen‐

sion link.

Note

Hold suspension link firmly whilst pressing out.

1- Pressure plate - VW 401-

2- Guide - VW 439-
3- Pressure plate - VW 402-
Pressing in mounting bracket with bush onto suspension link
– Coat hexagon profile of suspension link with thinned assembly
lubrication oil - G 294 421 A1- (1:20).

– Carefully press bush onto suspension link to stop.

1- Tube - VW 426-
2- Mounting bracket with bonded rubber bush.
3- Suspension link
4- Pressure plate - VW 401-

5. Assembly overview: front wheel suspension, suspension link 57

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

6 Assembly overview: wheel bearing

1 - Suspension strut
2 - Multi-point socket head bolt
❑ Tip of bolt must point in
direction of travel
3 - Front left speed sensor -
G47- / front right speed sensor
- G45-
❑ Can be tested in guided
fault finding using ⇒ Ve‐
hicle diagnostic tester
❑ Before inserting speed
sensor, clean inner sur‐
face of fitting hole and
coat with lubricating
paste - G 000 650- .
4 - Hexagon socket head bolt
❑ M6 × 16
❑ 8 Nm
5 - Track rod ball joint
6 - Wheel hub with wheel bear‐
ing
❑ The ABS sensor ring is
installed in the wheel
hub
❑ Various versions
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
7 - Nut
❑ M12 × 1.5
❑ Tighten to 100 Nm, then
loosen (turn back) 180°
and retighten to 100 Nm
❑ Self-locking
Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ Renew after each removal
8 - Internally ventilated brake disc
9 - Bolt
❑ Various versions
❑ Allocation ⇒ Electronic parts catalogue “ETKA”

58 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

WARNING
There
♦ are two versions of
the twelve-point head
bolt, with and without rib‐
bing. Distinguishing fea‐
ture ⇒ page 60 .
When
♦ installing a twelve-
point head bolt, always
note which version is be‐
ing installed.
The
♦ respective specified
torque must also be
used.
The
♦ specified torque for
twelve-point head bolts
»with« ribbing is 70 Nm +
90° when loosening and
tightening ⇒ page 84 .
The
♦ specified torque for
twelve-point head bolts
»without« ribbing is 200
Nm + 180° when loosen‐
ing and tightening
⇒ page 85 .

❑ Renew after each removal

10 - Bolt
❑ Torque setting ⇒ Brake systems; Rep. gr. 46 ; Repairing front brake .
11 - Multi-point socket head bolt
❑ M6 × 12
❑ 12 Nm
12 - Cover plate
13 - Wheel bearing housing
❑ Removing and installing ⇒ page 62
❑ With bolted-on brake carrier.
❑ If wheel bearing housing is renewed, wheels must be aligned ⇒ page 311
14 - Multi-point socket head bolt
❑ M12 x 1.5 x 45
❑ 70 Nm + 90° further
❑ Renew after each removal
15 - Drive shaft
❑ Removing and installing ⇒ page 87
16 - Nut
❑ M12 x 1.5 x 80
❑ 70 Nm + 90° further
❑ Self-locking
❑ Renew after each removal

6. Assembly overview: wheel bearing 59

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Distinguishing features between twelve-point head bolt with rib‐

bing and twelve-point head bolt without ribbing.
The twelve-point head bolts can be distinguished by the contact
surfaces -arrow A- and -arrow B-.
I - Twelve-point head bolt with ribbing -arrow A-
II - Twelve-point head bolt without ribbing -arrow B-

6.1 Removing and installing wheel bearing

unit
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

Perform the following steps:

Removing
– Loosen drive shaft bolt at wheel hub:
♦ Twelve-point head bolt with ribbing ⇒ page 84
♦ Twelve-point head bolt without ribbing ⇒ page 85

Caution

Wheel bearings must not be subjected to load after bolt secur‐

ing drive shaft to wheel hub has been loosened.
If wheel bearings are loaded with weight of vehicle, bearing will
be damaged. This reduces the service life of the wheel bearing.
It is not permissible to loosen drive shaft bolt more than 90° if
vehicle is standing on its wheels.
Do not attempt to move the vehicle without the drive shafts
fitted as this would damage the wheel bearing. If a vehicle must
nevertheless be moved, comply with the following:
♦ Install an outer joint instead of the drive shaft.
♦ Tighten outer joint to 120 Nm.

– Loosen wheel bolts.

– Raise vehicle.
– Remove wheel.

60 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove brake caliper with brake carrier and suspend from

body using wire ⇒ Brake systems; Rep. gr. 46 ; Repairing
front brake.
– Remove ABS speed sensor ⇒ Brake systems; Rep. gr. 46 ;
Repairing front brake .
– Remove brake disc.
– Remove nuts -arrows-
– Pull swivel joint out of suspension link.
– Pull drive shaft out of wheel hub.

– Remove bolts -arrows-

– Take wheel bearing unit -1- out of wheel bearing housing.
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:
– Install brake caliper ⇒ Brake systems; Rep. gr. 46 ; Repairing
front brake .
– Tighten drive shaft bolt at wheel hub:
♦ Twelve-point head bolt with ribbing ⇒ page 84
♦ Twelve-point head bolt without ribbing ⇒ page 85

Caution

During this step, vehicle must not be standing on its wheels.

The wheel bearing can be damaged by the weight of the vehi‐
cle if the bolt is loosened.

Distinguishing features between twelve-point head bolt with rib‐

bing and twelve-point head bolt without ribbing.
The twelve-point head bolts can be distinguished by the contact
surfaces -arrow A- and -arrow B-.
I - Twelve-point head bolt with ribbing -arrow A-
II - Twelve-point head bolt without ribbing -arrow B-
– Install ABS speed sensor ⇒ Brake systems; Rep. gr. 46 ;
Repairing front brake .

6. Assembly overview: wheel bearing 61

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Specified torques
Component Specified torque
Drive shaft to wheel hub “twelve-point head bolt with rib‐ 70 Nm + 90°
bing”
♦ Use new bolt

Drive shaft to wheel hub “twelve-point head bolt without 200 Nm + 180°
ribbing”
♦ Use new bolt

Wheel hub with wheel bearing to wheel bearing housing 70 Nm + 90°

♦ Use new bolts

6.2 Removing and installing wheel bearing housing

Special tools and workshop

equipment required

♦ Ball joint puller - 3287A-

♦ Spreader - 3424-
♦ Ball joint puller - T10187-
♦ Torque wrench - V.A.G 1332-

62 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Engine and gearbox jack - V.A.G 1383 A-

♦ Torque angle wrench - V.A.G 1756-

♦ Ejector - T10520-

Perform the following steps:

Removing
– Loosen drive shaft bolt at wheel hub:
♦ Twelve-point head bolt with ribbing ⇒ page 84
♦ Twelve-point head bolt without ribbing ⇒ page 85

Caution

Wheel bearings must not be subjected to load after bolt secur‐

ing drive shaft to wheel hub has been loosened.
If wheel bearings are loaded with weight of vehicle, bearing will
be damaged. This reduces the service life of the wheel bearing.
It is not permissible to loosen drive shaft bolt more than 90° if
vehicle is standing on its wheels.
Do not attempt to move the vehicle without the drive shafts
fitted as this would damage the wheel bearing. If a vehicle must
nevertheless be moved, comply with the following:
♦ Install an outer joint instead of the drive shaft.
♦ Tighten outer joint to 120 Nm.

– Loosen wheel bolts.

– Raise vehicle.
– Remove wheel.
– Remove brake caliper with brake carrier and suspend from
body using wire ⇒ Brake systems; Rep. gr. 46 ; Repairing
front brake.
– Remove ABS speed sensor ⇒ Brake systems; Rep. gr. 46 ;
Repairing front brake .
– Remove brake disc.
– Remove splash plate from wheel bearing housing.

6. Assembly overview: wheel bearing 63

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Loosen nut on track rod ball joint but do not remove complete‐
ly.

Caution

To protect thread, leave nut screwed a few turns onto joint pin.

– Push track rod off wheel bearing housing and remove nut.
1- Ball joint puller - T10187-

– Loosen nuts -arrows-.

– Pull swivel joint out of suspension link.
– Pull outer joint of drive shaft out of wheel hub.
If the drive shaft cannot be pulled out of the wheel bearing by
hand, use ejector - T10520- .

Before using press tool - T10520- ensure that thrust piece -1- is
inserted.

Using ejector - T10520- :

– To press out drive shaft -3-, secure ejector - T10520- -1- to
wheel hub using 3 wheel bolts -2-.

64 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– It is essential to follow specified sequence.

I - Tighten knurled nut -1- hand-tight.
II - Turn only bolt -2- using a spanner in order to press out drive
shaft with ejector - T10520- .

Note

At the end of the procedure or for pressing out drive shaft further,
the spindle must be moved to its original position in order to apply
the hydraulic force.

– Secure drive shaft to body with wire.

– Remove threaded connection between wheel bearing housing

and suspension strut -arrow-.

– Insert spreader - 3424- in slot in wheel bearing housing.

– Turn ratchet handle through 90° and detach from spreader -
3424- .
– Position engine and gearbox jack - V.A.G 1383 A- under wheel
bearing housing.
– Pull wheel bearing housing from suspension strut.

Note

If wheel bearing housing is renewed, swivel joint must be trans‐

ferred. Always use new nuts.

Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
– Tighten drive shaft bolt at wheel hub:
♦ Twelve-point head bolt with ribbing ⇒ page 84
♦ Twelve-point head bolt without ribbing ⇒ page 85

Caution

During this step, vehicle must not be standing on its wheels.

The wheel bearing can be damaged by the weight of the vehi‐
cle if the bolt is loosened.

6. Assembly overview: wheel bearing 65

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Distinguishing features between twelve-point head bolt with rib‐

bing and twelve-point head bolt without ribbing.
The twelve-point head bolts can be distinguished by the contact
surfaces -arrow A- and -arrow B-.
I - Twelve-point head bolt with ribbing -arrow A-
II - Twelve-point head bolt without ribbing -arrow B-
If wheel bearing housing is renewed, wheels must be aligned
⇒ page 311 .
– Install wheel and tighten bolts or nuts ⇒ page 304 .

Specified torques
Component Specified torque
Suspension strut to wheel bearing housing 70 Nm + 90°
♦ Use new bolts

Swivel joint to cast steel suspension link 60 Nm

♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Track rod ball joint to wheel bearing housing Tighten to 100 Nm, then loosen (turn back) 180°
♦ Use new bolts and retighten to 100 Nm

Drive shaft to wheel hub “twelve-point head bolt with rib‐ 70 Nm + 90°
bing”
♦ Use new bolt

Drive shaft to wheel hub “twelve-point head bolt without 200 Nm + 180°
ribbing”
♦ Use new bolt

66 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

7 Assembly overview: anti-roll bar

1 - Anti-roll bar
❑ Various versions
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Removing and installing
⇒ page 67
2 - Coupling rod
❑ Link between anti-roll
bar and suspension
strut
3 - Nut
❑ 65 Nm
4 - Subframe
5 - Bolt
❑ 20 Nm + 90° further
❑ Renew after each re‐
moval

7.1 Removing and installing anti-roll bar

Special tools and workshop equipment required
♦ Ball joint puller - T10187-

7. Assembly overview: anti-roll bar 67

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Torque wrench - V.A.G 1332-

Perform the following steps:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove front wheels.
– Remove footwell trim by unscrewing nuts -arrows-.

– Unscrew bolt -arrow- from universal joint -1- and pull off uni‐
versal joint in -direction of arrow-.

Caution

The following work must not be performed while the universal

joint is separated from the steering rack:
♦ Switch on ignition
♦ Turn steering mechanism
♦ Turn steering column
These points must absolutely be heeded because otherwise,
irreparable damage may be caused.

– Remove lower noise insulation ⇒ Rep. gr. 50 ; Assembly

overview - noise insulation .

68 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove hexagon nut -1- from coupling rod (left and right
sides).

– Remove nuts -arrows- on left and right sides of vehicle.

– Loosen nut on track rod ball joint but do not remove complete‐
ly.

Caution

To protect thread, leave nut screwed a few turns onto joint pin.

– Push track rod ball joint off wheel bearing housing and remove
nut.
1- Ball joint puller - T10187-
– Fixing position of subframe with brackets ⇒ page 13 .

– Unbolt anti-roll bar from subframe -7- and -8-

.

7. Assembly overview: anti-roll bar 69

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Disconnect pendulum support from gearbox by removing bolts

-14-.

– Detach exhaust system bracket from subframe -arrows-.

– Position engine and gearbox jack - V.A.G 1383 A- under sub‐

frame.
– Place, for example, a wooden block -1- between engine and
gearbox jack - V.A.G 1383 A- and subframe.

70 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove bolts -9- and -10- and lower subframe slightly. Ob‐
serve electrical wiring.
– Push anti-roll bar to right as seen in direction of travel.

– Lift anti-roll bar -1- forwards over subframe -2- and down while
turning anti-roll bar slightly.
Installing
Install in reverse order.
– Attach lower noise insulation ⇒ Rep. gr. 50 ; Assembly over‐
view - noise insulation .

Note

♦ Coat seal on steering rack with suitable lubricant, e.g. soft

soap, before installing steering rack.
♦ After fitting the steering rack to the universal joint shaft ensure
that the seal is not kinked against the assembly plate on the
steering rack. The opening to the footwell must be sealed cor‐
rectly. Otherwise, this can result in water leaks and/or noise.
♦ Ensure sealing surfaces are clean.

Specified torques
Component Specified torque
Swivel joint to cast steel suspension link 60 Nm
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Anti-roll bar to coupling rod 65 Nm

♦ Use new bolts
♦ Counterhold on multi-point socket of joint pin

Suspension link to subframe 70 Nm + 180°

♦ Use new bolt
♦ Tighten bolt in unladen state

7. Assembly overview: anti-roll bar 71

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Component Specified torque

Steering box to subframe 50 Nm + 90°
♦ Use new bolts

Track rod ball joint to wheel bearing housing Tighten to 100 Nm, then loosen (turn back) 180°
♦ Use new bolts and retighten to 100 Nm

Universal joint to steering rack 30 Nm

♦ Use new bolt

Exhaust system bracket to subframe

⇒ Engine; Rep. gr. 26

Specified torques, subframe to body

Bolt Specified torque
M12 x 1.5 x 90 70 Nm + 180° further
♦ Use new bolts

M12 x 1.5 x 100 70 Nm + 180° further

♦ Use new bolts

Specified torques for pendulum support to gearbox

Bolt Specified torque
M10 × 35 50 Nm + 90° further
♦ Use new bolt

M10 × 75 50 Nm + 90° further

♦ Use new bolt

M12 x 1.5 x 85 ; M12 x 1.5 x 50 60 Nm + 90° further

♦ Use new bolt

– After installing, perform basic settings for steering angle send‐

er - G85- ⇒ Vehicle diagnostic tester.

72 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

8 Assembly overview: suspension strut

Note

Assembly overview - suspension strut for adaptive chassis control DCC ⇒ page 278

1 - Nut
❑ 60 Nm
❑ Self-locking
❑ Renew after each re‐
moval
2 - Suspension strut mounting
❑ Note installation posi‐
tion ⇒ page 79
3 - Deep groove ball thrust
bearing
4 - Coil spring
❑ Removing and installing
⇒ page 82
❑ Observe colour coding
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Surface of coil must not
be damaged.
5 - Protective cover
6 - Buffer stop
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
7 - Damper
❑ Can be renewed sepa‐
rately
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”

8. Assembly overview: suspension strut 73

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

8.1 Removing and installing suspension strut

Note

Removing and installing suspension strut for adaptive chassis control DCC ⇒ page 280

Special tools and workshop

equipment required

♦ Spreader - 3424-
♦ Torque wrench - V.A.G 1332-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Support - T10149-

74 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Ejector - T10520-

Perform the following steps:

Removing
– Loosen drive shaft bolt at wheel hub:
♦ Twelve-point head bolt with ribbing ⇒ page 84
♦ Twelve-point head bolt without ribbing ⇒ page 85

Caution

Wheel bearings must not be subjected to load after bolt secur‐

ing drive shaft to wheel hub has been loosened.
If wheel bearings are loaded with weight of vehicle, bearing will
be damaged. This reduces the service life of the wheel bearing.
It is not permissible to loosen drive shaft bolt more than 90° if
vehicle is standing on its wheels.
Do not attempt to move the vehicle without the drive shafts
fitted as this would damage the wheel bearing. If a vehicle must
nevertheless be moved, comply with the following:
♦ Install an outer joint instead of the drive shaft.
♦ Tighten outer joint to 120 Nm.

– Loosen wheel bolts.

– Raise vehicle.
– Remove wheel.
– Unscrew nut -arrow- and pull coupling rod -1- off suspension
strut.

8. Assembly overview: suspension strut 75

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unscrew nuts -arrows-.

– Pull wheel bearing housing with swivel joint out of suspension
link.
– Pull outer joint of drive shaft out of wheel hub.
If the drive shaft cannot be pulled out of the wheel bearing by
hand, use ejector - T10520- .

Before using press tool - T10520- ensure that thrust piece -1- is
inserted.

Using ejector - T10520- :

– To press out drive shaft -3-, secure ejector - T10520- -1- to
wheel hub using 3 wheel bolts -2-.

76 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– It is essential to follow specified sequence.

I - Tighten knurled nut -1- hand-tight.
II - Turn only bolt -2- using a spanner in order to press out drive
shaft with ejector - T10520- .

Note

At the end of the procedure or for pressing out drive shaft further,
the spindle must be moved to its original position in order to apply
the hydraulic force.

– Secure drive shaft to body with wire.

Caution

Do not allow the drive shaft to hang down under its own weight,
for this would allow the inner joint to bend too far and be dam‐
aged.

– Bolt swivel joint to suspension link again.

– Use wheel bolt to attach engine and gearbox jack - V.A.G 1383
A- with support - T10149- to wheel hub.

WARNING

♦ Do not raise or lower the vehicle while the engine and

gearbox jack - V.A.G 1383 A- is positioned under the ve‐
hicle. The vehicle could slip off the lifting platform.
♦ Do not leave engine and gearbox jack - V.A.G 1383 A-
under vehicle longer than necessary.

– Separate threaded connection between wheel bearing hous‐

ing and suspension strut -arrow-.

8. Assembly overview: suspension strut 77

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Insert spreader - 3424- in slot in wheel bearing housing.

– Turn ratchet handle through 90° and detach from spreader -
3424- .
– Press brake disc towards suspension strut by hand.
Otherwise the shock absorber tube can cant in the bore of the
wheel bearing housing.
– Pull wheel bearing housing downwards off shock absorber
tube and lower with engine and gearbox jack - V.A.G 1383 A-
until shock absorber tube is free.
– Firmly tie wheel bearing housing to subframe.
– Pull engine and gearbox jack - V.A.G 1383 A- out from under
wheel bearing housing.

WARNING

♦ Do not leave engine and gearbox jack - V.A.G 1383 A-

under vehicle longer than necessary.

– Remove windscreen wiper motor ⇒ Rep. gr. 92 ; Windscreen

wash/wipe system; Removing and installing windscreen wiper
system .

– Remove hexagon bolts -arrows- for upper shock absorber

mounting and remove suspension strut.
Installing

– Use wheel bolt to attach engine and gearbox jack - V.A.G 1383
A- with support - T10149- to wheel hub.
– Place suspension strut on wheel bearing housing and fix in
place with the multi-point socket head bolt and a new nut.
The tip of the multi-point socket head bolt must point in the direc‐
tion of travel.
– Remove spreader - 3424- .

78 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Insert spring plate with one of the two markings -arrows- pointing
in direction of travel.
– Untie wheel bearing housing from subframe.

– Carefully raise wheel bearing housing with the gearbox jack

until bolts for connecting suspension strut to strut turret
-arrows- can be inserted.
If necessary, use a ladder, e.g. step ladder - VAS 5085- , to insert
the bolts.
– Tighten hexagon bolts -arrows- for upper shock absorber
mounting.
– Detach support - T10149- .

– Tighten threaded connection between wheel bearing housing

and suspension strut -arrow-

8. Assembly overview: suspension strut 79

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unscrew nuts -arrows-.

– Fit drive shaft in wheel hub.
– Fit wheel bearing housing with swivel joint in suspension link.
– Bolt swivel joint to suspension link -arrows-.

Note

Ensure that boot is not damaged or twisted.

– Tighten drive shaft bolt at wheel hub:

♦ Twelve-point head bolt with ribbing ⇒ page 84
♦ Twelve-point head bolt without ribbing ⇒ page 85

Caution

During this step, vehicle must not be standing on its wheels.

The wheel bearing can be damaged by the weight of the vehi‐
cle if the bolt is loosened.

Distinguishing features between twelve-point head bolt with rib‐

bing and twelve-point head bolt without ribbing.
The twelve-point head bolts can be distinguished by the contact
surfaces -arrow A- and -arrow B-.
I - Twelve-point head bolt with ribbing -arrow A-
II - Twelve-point head bolt without ribbing -arrow B-
– Install windscreen wiper motor ⇒ Rep. gr. 92 ; Windscreen
wash/wipe system; Removing and installing windscreen wiper
system .
Continue installation in reverse order of removal.
– Install wheel and tighten bolts or nuts ⇒ page 304 .

Specified torques
Component Specified torque
Suspension strut to wheel bearing housing 70 Nm + 90°
♦ Use new bolts

Suspension strut to body (suspension turret) 20 Nm + 90°

♦ Use new bolts

Swivel joint to cast steel suspension link 60 Nm

♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Coupling rod to suspension strut 65 Nm

♦ Use new bolts
♦ Counterhold on multi-point socket of joint pin

80 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Component Specified torque

Drive shaft to wheel hub “twelve-point head bolt with rib‐ 70 Nm + 90°
bing”
♦ Use new bolt

Drive shaft to wheel hub “twelve-point head bolt without 200 Nm + 180°
ribbing”
♦ Use new bolt

8.2 Repairing suspension strut

Special tools and workshop

equipment required

♦ Torque wrench - V.A.G 1332-

♦ Spring compressor - V.A.G 1752/1-
♦ Spring retainer - V.A.G 1752/4-
♦ Strut support clamp - V.A.G 1752/20-
♦ Shock absorber tool set - T10001-
♦ Commercially available ratchet handle

8. Assembly overview: suspension strut 81

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Perform the following steps:

– Remove coil spring strut ⇒ page 74 .
Removing coil spring
– Clamp suspension strut support clamp - V.A.G 1752/20- -4- in
a vice.
– Clamp suspension strut in suspension strut support clamp -
V.A.G 1752/20- -4-.
– Pre-tension coil spring with spring compressor - V.A.G 1752/1-
until deep groove ball thrust bearing is free at top.
1- Torque wrench - V.A.G 1332-
2- Hexagon bit, long reach - T10001/8-
3- Spring compressor - V.A.G 1752/1-
4- Strut support clamp - V.A.G 1752/20-
5- Spring retainer - V.A.G 1752/4-
6- Hexagon bit, long reach - T10001/5-
7- Ratchet wrench - T10001/11-

WARNING

First compress spring far enough to ensure that upper spring

plate is free.

– Ensure that coil spring is correctly seated in spring retainer -

V.A.G 1752/4- -arrow-.
– Unscrew hexagon nut from piston rod.
– Remove individual components of suspension strut and coil
spring with spring compressor - V.A.G 1752/1- .
Install coil spring.
– Fit coil spring with spring compressor - V.A.G 1752/1- onto
lower spring support.

The end of the coil spring must lie against the stop -arrow-.
– Tighten new hexagon nut on piston rod.
– Relieve tension on spring compressor - V.A.G 1752/1- and
remove from coil spring.
– Install suspension strut ⇒ page 78 .

Specified torque
Component Specified torque
Suspension strut mounting to shock absorber 60 Nm
♦ Use new bolts

82 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

8. Assembly overview: suspension strut 83

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

9 Removing and installing drive shafts

Loosening and tightening twelve-point head bolt, with ribbing, se‐
curing drive shaft ⇒ page 84 .
Loosening and tightening twelve-point head bolt, without ribbing,
securing drive shaft ⇒ page 85 .
Removing and installing drive shaft with constant velocity joint
⇒ page 87 .
Removing and installing left drive shaft with (push-on) constant
velocity slip joint ⇒ page 90 .
Removing and installing right drive shaft with (push-on) constant
velocity slip joint ⇒ page 96 .
Removing and installing drive shafts with triple roller joint
AAR3300i ⇒ page 102 .

9.1 Loosening and tightening twelve-point

head bolt, with ribbing, securing drive
shaft
Special tools and workshop equipment required
♦ Socket, 24 mm - T10361A-

♦ Torque angle wrench - V.A.G 1756 A-

84 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Distinguishing features between twelve-point head bolt with rib‐

bing and twelve-point head bolt without ribbing.
The twelve-point head bolts can be distinguished by the contact
surfaces -arrow A- and -arrow B-.
I - Twelve-point head bolt with ribbing -arrow A-
II - Twelve-point head bolt without ribbing -arrow B-

Caution

Wheel bearings must not be subjected to load after bolt secur‐

ing drive shaft to wheel hub has been loosened.
If wheel bearings are loaded with weight of vehicle, bearing will
be damaged. This reduces the service life of the wheel bearing.
It is not permissible to loosen drive shaft bolt more than 90° if
vehicle is standing on its wheels.
Do not attempt to move the vehicle without the drive shafts
fitted as this would damage the wheel bearing. If a vehicle must
nevertheless be moved, comply with the following:
♦ Install an outer joint instead of the drive shaft.
♦ Tighten outer joint to 120 Nm.

Loosening twelve-point head bolt

– To avoid damage to wheel bearing, do not loosen twelve-point
head bolt using 24 mm socket - T10361A- further than 90° with
vehicle still standing on its wheels.
– Raise vehicle so that wheels are off the ground.
– Have second mechanic apply brakes.

– Remove twelve-point head bolt -arrow-.

Fitting twelve-point head bolt
– Renew twelve-point head bolt.

Note

The wheels must not be in contact with the ground when the drive
shaft bolt is tightened; otherwise, the wheel bearing will be dam‐
aged.

– Have second mechanic apply brakes.

– Tighten twelve-point bolt to 70 Nm.
– Lower vehicle onto its wheels.
– Turn twelve-point head bolt 90° further.

9.2 Loosening and tightening twelve-point

head bolt, without ribbing, securing drive
shaft
Special tools and workshop equipment required

9. Removing and installing drive shafts 85

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Socket, 24 mm - T10361A-

♦ Torque angle wrench - V.A.G 1756 A-

Distinguishing features between twelve-point head bolt with rib‐

bing and twelve-point head bolt without ribbing.
The twelve-point head bolts can be distinguished by the contact
surfaces -arrow A- and -arrow B-.
I - Twelve-point head bolt with ribbing -arrow A-
II - Twelve-point head bolt without ribbing -arrow B-

Caution

Wheel bearings must not be subjected to load after bolt secur‐

ing drive shaft to wheel hub has been loosened.
If wheel bearings are loaded with weight of vehicle, bearing will
be damaged. This reduces the service life of the wheel bearing.
It is not permissible to loosen drive shaft bolt more than 90° if
vehicle is standing on its wheels.
Do not attempt to move the vehicle without the drive shafts
fitted as this would damage the wheel bearing. If a vehicle must
nevertheless be moved, comply with the following:
♦ Install an outer joint instead of the drive shaft.
♦ Tighten outer joint to 120 Nm.

Loosening twelve-point head bolt

– To avoid damage to wheel bearing, do not loosen twelve-point
head bolt using 24 mm socket - T10361A- further than 90° with
vehicle still standing on its wheels.
– Raise vehicle so that wheels are off the ground.
– Have second mechanic apply brakes.

86 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove twelve-point head bolt -arrow-.

Fitting twelve-point head bolt
– Renew twelve-point head bolt.

Note

The wheels must not be in contact with the ground when the drive
shaft bolt is tightened; otherwise, the wheel bearing will be dam‐
aged.

– Have second mechanic apply brakes.

– Tighten twelve-point bolt to 200 Nm.
– Lower vehicle onto its wheels.
– Turn twelve-point head bolt 180° further.

9.3 Removing and installing drive shaft with

constant velocity joint
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

♦ Ejector - T10520-

Caution

When removing and installing drive shafts, do not allow them

to hang free and stop against joints due to over bending.

Removing
– Loosen drive shaft bolt at wheel hub:
♦ Twelve-point head bolt with ribbing ⇒ page 84

9. Removing and installing drive shafts 87

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Twelve-point head bolt without ribbing ⇒ page 85

Caution

Wheel bearings must not be subjected to load after bolt secur‐

ing drive shaft to wheel hub has been loosened.
If wheel bearings are loaded with weight of vehicle, bearing will
be damaged. This reduces the service life of the wheel bearing.
It is not permissible to loosen drive shaft bolt more than 90° if
vehicle is standing on its wheels.
Do not attempt to move the vehicle without the drive shafts
fitted as this would damage the wheel bearing. If a vehicle must
nevertheless be moved, comply with the following:
♦ Install an outer joint instead of the drive shaft.
♦ Tighten outer joint to 120 Nm.

– Remove lower noise insulation ⇒ Rep. gr. 50 ; Assembly

overview - noise insulation .
– Unbolt drive shaft from gearbox flange shaft.
– Remove wheel.
– Push drive shaft outer joint out of wheel hub by hand.
– Unscrew nuts -arrows-.
– Pull wheel bearing housing with swivel joint out of suspension
link.
– Pull drive shaft out of wheel hub.
If the drive shaft cannot be pulled out of the wheel bearing by
hand, use ejector - T10520- .

Before using press tool - T10520- ensure that thrust piece -1- is
inserted.

88 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Using ejector - T10520- :

– To press out drive shaft -3-, secure ejector - T10520- -1- to
wheel hub using 3 wheel bolts -2-.

– It is essential to follow specified sequence.

I - Tighten knurled nut -1- hand-tight.
II - Turn only bolt -2- using a spanner in order to press out drive
shaft with ejector - T10520- .

Note

At the end of the procedure or for pressing out drive shaft further,
the spindle must be moved to its original position in order to apply
the hydraulic force.

Installing
Remove any paint residues and/or corrosion on thread and
splines of outer joint.
– Insert drive shaft.
– Guide outer joint into wheel hub splines as far as possible.

– Bolt swivel joint to suspension link -arrows-.

Note

Ensure that boot is not damaged or twisted.

– Fit inner joint of drive shaft in position and pre-tighten bolts in

diagonal sequence to 10 Nm.
– Tighten multi-point socket-head bolts diagonally to the speci‐
fied torque.
– Attach lower noise insulation ⇒ Rep. gr. 50 ; Assembly over‐
view - noise insulation .
– Tighten drive shaft bolt at wheel hub:
♦ Twelve-point head bolt with ribbing ⇒ page 84
♦ Twelve-point head bolt without ribbing ⇒ page 85

Caution

During this step, vehicle must not be standing on its wheels.

The wheel bearing can be damaged by the weight of the vehi‐
cle if the bolt is loosened.

9. Removing and installing drive shafts 89

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Distinguishing features between twelve-point head bolt with rib‐

bing and twelve-point head bolt without ribbing.
The twelve-point head bolts can be distinguished by the contact
surfaces -arrow A- and -arrow B-.
I - Twelve-point head bolt with ribbing -arrow A-
II - Twelve-point head bolt without ribbing -arrow B-
– Install wheel and tighten bolts or nuts ⇒ page 304 .

Specified torques
Component Specified torque
Swivel joint to cast steel suspension link 60 Nm
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Drive shaft to wheel hub “twelve-point head bolt with rib‐ 70 Nm + 90°
bing”
♦ Use new bolt

Drive shaft to wheel hub “twelve-point head bolt without 200 Nm + 180°
ribbing”
♦ Use new bolt

Drive shaft to flange shaft on gearbox “M10 multi-point 70 Nm

socket” ♦ Pre-tighten diagonally to 10 Nm
♦ Use new bolts

9.4 Removing and installing left drive shaft with (push-on) constant velocity slip
joint

90 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Special tools and workshop

equipment required

♦ Multi-purpose tool - VW 771-

♦ Tensioning strap - T10038-
♦ Drive shaft puller - T10382-
♦ Torque wrench - V.A.G 1332-
♦ Torque angle wrench - V.A.G 1756-
Special tools and workshop equipment required
♦ Ejector - T10520-

9. Removing and installing drive shafts 91

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Removing

Caution

When removing and installing drive shafts, do not allow them

to hang free and stop against joints due to over bending.

Removing
– Loosen drive shaft bolt at wheel hub:
♦ Twelve-point head bolt with ribbing ⇒ page 84
♦ Twelve-point head bolt without ribbing ⇒ page 85

Caution

Wheel bearings must not be subjected to load after bolt secur‐

ing drive shaft to wheel hub has been loosened.
If wheel bearings are loaded with weight of vehicle, bearing will
be damaged. This reduces the service life of the wheel bearing.
It is not permissible to loosen drive shaft bolt more than 90° if
vehicle is standing on its wheels.
Do not attempt to move the vehicle without the drive shafts
fitted as this would damage the wheel bearing. If a vehicle must
nevertheless be moved, comply with the following:
♦ Install an outer joint instead of the drive shaft.
♦ Tighten outer joint to 120 Nm.

– Remove lower noise insulation ⇒ Rep. gr. 50 ; Assembly

overview - noise insulation .
– Remove wheel.
– Unscrew nuts -arrows-.
– Pull wheel bearing housing with swivel joint out of suspension
link.
– Push drive shaft outer joint out of wheel hub by hand.
If the drive shaft cannot be pulled out of the wheel bearing by
hand, use ejector - T10520- .

92 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Before using press tool - T10520- ensure that thrust piece -1- is
inserted.

Using ejector - T10520- :

– To press out drive shaft -3-, secure ejector - T10520- -1- to
wheel hub using 3 wheel bolts -2-.

– It is essential to follow specified sequence.

I - Tighten knurled nut -1- hand-tight.
II - Turn only bolt -2- using a spanner in order to press out drive
shaft with ejector - T10520- .

Note

At the end of the procedure or for pressing out drive shaft further,
the spindle must be moved to its original position in order to apply
the hydraulic force.

Note

In order to pull the drive shaft out of the gearbox using the drive
shaft puller - T10382- , the suspension strut with all attachments
must be pulled to the rear.

9. Removing and installing drive shafts 93

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Using tensioning strap - T10038- e.g. on lifting platform arm,

pull suspension strut with attachments back until the drive
shaft puller - T10382- can be applied parallel to drive shaft.
– Secure drive shaft to prevent it from falling.

– Position puller - T10382/1- behind constant velocity slip joint

-1-.
Cut-out -arrow- of puller - T10382/1- must face constant velocity
slip joint -1-.

94 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Install spindles - T10382/2- and traverse - T10382/3- on puller

plate - T10382/1- .
– Install multi-purpose tool - VW 771- on traverse - T10382/3- .
– Pull out drive shaft with a couple of strikes of multi-purpose
tool - VW 771- .
– Remove drive shaft from vehicle.
Installing
Remove any paint residues and/or corrosion on thread and
splines of outer joint.
– Insert new retaining ring in groove in stub shaft on gearbox.
– Lightly grease splines of stub shaft with universal grease - G
060 735 A2- .
– Mesh outer and inner splines of gearbox and constant velocity
slip joint.
– Slide drive shaft into constant velocity joint to stop by hand.
– Now push constant velocity joint onto stub shaft of gearbox
with a »sudden, hard push«.

Note

Never use a hammer or other driving tools.

– Check that constant velocity slip joint is securely seated by

pulling constant velocity slip joint against resistance of retain‐
ing ring.

Caution

For this test, it is only permitted to pull on constant velocity slip

joint and not on drive shaft.

– Remove tensioning strap - T10038- .

– Guide outer joint into wheel hub splines as far as possible.

9. Removing and installing drive shafts 95

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Bolt swivel joint to suspension link -arrows-.

Note

Ensure that boot is not damaged or twisted.

– Attach lower noise insulation ⇒ Rep. gr. 50 ; Assembly over‐

view - noise insulation .
– Tighten drive shaft bolt at wheel hub:
♦ Twelve-point head bolt with ribbing ⇒ page 84
♦ Twelve-point head bolt without ribbing ⇒ page 85

Caution

During this step, vehicle must not be standing on its wheels.

The wheel bearing can be damaged by the weight of the vehi‐
cle if the bolt is loosened.

Distinguishing features between twelve-point head bolt with rib‐

bing and twelve-point head bolt without ribbing.
The twelve-point head bolts can be distinguished by the contact
surfaces -arrow A- and -arrow B-.
I - Twelve-point head bolt with ribbing -arrow A-
II - Twelve-point head bolt without ribbing -arrow B-
– Install wheel and tighten bolts or nuts ⇒ page 304 .

Specified torques
Component Specified torque
Swivel joint to cast steel suspension link 60 Nm
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Drive shaft to wheel hub “twelve-point head bolt with rib‐ 70 Nm + 90°
bing”
♦ Use new bolt

Drive shaft to wheel hub “twelve-point head bolt without 200 Nm + 180°
ribbing”
♦ Use new bolt

9.5 Removing and installing right drive shaft with (push-on) constant velocity
slip joint

96 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Special tools and workshop

equipment required

♦ Multi-purpose tool - VW 771-

♦ Tensioning strap - T10038-
♦ Drive shaft puller - T10382-
♦ Torque wrench - V.A.G 1332-
♦ Torque angle wrench - V.A.G 1756-

♦ Ejector - T10520-

9. Removing and installing drive shafts 97

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Caution

When removing and installing drive shafts, do not allow them

to hang free and stop against joints due to over bending.

Removing
– Loosen drive shaft bolt at wheel hub:
♦ Twelve-point head bolt with ribbing ⇒ page 84
♦ Twelve-point head bolt without ribbing ⇒ page 85

Caution

Wheel bearings must not be subjected to load after bolt secur‐

ing drive shaft to wheel hub has been loosened.
If wheel bearings are loaded with weight of vehicle, bearing will
be damaged. This reduces the service life of the wheel bearing.
It is not permissible to loosen drive shaft bolt more than 90° if
vehicle is standing on its wheels.
Do not attempt to move the vehicle without the drive shafts
fitted as this would damage the wheel bearing. If a vehicle must
nevertheless be moved, comply with the following:
♦ Install an outer joint instead of the drive shaft.
♦ Tighten outer joint to 120 Nm.

– Remove lower noise insulation ⇒ Rep. gr. 50 ; Assembly

overview - noise insulation .
– Remove wheel.
– Unscrew nuts -arrows-.
– Pull wheel bearing housing with swivel joint out of suspension
link.
– Unbolt coupling rod from anti-roll bar on right side.
– Push drive shaft outer joint out of wheel hub by hand.
If the drive shaft cannot be pulled out of the wheel bearing by
hand, use ejector - T10520- .

98 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Before using press tool - T10520- ensure that thrust piece -1- is
inserted.

Using ejector - T10520- :

– To press out drive shaft -3-, secure ejector - T10520- -1- to
wheel hub using 3 wheel bolts -2-.

– It is essential to follow specified sequence.

I - Tighten knurled nut -1- hand-tight.
II - Turn only bolt -2- using a spanner in order to press out drive
shaft with ejector - T10520- .

– If fitted, remove bolts -1- and detach heat shield -2-.

Note

At the end of the procedure or for pressing out drive shaft further,
the spindle must be moved to its original position in order to apply
the hydraulic force.

– Secure drive shaft to prevent it from falling.

9. Removing and installing drive shafts 99

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Set up drive shaft puller - T10382- .

For the constant velocity slip joint -1-, notch -arrow- in the puller
plate - T10382/1- must face the spindles - T10382/2- .
– Assemble drive shaft puller - T10382- complete with multi-
purpose tool - VW 771- .

Note

In order to pull the drive shaft out of the gearbox using the drive
shaft puller - T10382- , the suspension strut with all attachments
must be pulled to the rear.

– Using tensioning strap - T10038- e.g. on lifting platform arm,

pull suspension strut with attachments back until the drive
shaft puller - T10382- can be applied parallel to drive shaft.

100 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Set up drive shaft puller - T10382- and pull out drive shaft.
– Remove drive shaft from vehicle.
Installing
Remove any paint residues and/or corrosion on thread and
splines of outer joint.
– Insert new retaining ring in groove in stub shaft on gearbox.
– Lightly grease splines of stub shaft with universal grease - G
060 735 A2- .
– Mesh outer and inner splines of gearbox and constant velocity
slip joint.
– Slide drive shaft into constant velocity joint to stop by hand.
– Now push constant velocity joint onto stub shaft of gearbox
with a »sudden, hard push«.

Note

Never use a hammer or other driving tools.

– Check that constant velocity slip joint is securely seated by

pulling constant velocity slip joint against resistance of retain‐
ing ring.

Caution

For this test, it is only permitted to pull on constant velocity slip

joint and not on drive shaft.

– Remove tensioning strap - T10038- .

– Guide outer joint into wheel hub splines as far as possible.

– Bolt swivel joint to suspension link -arrows-.

Note

Ensure that boot is not damaged or twisted.

– Attach lower noise insulation ⇒ Rep. gr. 50 ; Assembly over‐

view - noise insulation .
– Tighten drive shaft bolt at wheel hub:
♦ Twelve-point head bolt with ribbing ⇒ page 84
♦ Twelve-point head bolt without ribbing ⇒ page 85

Caution

During this step, vehicle must not be standing on its wheels.

The wheel bearing can be damaged by the weight of the vehi‐
cle if the bolt is loosened.

9. Removing and installing drive shafts 101

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Distinguishing features between twelve-point head bolt with rib‐

bing and twelve-point head bolt without ribbing.
The twelve-point head bolts can be distinguished by the contact
surfaces -arrow A- and -arrow B-.
I - Twelve-point head bolt with ribbing -arrow A-
II - Twelve-point head bolt without ribbing -arrow B-
– Install wheel and tighten bolts or nuts ⇒ page 304 .

Specified torques
Component Specified torque
Swivel joint to cast steel suspension link 60 Nm
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Drive shaft to wheel hub “twelve-point head bolt with rib‐ 70 Nm + 90°
bing”
♦ Use new bolt

Drive shaft to wheel hub “twelve-point head bolt without 200 Nm + 180°
ribbing”
♦ Use new bolt

9.6 Removing and installing drive shafts

with triple roller joint AAR3300i
Special tools and workshop equipment required
♦ Ejector - T10520-

102 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Torque wrench - V.A.G 1332-

Caution

When removing and installing drive shafts, do not allow them

to hang free and stop against joints due to over bending.

Removing
– Loosen drive shaft bolt at wheel hub:
♦ Twelve-point head bolt with ribbing ⇒ page 84
♦ Twelve-point head bolt without ribbing ⇒ page 85

Caution

Wheel bearings must not be subjected to load after bolt secur‐

ing drive shaft to wheel hub has been loosened.
If wheel bearings are loaded with weight of vehicle, bearing will
be damaged. This reduces the service life of the wheel bearing.
It is not permissible to loosen drive shaft bolt more than 90° if
vehicle is standing on its wheels.
Do not attempt to move the vehicle without the drive shafts
fitted as this would damage the wheel bearing. If a vehicle must
nevertheless be moved, comply with the following:
♦ Install an outer joint instead of the drive shaft.
♦ Tighten outer joint to 120 Nm.

– Remove wheel.
– Remove lower noise insulation ⇒ Rep. gr. 50 ; Assembly
overview - noise insulation .
– If fitted, remove bolts -1- and detach heat shield -2-.
– Unbolt drive shaft from gearbox flange shaft.

9. Removing and installing drive shafts 103

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unscrew nuts -arrows-.

– Pull wheel bearing housing with swivel joint out of suspension
link.
– Pull drive shaft out of wheel hub.
If the drive shaft cannot be pulled out of the wheel bearing by
hand, use ejector - T10520- .

Before using press tool - T10520- ensure that thrust piece -1- is
inserted.

Using ejector - T10520- :

– To press out drive shaft -3-, secure ejector - T10520- -1- to
wheel hub using 3 wheel bolts -2-.

104 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– It is essential to follow specified sequence.

I - Tighten knurled nut -1- hand-tight.
II - Turn only bolt -2- using a spanner in order to press out drive
shaft with ejector - T10520- .

Note

At the end of the procedure or for pressing out drive shaft further,
the spindle must be moved to its original position in order to apply
the hydraulic force.

Installing
Remove any paint residues and/or corrosion on thread and
splines of outer joint.
– Insert drive shaft.
– Guide outer joint into wheel hub splines as far as possible.

– Bolt swivel joint to suspension link -arrows-.

Note

Ensure that boot is not damaged or twisted.

– Fit inner joint of drive shaft in position and pre-tighten bolts in

diagonal sequence to 10 Nm.
– Tighten multi-point socket-head bolts diagonally to the speci‐
fied torque.
– Attach lower noise insulation ⇒ Rep. gr. 50 ; Assembly over‐
view - noise insulation .
– Tighten drive shaft bolt at wheel hub:
♦ Twelve-point head bolt with ribbing ⇒ page 84
♦ Twelve-point head bolt without ribbing ⇒ page 85

Caution

During this step, vehicle must not be standing on its wheels.

The wheel bearing can be damaged by the weight of the vehi‐
cle if the bolt is loosened.

Distinguishing features between twelve-point head bolt with rib‐

bing and twelve-point head bolt without ribbing.
The twelve-point head bolts can be distinguished by the contact
surfaces -arrow A- and -arrow B-.
I - Twelve-point head bolt with ribbing -arrow A-
II - Twelve-point head bolt without ribbing -arrow B-
– Install wheel and tighten bolts or nuts ⇒ page 304 .

9. Removing and installing drive shafts 105

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Specified torques
Component Specified torque
Swivel joint to cast steel suspension link 60 Nm
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Drive shaft to wheel hub “twelve-point head bolt with rib‐ 70 Nm + 90°
bing”
♦ Use new bolt

Drive shaft to wheel hub “twelve-point head bolt without 200 Nm + 180°
ribbing”
♦ Use new bolt

Drive shaft to flange shaft on gearbox “M10 multi-point 70 Nm

socket” ♦ Pre-tighten diagonally to 10 Nm
♦ Use new bolts

106 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

10 Repairing drive shaft - overview of drive shafts

I - Assembly overview: drive

shaft with VL107 constant ve‐
locity joint ⇒ page 109
II - Assembly overview: drive
shaft with VL107 constant ve‐
locity slip joint (push-on)
⇒ page 118
IV - Assembly overview: drive
shaft with triple roller joint
AAR3300i ⇒ page 125

Distinguishing between drive shafts when installed

VL107 VL107 (inserted) AAR3300i
Diameter of inner joint in 107 107 -
mm
Cover between inner joint X - -
and drive flange
Inner joint pushed onto - X X
gearbox
Inner joint with flange shaft X - X
bolted to gearbox (only
manual and dual clutch
gearboxes)

10. Repairing drive shaft - overview of drive shafts 107

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

10.1 Heat shield for drive shafts

Front-wheel drive:
Component Specified torque
Hexagon bolt -1- 25 Nm

108 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

11 Assembly overview: drive shaft with VL107 constant velocity joint

1 - Bolt
❑ Various versions
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”

WARNING
There
♦ are two versions of
the twelve-point head
bolt, with and without rib‐
bing. Distinguishing fea‐
ture ⇒ page 110 .
When
♦ installing a twelve-
point head bolt, always
note which version is be‐
ing installed.
The
♦ respective specified
torque must also be
used.
The
♦ specified torque for
twelve-point head bolts
»with« ribbing is 70 Nm +
90° when loosening and
tightening ⇒ page 84 .
The
♦ specified torque for
twelve-point head bolts
»without« ribbing is 200
Nm + 180° when loosen‐
ing and tightening
⇒ page 85 .

❑ Renew after each re‐

moval
2 - Outer constant velocity joint
❑ Renew only as com‐
plete unit
❑ Removing ⇒ page 112
Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ Installing: drive onto shaft to stop using plastic hammer
❑ Checking ⇒ page 115
3 - Retaining ring
❑ Renew after each removal
❑ Insert in groove in shaft
4 - Clip
❑ Renew after each removal
❑ Tightening ⇒ page 114
5 - Boot
❑ Check for splits and chafing
❑ Material: Hytrel (polyester elastomer)
6 - Clip
❑ Renew after each removal
❑ Tightening ⇒ page 115

11. Assembly overview: drive shaft with VL107 constant velocity joint 109
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

7 - Drive shaft
8 - Clip
❑ Renew after each removal
❑ Tightening ⇒ page 115
9 - Boot for constant velocity joint
❑ Material: Hytrel (polyester elastomer)
❑ Without breather hole
❑ Check for splits and chafing
❑ Drive off constant velocity joint with a drift
❑ Coat sealing surface of constant velocity joint with -D 454 300 A2- before installing.
10 - Clip
❑ Renew after each removal
❑ Tightening ⇒ page 114
11 - Locking plate
12 - Cap
❑ Drive off carefully with drift
❑ Coat sealing surface of constant velocity joint with -D 454 300 A2- before installing.
❑ Adhesive surface must be free of oil and grease!
13 - Inner constant velocity joint
❑ Renew only as complete unit
❑ Pressing off ⇒ page 113
❑ Pressing on ⇒ page 113
❑ Checking ⇒ page 116
14 - Retaining ring
❑ Remove and install with snap ring pliers - VW 161 A- .
15 - Cover
❑ Renew after each removal
❑ Always renew
❑ Pressing off ⇒ page 113
16 - Multi-point socket head bolt
❑ M10 × 52
❑ Pre-tighten diagonally to 10 Nm and then tighten diagonally to specified torque
❑ 70 Nm
❑ Always renew bolts after removing

Distinguishing features between twelve-point head bolt with rib‐

bing and twelve-point head bolt without ribbing.
The twelve-point head bolts can be distinguished by the contact
surfaces -arrow A- and -arrow B-.
I - Twelve-point head bolt with ribbing -arrow A-
II - Twelve-point head bolt without ribbing -arrow B-

110 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

11.1 Dismantling and assembling drive shaft with VL107 constant velocity joint

Special tools and workshop

equipment required

♦ Thrust plate - VW 401-

♦ Thrust plate - VW 402-
♦ Press tool - VW 408 A-
♦ Support sleeve - VW 522-
♦ Joint tensioner - 40 - 204 A-
♦ Clamp tensioner - V.A.G 1682-

11. Assembly overview: drive shaft with VL107 constant velocity joint 111
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Torque wrench - V.A.G 1331-

♦ Multi-purpose tool - VW 771-

♦ Puller - T10382-

Removing outer constant velocity joint

– Clamp drive shaft in vice using jaw protectors.
– Fold back boot.
– Set puller - T10382- up so that smooth side of puller plate -
T10382/1- points to spindles - T10382/2- .
– Assemble puller - T10382- complete with multi-purpose tool -
VW 771- .

112 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Pull constant velocity joint from drive shaft with puller -

T10382- and multi-purpose tool - VW 771- .
1- Puller plate - T10382/1-
2- Spindles - T10382/2-
Driving on outer constant velocity joint
– Install new retaining ring.
– If necessary, push new joint boot onto drive shaft.
– Knock onto shaft with plastic hammer until retaining ring en‐
gages.

Driving off cover for inner joint

– Remove retaining ring.
– Remove both clips and slide boot towards outer joint.
– Drive off boot with drift.

Pressing off inner constant velocity joint

Installing

Pressing on inner constant velocity joint

– Press joint on to stop.
– Install retaining ring.

11. Assembly overview: drive shaft with VL107 constant velocity joint 113
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Coat sealing surface of cover with -D 454 300 A2- .

– Apply an unbroken bead of sealant of 2 … 3 mm in diameter
onto clean surface of cover in area of inner holes -arrow-.

– Using bolts -arrows-, align new cover in relation to bolt holes.

The alignment must be very accurate, because no further align‐
ment is possible once the part has been hammered on.
– Drive on cover with a plastic hammer.
– Wipe off surplus sealant.

Tighten clip on outer joint

– Apply special pliers -V.A.G 1682- as shown in diagram. En‐
sure jaws of tensioner lie in corners -arrows B- of ear on O-
type clip.
– Tighten clamp by turning spindle with a torque wrench (do not
cant pliers).

Note

♦ Due to the hard material of the protective bellows (compared

to rubber) and the necessity of using a stainless steel clip, it is
only possible to tension the clip with clamp tensioner - V.A.G
1682- .
♦ Specified torque: 25 Nm.
♦ Use torque wrench -C- with setting range 5 … 50 Nm (e.g.
torque wrench - V.A.G 1331- ).
♦ Ensure that the spindle thread -A- moves smoothly. Lubricate
with MOS2 grease if necessary.
♦ If the spindle is tight owing to the thread being dirty, for exam‐
ple, the force required to tighten the clip will not be attained in
spite of correct specified torque specification.

114 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Tightening clip on small diameter

11.2 Checking outer constant velocity joint

The joint is to be dismantled to renew the grease if it is heavily
soiled, or to check the running surfaces of the balls for wear and
damage.
Removing
– Before dismantling, mark position of ball hub in relation to ball
cage and joint body with an electric scriber or oil stone.
– Swing ball hub and ball cage.
– Remove balls one at a time.

– Turn cage until the two rectangular windows -arrow- lie on joint
body.
– Take out cage with hub.

11. Assembly overview: drive shaft with VL107 constant velocity joint 115
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Swing segment of hub into square cage window.

– Tip hub out of cage.
The 6 balls for each joint belong to a tolerance group. Check stub
axle, hub, cage and balls for small indentations (pitting) and
traces of seizing. Excessive circumferential backlash in the joint
is noticeable during load change jolts. In this case the joint must
be replaced. Smoothing and traces of wear of the balls are no
reason to change the joint.
Installing
– Pack half the total quantity of grease into the joint body.
– Fit cage with hub into joint body.
– Press in opposing balls one after the other; the original position
of the hub relative to the cage and joint body must be restored.
– Fit new retaining ring into hub.
– Distribute remaining grease in boot.

11.3 Checking inner constant velocity joint

Removing
The joint is to be dismantled to renew the grease if it is heavily
soiled, and to check the running surfaces and the balls for wear
and damage.
– Swing ball hub and ball cage.
– Press out joint body in direction of arrow.
– Press balls out of cage.

Note

The ball hub and joint body are paired. Do not interchange them.

– Tip ball hub out of ball cage via ball track -arrows-.
– Check joint body, ball hub, ball cage and balls for pitting and
traces of seizing.
Excessive circumferential backlash in the joint is noticeable dur‐
ing load change jolts. In this case the joint must be replaced.
Smoothing and traces of wear of the balls are no reason to renew
the joint.
Installing

116 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Insert hub into cage via the two chamfers. The hub can be
installed in any position. Press balls into cage.
The ball hub has two different distances between the ball tracks:
a smaller one and a larger one.

– Insert hub complete with cage and balls into joint body, making
sure that a smaller gap -b- faces open side of joint body.
– Also take note of chamfer on interior diameter of ball hub. It
must be visible after swivelling in.

– Swing ball hub into place by swinging hub out of cage as

shown in figure -arrows-.

– Swivel in hub with balls by applying firm pressure to cage

-arrow-.
Checking function of constant velocity joint
The constant velocity joint is correctly assembled if the ball hub
can be moved by hand backwards and forwards over its entire
range of axial movement.

11. Assembly overview: drive shaft with VL107 constant velocity joint 117
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

12 Assembly overview: drive shaft with VL107 constant velocity slip joint

1 - Outer constant velocity joint

❑ Renew only as com‐
plete unit
❑ Removing ⇒ page 121
❑ Installing: drive onto
shaft to stop using plas‐
tic hammer.
❑ Checking ⇒ page 123
2 - Bolt
❑ Various versions
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”

WARNING
There
♦ are two versions of
the twelve-point head
bolt, with and without rib‐
bing. Distinguishing fea‐
ture ⇒ page 119 .
When
♦ installing a twelve-
point head bolt, always
note which version is be‐
ing installed.
The
♦ respective specified
torque must also be
used.
The
♦ specified torque for
twelve-point head bolts
»with« ribbing is 70 Nm +
90° when loosening and
tightening ⇒ page 84 .
The
♦ specified torque for
twelve-point head bolts
»without« ribbing is 200
Nm + 180° when loosen‐
ing and tightening
⇒ page 85 .

❑ Renew after each removal

3 - Retaining ring
❑ Renew after each removal
❑ Insert in groove in shaft
4 - Clip
❑ Renew after each removal
❑ Tightening ⇒ page 122
5 - Boot
❑ Check for splits and chafing
❑ Material: Hytrel (polyester elastomer)
6 - Clip
❑ Renew after each removal
❑ Tightening ⇒ page 123

118 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

7 - Drive shaft
8 - Clip
❑ Renew after each removal
❑ Tightening ⇒ page 123
9 - Boot for constant velocity slip joint
❑ Material: Hytrel (polyester elastomer)
❑ Without breather hole
❑ Check for splits and chafing
10 - Retaining ring
❑ Renew after each removal
❑ Insert in groove in shaft
11 - Clip
❑ Renew after each removal
❑ Tightening ⇒ page 122
12 - Constant velocity slip joint
❑ Renew only as complete unit
❑ Removing ⇒ page 122
❑ Installing: drive onto shaft to stop using plastic hammer
13 - Cap
❑ Pulling off ⇒ page 123
❑ Driving on ⇒ page 123

Distinguishing features between twelve-point head bolt with rib‐

bing and twelve-point head bolt without ribbing.
The twelve-point head bolts can be distinguished by the contact
surfaces -arrow A- and -arrow B-.
I - Twelve-point head bolt with ribbing -arrow A-
II - Twelve-point head bolt without ribbing -arrow B-

12. Assembly overview: drive shaft with VL107 constant velocity slip joint 119
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

12.1 Dismantling and assembling drive shaft with VL107 constant velocity slip
joint

Special tools and workshop

equipment required

♦ Thrust plate - VW 401-

♦ Thrust plate - VW 402-
♦ Press tool - VW 408 A-
♦ Support sleeve - VW 522-
♦ Joint tensioner - 40 - 204 A-
♦ Clamp tensioner - V.A.G 1682-

120 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Torque wrench - V.A.G 1331-

♦ Multi-purpose tool - VW 771-

♦ Puller - T10382-

Removing outer constant velocity joint

– Clamp drive shaft in vice using jaw protectors.
– Fold back boot.
– Set puller - T10382- up so that smooth side of puller plate -
T10382/1- points to spindles - T10382/2- .
– Assemble puller - T10382- complete with multi-purpose tool -
VW 771- .

12. Assembly overview: drive shaft with VL107 constant velocity slip joint 121
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Pull constant velocity joint from drive shaft with puller -

T10382- and multi-purpose tool - VW 771- .
1- Puller plate - T10382/1-
2- Spindles - T10382/2-
Driving on outer constant velocity joint
– Install new retaining ring.
– If necessary, push new joint boot onto drive shaft.
– Knock onto shaft with plastic hammer until retaining ring en‐
gages.

Removing inner constant velocity slip joint

– Clamp drive shaft in vice using jaw protectors.
– Fold back boot.
– Drive constant velocity slip joint off drive shaft using drift -A-.
The drift must be positioned exactly on the star of the constant
velocity joint.
Driving joint on
– Knock onto shaft with plastic hammer until retaining ring en‐
gages.

Tighten clip on outer joint

– Position clamp tensioner - V.A.G 1682- as shown in diagram.
Ensure jaws of tensioner lie in corners -arrows B- of ear on O-
type clip.
– Tighten clamp by turning spindle with a torque wrench (do not
cant pliers).

Note

♦ Due to the hard material of the protective bellows (compared

to rubber) and the necessity of using a stainless steel clip, it is
only possible to tension the clip with clamp tensioner - V.A.G
1682- .
♦ Specified torque: 25 Nm.
♦ Use torque wrench -C- with setting range 5 … 50 Nm (e.g.
torque wrench - V.A.G 1331- ).
♦ Ensure that the spindle thread -A- moves smoothly. Lubricate
with MOS2 grease if necessary.
♦ If the spindle is tight owing to the thread being dirty, for exam‐
ple, the force required to tighten the clip will not be attained in
spite of correct specified torque specification.

122 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Tightening clip on small diameter

Pulling deflector cap off constant velocity slip joint

1- Three arm puller, e.g. Kukko 45-2
2- Thrust pad - VW 447 H-

Driving deflector cap onto constant velocity slip joint

1- Press tool - T10243-
Drive deflector cap onto joint until shoulder -arrow A- engages in
groove -arrow B-.

12.2 Checking outer constant velocity joint

The joint is to be dismantled to renew the grease if it is heavily
soiled, or to check the running surfaces of the balls for wear and
damage.

12. Assembly overview: drive shaft with VL107 constant velocity slip joint 123
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Removing
– Before dismantling, mark position of ball hub in relation to ball
cage and joint body with an electric scriber or oil stone.
– Swing ball hub and ball cage.
– Remove balls one at a time.

– Turn cage until the two rectangular windows -arrow- lie on joint
body.
– Take out cage with hub.

– Swing segment of hub into square cage window.

– Tip hub out of cage.
The 6 balls for each joint belong to a tolerance group. Check stub
axle, hub, cage and balls for small indentations (pitting) and
traces of seizing. Excessive circumferential backlash in the joint
is noticeable during load change jolts. In this case the joint must
be replaced. Smoothing and traces of wear of the balls are no
reason to change the joint.
Installing
– Pack half the total quantity of grease into the joint body.
– Fit cage with hub into joint body.
– Press in opposing balls one after the other; the original position
of the hub relative to the cage and joint body must be restored.
– Fit new retaining ring into hub.
– Distribute remaining grease in boot.

124 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

13 Assembly overview: drive shaft with triple roller joint AAR3300i

1 - Outer constant velocity joint

❑ Renew only as com‐
plete unit
❑ Removing ⇒ page 129
❑ Installing: drive onto
shaft with plastic ham‐
mer until compressed
retaining ring seats
❑ Checking ⇒ page 123
2 - Bolt
❑ Various versions
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”

WARNING
There
♦ are two versions of
the twelve-point head
bolt, with and without rib‐
bing. Distinguishing fea‐
ture ⇒ page 126 .
When
♦ installing a twelve-
point head bolt, always
note which version is be‐
ing installed.
The
♦ respective specified
torque must also be
used.
The
♦ specified torque for
twelve-point head bolts
»with« ribbing is 70 Nm +
90° when loosening and
tightening ⇒ page 84 .
The
♦ specified torque for
twelve-point head bolts
»without« ribbing is 200
Nm + 180° when loosen‐
ing and tightening
⇒ page 85 .

❑ Renew after each removal

3 - Retaining ring
❑ Renew after each removal
❑ Insert in groove in shaft
4 - Clip
❑ Renew after each removal
❑ Tightening
5 - Boot for constant velocity joint
❑ Check for splits and chafing
❑ Material: Hytrel (polyester elastomer)
6 - Clip
❑ Renew after each removal
❑ Tightening ⇒ page 132

13. Assembly overview: drive shaft with triple roller joint AAR3300i 125
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

7 - Drive shaft
8 - Clip
❑ Renew after each removal
❑ Tightening ⇒ page 132
9 - Boot for triple roller joint
❑ Check for splits and chafing
10 - Clip
❑ Renew after each removal
❑ Tightening ⇒ page 131
11 - Triple roller star with rollers
The chamfer -arrow- points towards drive shaft splines.
❑ Removing ⇒ page 129
12 - Retaining ring
❑ Renew after each removal
❑ Insert in groove in shaft
13 - Multi-point socket head bolt
❑ M10 × 23
❑ Pre-tighten diagonally to 10 Nm and then tighten diagonally to specified torque
❑ 70 Nm
14 - Adapter
15 - Joint body
❑ Removing ⇒ page 129

Distinguishing features between twelve-point head bolt with rib‐

bing and twelve-point head bolt without ribbing.
The twelve-point head bolts can be distinguished by the contact
surfaces -arrow A- and -arrow B-.
I - Twelve-point head bolt with ribbing -arrow A-
II - Twelve-point head bolt without ribbing -arrow B-

126 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

13.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i

Special tools and workshop

equipment required

♦ Thrust plate - VW 401-

♦ Thrust plate - VW 402-
♦ Press tool - VW 408 A-
♦ Press tool - VW 411-
♦ Tube - VW 416 B-
♦ Thrust plate - VW 447 H-

13. Assembly overview: drive shaft with triple roller joint AAR3300i 127
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Hose clip pliers - V.A.G 1275-

♦ Torque wrench - V.A.G 1331-
♦ Torque wrench - V.A.G 1332-
♦ Clamp tensioner - V.A.G 1682-
♦ Assembly tool - T10065-

♦ Multi-purpose tool - VW 771-

128 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Puller - T10382-

Removing outer constant velocity joint

– Clamp drive shaft in vice using jaw protectors.
– Fold back boot.
– Set puller - T10382- up so that smooth side of puller plate -
T10382/1- points to spindles - T10382/2- .
– Assemble puller - T10382- complete with multi-purpose tool -
VW 771- .
– Pull constant velocity joint from drive shaft with puller -
T10382- and multi-purpose tool - VW 771- .
1- Puller plate - T10382/1-
2- Spindles - T10382/2-
Driving on outer constant velocity joint
– Install new retaining ring.
– If necessary, push new joint boot onto drive shaft.
– Knock onto shaft with plastic hammer until retaining ring en‐
gages.
Dismantling triple roller joint
– Clamp drive shaft in vice using jaw protectors.
– Open both clip on inner joint and push back boot.
– Pull joint body off drive shaft.

– Remove retaining ring.

1 - Pliers (commercially available)
- or -VW 161 A-
– Set drive shaft into press.

13. Assembly overview: drive shaft with triple roller joint AAR3300i 129
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Press triple roller star off drive shaft.

– Pull boot off shaft.
– Clean shaft, joint body and groove for seal.
Assembling triple roller joint
– Push small hose clip for boot onto shaft.
– Push joint boot onto shaft.
– Push joint body onto shaft.
Fitting triple roller star
Drive shaft (tapered version)
Chamfer on star faces towards shaft and is used as an assembly
aid.

– Fit triple roller star onto shaft and press on to stop.

– Ensure that pressure does not exceed 3.0 t.
– If necessary, coat splines of drive shafts and triple roller star
with lubricating paste - G 052 142 A2- .
– Insert retaining ring, ensuring that it is seated correctly.
– Press half of total amount of grease from repair kit into triple
roller joint.
– Slide joint body over rollers and hold.
– Press remaining amount of grease from repair kit into rear of
triple roller joint.
– Install joint boot.
Fitting triple roller star
Drive shaft (cylindrical version)

– Fit triple roller star onto shaft and press on to stop.

– Ensure that pressure does not exceed 3.0 t.
– If necessary, coat splines of drive shafts and triple roller star
with lubricating paste - G 052 142 A2- .
– Insert retaining ring, ensuring that it is seated correctly.
– Press 70 grams of drive shaft grease from repair set into triple
roller joint.
– Slide joint body over rollers and hold.
– Press 60 grams of drive shaft grease from repair kit into back
of triple roller joint.
– Install joint boot.

130 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Fit hose clip.

Note

To make it easier to insert the multi-point socket-head bolts when

installing the drive shaft, position ear -arrow A- of hose clip be‐
tween mounting flanges -arrows B- of joint body.

Tightening clip on large diameter of inner joint

– Position clamp tensioner - V.A.G 1682- as shown in illustra‐
tion. Ensure jaws of tensioner lie in corners -arrows B- of ear
on O-type clip.
– Tighten clamp by turning spindle with a torque wrench (do not
cant pliers).

Note

♦ Due to the hard material of the protective bellows (compared

to rubber) and the necessity of using a stainless steel clip, it is
only possible to tension the clip with clamp tensioner - V.A.G
1682- .
♦ Specified torque: 25 Nm.
♦ Use torque wrench -C- with adjustment range 5 … 50 Nm, (e.g.
torque wrench - V.A.G 1331- ).
♦ Ensure that the spindle thread -A- moves smoothly. Lubricate
with MOS2 grease if necessary.
♦ If the spindle is tight owing to the thread being dirty, for exam‐
ple, the force required to tighten the clip will not be attained in
spite of correct specified torque specification.

Tighten clip on outer joint

– Position clamp tensioner - V.A.G 1682- as shown in diagram.
Ensure jaws of tensioner lie in corners -arrows B- of ear on O-
type clip.
– Tighten clamp by turning spindle with a torque wrench (do not
cant pliers).

13. Assembly overview: drive shaft with triple roller joint AAR3300i 131
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Tightening clip on small diameter of inner/outer joint

Checking outer constant velocity joint ⇒ page 123
Checking function of constant velocity joint ⇒ page 117

132 Rep. gr.40 - Front suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

42 – Rear suspension
1 Evaluating accident vehicles
A check list for evaluating running gear of accident vehicles can
be found under ⇒ page 1 .

1. Evaluating accident vehicles 133

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

2 Rear axle in unladen position

Special tools and workshop

equipment required

♦ Engine and gearbox jack - V.A.G 1383 A-

♦ Tensioning strap - T10038-
♦ Support - T10149-

Note

All bolts on running gear components with bonded rubber bushes

may be tightened only when the component is in the unladen po‐
sition (normal position).

Bonded rubber bushes can be twisted only to a limited extent.

Axle components with bonded rubber bushes must therefore be
brought to a position equivalent to the unladen (normal) position
before being tightened.
Otherwise, the bonded rubber bush would be subject to torsion
loading, shortening its service life.

134 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

To simulate this position on the lifting platform, raise the axle on

one side using the engine and gearbox jack - V.A.G 1383 A- and
support - T10149- .
Before the axle on one side is raised, both sides of the vehicle
must be strapped to the lifting platform arms with tensioning
straps - T10038- .
1- Tensioning strap - T10038-

WARNING

If the vehicle is not strapped down, there is a danger that the

vehicle will slip off the lifting platform!

– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- with a wheel bolt.
Threaded connections may be tightened only when dimension
-a- between the centre of wheel hub and lower edge of wheel
housing, measured before starting work, has been attained.

2. Rear axle in unladen position 135

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Measuring dimension -a-

The dimension -a- depends on the ride height of the installed run‐
ning gear:

Running gear 1) Ride height -a- in mm

Standard running gear (G02) 428 ± 10 mm
Standard running gear with 418 ± 10 mm
adaptive chassis control DCC
(G40)
Sports running gear (G03) 393 ± 10 mm
Blue Motion (G40) 418 ± 10 mm
Fully automatic ride height set‐ 418 ± 10 mm
ting (G02+1JH)
Lowered standard running gear 420 ± 10 mm
Mobile service 420 ± 10 mm
ADAC 408 ± 10 mm
1)The type of running gear fitted to the vehicle is recorded on the
vehicle data sticker. The running gear is identified by the PR
number. Which PR No. is allocated to which running gear can be
found here ⇒ page 314 .
– Raise wheel bearing housing using engine and gearbox jack
- V.A.G 1383 A- until dimension -a- is attained.

WARNING

♦ Never raise or lower the vehicle while the engine and

gearbox jack is positioned beneath the vehicle.
♦ Do not leave the engine and gearbox jack under the ve‐
hicle for longer than necessary.

– Tighten respective nuts and bolts.

– Lower wheel bearing housing.
– Pull engine and gearbox jack out from underneath vehicle.
– Remove support - T10149- .

136 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

3 Overview - rear axle

Note

♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

♦ Always renew self-locking nuts.
♦ Always renew corroded nuts and bolts.
♦ Bonded rubber bushes can be twisted only to a limited extent. Therefore, tighten the bolted connections of
components with bonded rubber bushes only when the wheel bearing housing has been raised (unladen
state) ⇒ page 134 .
♦ Always renew bonded rubber bush on both sides of the vehicle.

I - Assembly overview: sub‐

frame (front-wheel drive)
⇒ page 139
II - Assembly overview: trans‐
verse link, track rod (front-
wheel drive) ⇒ page 154

3. Overview - rear axle 137

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

III - Assembly overview: wheel

bearing housing, trailing arm
(front-wheel drive)
⇒ page 164
IV - Assembly overview: shock
absorber, coil spring (front-
wheel drive) ⇒ page 181
IV - Assembly overview: shock
absorber for adaptive chassis
control DCC (front-wheel
drive) ⇒ page 289
V - Assembly overview: anti-
roll bar (front-wheel drive)
⇒ page 188

138 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

4 Assembly overview: subframe (front-wheel drive)

The -arrow- points in direction of travel.

1 - Subframe
2 - Rear bonded rubber bush
❑ Renewing ⇒ page 146
3 - Front bonded rubber bush
❑ Renewing ⇒ page 146

4.1 Fixing position of subframe

Special tools and workshop equipment required
♦ Locating pins - T10096-

4. Assembly overview: subframe (front-wheel drive) 139

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Engine and gearbox jack - V.A.G 1383 A-

Perform the following steps:

Installing locating pins - T10096-
– Position engine and gearbox jack - V.A.G 1383 A- underneath
subframe and secure with tensioning strap.

– Unscrew one hexagon bolt -1- or -2- on both sides.

Note

Only the right side of vehicle is shown to improve clarity.

– Secure position of subframe with locating pins - T10096- .

Note

The locating pins - T10096- may be tightened only to a maximum

of 20 Nm; otherwise the threads of the locating pins may be dam‐
aged.

– Replace securing bolts on subframe with locating pins -

T10096- one after the other on both sides of the vehicle and
tighten to 20 Nm.
The position of the subframe is now fixed.

4.2 Lowering rear axle

Special tools and workshop equipment required

140 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Torque wrench - V.A.G 1332-

♦ Engine and gearbox jack - V.A.G 1383 A-

Perform the following steps:

Lowering subframe with attachments
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheels.
– Unbolt brake calipers on both sides of vehicle and suspend
from body.
– Remove coil springs ⇒ page 182 .
– Remove rear silencer of exhaust system ⇒ Rep. gr. 26 ; Ex‐
haust system; Removing and installing parts of the exhaust
system .
Vehicles with rear left vehicle level sender - G76-
– Disconnect connector -1-.
Continued for all vehicles

4. Assembly overview: subframe (front-wheel drive) 141

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unclip brake lines -1- from bracket -arrow- on left of body.

– Pull retaining clip -2- from subframe -3- and detach brake
hose.

Note

Do not open brake line.

– Secure vehicle to support arms of lifting platform on both sides

using tensioning straps - T10038- .
1- Tensioning strap - T10038-

WARNING

If the vehicle is not strapped down, it may slip off the lifting
platform.

– Fix position of subframe ⇒ page 139 .

– Carefully lower subframe with attachments about 2 cm.

– Unclip brake line on left side -arrow-.

– Unclip brake line above left drive shaft flange.

Note

The clips will be destroyed and must be renewed.

Vehicles with SCR system

– Unclip supply line for reducing agent ⇒ Rep. gr. 26 ; SCR
system (Selective Catalytic Reduction); Assembly overview -
supply line for reducing agent .
Continuation for all vehicles
– Lower subframe with attachments about 140 mm.
Installing subframe with attachments
Install in reverse order. During this step, observe the following:
– Fit wheels, torque setting ⇒ page 304 .

Specified torques
Component Specified torque
Subframe to body 70 Nm + 180° further
♦ Use new bolts

4.3 Removing and installing rear axle

Special tools and workshop equipment required

142 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Torque wrench - V.A.G 1332-

♦ Engine and gearbox jack - V.A.G 1383 A-

Perform the following steps:

Removing subframe with attachments
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheels.
– Remove coil springs ⇒ page 182 .
– Remove rear silencer of exhaust system ⇒ Rep. gr. 26 ; Ex‐
haust system; Removing and installing parts of the exhaust
system .
Vehicles with rear left vehicle level sender - G76-
– Disconnect connector -1-.
Continued for all vehicles

4. Assembly overview: subframe (front-wheel drive) 143

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unscrew screw -arrow-.

– Disconnect connectors for rear right speed sensor - G44- and
rear left speed sensor - G46- .

– Unclip brake lines -1- from bracket -arrow- on left of body.

– Pull retaining clip -2- from subframe -3- and detach brake
hose.

Note

Do not open brake line.

– Disconnect connectors of electric parking brake at brake cal‐

iper.

– Remove holders -arrows- by pressing out inner pins of rivets.

– Disconnect connector for rear left vehicle level sender - G76- .

– Secure vehicle to support arms of lifting platform on both sides

using tensioning straps - T10038- .
1- Tensioning strap - T10038-

WARNING

If the vehicle is not strapped down, it may slip off the lifting
platform.

– Fix position of subframe ⇒ page 139 .

144 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove line -1- from mounting bracket -arrow A-.

– Mark installation position of bearing bracket -2- on body.
– Unscrew bolts -arrows B-.
– Carefully lower subframe with attachments about 2 cm.

– Unclip brake lines on both sides -arrow-.

– Unclip brake line from remaining clips on subframe.

Note

The clips will be destroyed and must be renewed.

Vehicles with SCR system

– Unclip supply line for reducing agent ⇒ Rep. gr. 26 ; SCR
system (Selective Catalytic Reduction); Assembly overview -
supply line for reducing agent .
Continuation for all vehicles
– Carefully lower subframe with attachments.

Note

When lowering, ensure sufficient clearance to brake lines and

electrical wiring.

Installing subframe with attachments

Install in reverse order. During this procedure, observe the fol‐
lowing:
– Fit wheels, torque setting ⇒ page 304 .

Specified torques
Component Specified torque
Subframe to body 70 Nm + 180° further
♦ Use new bolts

Shock absorber to wheel bearing housing 180 Nm

Mounting bracket to body 50 Nm + 90° further
♦ Use new bolts

4.4 Repairing subframe

4. Assembly overview: subframe (front-wheel drive) 145

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Special tools and workshop

equipment required

♦ Tensioning strap - T10038-

♦ Locating pins - T10096-
♦ Assembly tool - T10263-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Hydraulic press - VAS 6178- and thrust piece - T10205/13-
♦ Foot pump - VAS 6179-
Pressing out front bonded rubber bush ⇒ page 146
Pressing in front bonded rubber bush ⇒ page 148
Pressing out rear bonded rubber bush ⇒ page 150
Pressing in rear bonded rubber bush ⇒ page 152
Pressing out front bonded rubber bush
– Loosen wheel bolts.
– Raise vehicle.
– Remove rear wheels.
– Remove coil springs ⇒ page 182 .

146 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove rear silencer of exhaust system ⇒ Rep. gr. 26 ; Ex‐

haust system; Removing and installing parts of the exhaust
system .
– Disconnect electrical connections between rear axle and
body.
– Remove anti-roll bar ⇒ page 188 .
– Remove track rods ⇒ page 161 .
– Pull out clip -1-.

Note

Do not open brake line.

– Secure vehicle to support arms of lifting platform on both sides

using tensioning straps - T10038- .
1- Tensioning strap - T10038-

WARNING

If the vehicle is not strapped down, it may slip off the lifting
platform.

– Position engine and gearbox jack - V.A.G 1383 A- underneath

subframe and secure with tensioning strap.

– Unscrew one hexagon bolt -1- or -2- on both sides.

Note

Only the right side of vehicle is shown to improve clarity.

To fix position of subframe, locating pins - T10096- must be

screwed in successively at positions -1- and -2- on both sides of
vehicle.

4. Assembly overview: subframe (front-wheel drive) 147

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Secure position of subframe with locating pins - T10096- .

Note

The locating pins - T10096- may be tightened only to a maximum

of 20 Nm; otherwise the threads of the locating pins may be dam‐
aged.

– Replace securing bolts on subframe with locating pins -

T10096- one after the other on both sides of the vehicle and
tighten to 20 Nm.
The position of the subframe is now fixed.
– Lower subframe 10 cm using engine and gearbox jack - V.A.G
1383 A- .
– Mark installation position of bonded rubber bush in relation to
subframe, for example using a felt-tip pen.

– Fit tools as shown in illustration.

1 - Nut - T10263/5-
2 - Washer , from -T10263-
3 - Tube - T10263/6-
4 - Hydraulic press - VAS 6178- and thrust piece - T10205/13-
5 - Nut - T10263/5-
6 - Spindle - T10263/4-
– Take up play in special tools.
– Press out bonded rubber bush.

Note

The outer ring of the bush shears off when the bonded rubber
bush is pressed out. This occurs with a loud bang.

– The bonded rubber bush must be removed from the tube -

T10356/6- once the bush has been pressed out.
– Clamp tube - T10356/6- on the intended surfaces in a vice.
– Insert a screwdriver between tube - T10356/6- and bonded
rubber bush and lever bush out of tube -arrow-. If necessary,
apply a drift to bush and drive out with light hammer blows.
Pressing in front bonded rubber bush
Install in reverse order. During this procedure, observe the fol‐
lowing:

148 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Distinguishing features of bonded rubber bushes

I - Front bonded rubber bush
II - Rear bonded rubber bush
The front bonded rubber bushes have 2 notches on the upper side
-arrows- and differ to the rear slightly in height ⇒ Electronic Parts
Catalogue “ETKA” .
Bonded rubber bush must be installed with correct orientation.
Refer to marking on subframe when doing so.

– Insert bonded rubber bush -1- in subframe so that the nose

and the plate -arrows- face perpendicular to direction of travel.
– Apply thrust piece - T10263/3- -2- so that flattened sides also
face perpendicular to direction of travel.

4. Assembly overview: subframe (front-wheel drive) 149

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Set up special tools with bonded rubber bush on subframe as

shown.
1 - Nut - T10263/5-
2 - Press tool - T10263/3-
3 - Bonded rubber bush
4 - Press tool - T10263/2-
5 - Hydraulic press - VAS 6178- and thrust piece - T10205/13-
6 - Nut - T10263/5-
7 - Spindle - T10263/4-
– Take up play in special tools and bonded rubber bush.
– Operate pump to press bonded rubber bush in until collar lies
»flush« on subframe.
– Install track rods ⇒ page 188 .
– Install anti-roll bar ⇒ page 161 .
– Join electrical connections between rear axle and body.
– Install rear silencer of exhaust system ⇒ Rep. gr. 26 ; Exhaust
system; Removing and installing parts of the exhaust system .
– Install coil springs ⇒ page 182 .
– Fit wheels, torque setting ⇒ page 304 .
Pressing out rear bonded rubber bush
– Loosen wheel bolts.
– Raise vehicle.
– Remove rear wheels.
– Remove coil springs ⇒ page 182 .
– Remove rear silencer of exhaust system ⇒ Rep. gr. 26 ; Ex‐
haust system; Removing and installing parts of the exhaust
system .

– Pull out clip -1-.

Note

Do not open brake line.

150 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Secure vehicle to support arms of lifting platform on both sides

using tensioning straps - T10038- .
1- Tensioning strap - T10038-

WARNING

If the vehicle is not strapped down, it may slip off the lifting
platform.

– Position engine and gearbox jack - V.A.G 1383 A- underneath

subframe and secure with tensioning strap.

– Unscrew one hexagon bolt -1- or -2- on both sides.

Note

Only the right side of vehicle is shown to improve clarity.

To fix position of subframe, locating pins - T10096- must be

screwed in successively at positions -1- and -2- on both sides of
vehicle.

– Secure position of subframe with locating pins - T10096- .

Note

The locating pins - T10096- may be tightened only to a maximum

of 20 Nm; otherwise the threads of the locating pins may be dam‐
aged.

– Replace securing bolts on subframe with locating pins -

T10096- one after the other on both sides of the vehicle and
tighten to 20 Nm.
The position of the subframe is now fixed.
– Lower subframe 10 cm using engine and gearbox jack - V.A.G
1383 A- .
– Mark installation position of bonded rubber bush in relation to
subframe, for example using a felt-tip pen.

4. Assembly overview: subframe (front-wheel drive) 151

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Fit tools as shown in illustration.

1 - Nut - T10263/5-
2 - Washer , from -T10263-
3 - Tube - T10263/6-
4 - Hydraulic press - VAS 6178- and thrust piece - T10205/13-
5 - Nut - T10263/5-
6 - Spindle - T10263/4-
– Take up play in special tools.
– Press out bonded rubber bush by operating the pump.

Note

The outer ring of the bush shears off when the bonded rubber
bush is pressed out. This occurs with a loud bang.

– The bonded rubber bush must be removed from the tube -

T10356/6- once the bush has been pressed out.
– Clamp tube - T10356/6- on the intended surfaces in a vice.
– Insert a screwdriver between tube - T10356/6- and bonded
rubber bush and lever bush out of tube -arrow-. If necessary,
apply a drift to bush and drive out with light hammer blows.
Pressing in rear bonded rubber bush
Install in reverse order. During this procedure, observe the fol‐
lowing:

Distinguishing features of bonded rubber bushes

I - Front bonded rubber bush
II - Rear bonded rubber bush
The front bonded rubber bushes have 2 notches on the upper side
-arrows- and differ to the rear slightly in height ⇒ Electronic Parts
Catalogue “ETKA” .
Bonded rubber bush must be installed with correct orientation.
Refer to marking on subframe when doing so.

152 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Insert bonded rubber bush -1- in subframe so that the nose

and the plate -arrows- face perpendicular to direction of travel.
– Apply thrust piece - T10263/3- -2- so that flattened sides also
face perpendicular to direction of travel.

– Set up special tools with bonded rubber bush on subframe as

shown.
1 - Nut - T10263/5-
2 - Press tool - T10263/3-
3 - Bonded rubber bush
4 - Press tool - T10263/2-
5 - Hydraulic press - VAS 6178- and thrust piece - T10205/13-
6 - Nut - T10263/5-
7 - Spindle - T10263/4-
– Take up play in special tools and bonded rubber bush.
– Carefully operate pump to press bonded rubber bush in until
collar lies »flush« on subframe.
– Install rear silencer of exhaust system ⇒ Rep. gr. 26 ; Exhaust
system; Removing and installing parts of the exhaust system .
– Install coil springs ⇒ page 182 .
– Fit wheels, torque setting ⇒ page 304 .

Specified torques
Component Specified torque
Subframe to body 70 Nm + 180° further
♦ Use new bolts

4. Assembly overview: subframe (front-wheel drive) 153

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

5 Assembly overview: transverse link, track rod (front-wheel drive)

1 - Subframe
❑ Removing and installing
⇒ page 142
❑ Repairing ⇒ page 145
2 - Eccentric washer
❑ Inner hole with lug
3 - Nut
❑ 95 Nm
❑ Self-locking
❑ Renew after each re‐
moval
❑ Always tighten threaded
connections in unladen
position ⇒ page 134
4 - Eccentric washer
❑ Inner hole with lug
5 - Nut
❑ 95 Nm
❑ Self-locking
❑ Renew after each re‐
moval
❑ Always tighten threaded
connections in unladen
position ⇒ page 134
6 - Bolt
❑ 70 Nm + 180° further
❑ Renew after each re‐
moval
7 - Lower transverse link
❑ Removing and installing
⇒ page 159
8 - Bolt
❑ Renew after each removal
9 - Nut
❑ 70 Nm + 180° further
❑ Self-locking
❑ Renew after each removal
❑ Always tighten threaded connections in unladen position ⇒ page 134
10 - Bolt
❑ 130 Nm + 180° further
❑ Renew after each removal
❑ Always tighten threaded connections in unladen position ⇒ page 134
11 - Nut
❑ Self-locking
❑ Renew after each removal

154 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

12 - Washer
13 - Wheel bearing housing
❑ Removing and installing ⇒ page 165
14 - Washer
15 - Bolt
❑ 130 Nm + 180° further
❑ Renew after each removal
❑ Always tighten threaded connections in unladen position ⇒ page 134
16 - Track rod
❑ Forwards closed (left and right track rods differ)
❑ Removing and installing ⇒ page 161
17 - Washer
18 - Washer
19 - Nut
❑ Self-locking
❑ Renew after each removal
❑ Always tighten threaded connections in unladen position ⇒ page 134
20 - Upper transverse link
❑ Removing and installing ⇒ page 157
21 - Bolt
❑ Renew after each removal
❑ Always tighten threaded connections in unladen position ⇒ page 134
22 - Nut
❑ 70 Nm + 180° further
❑ Self-locking
❑ Renew after each removal
❑ Always tighten threaded connections in unladen position ⇒ page 134
23 - Eccentric bolt
❑ For track adjustment
❑ Check wheel alignment whenever this component is loosened ⇒ page 311 .
24 - Eccentric bolt
❑ For camber adjustment
❑ Check wheel alignment whenever this component is loosened ⇒ page 311 .

5. Assembly overview: transverse link, track rod (front-wheel drive) 155

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

5.1 Assembly overview: rear left vehicle level sender - G76- , front-wheel drive

Note

♦ Assembly overview: rear left vehicle level sender - G76- for adaptive chassis control DCC, front-wheel drive
⇒ page 269
♦ The vehicle level sender is available as a replacement part only complete with coupling rod and upper and
lower retaining plates.
♦ Renewing without removing subframe ⇒ page 156 .
♦ Headlight range control unit - J431-

1 - Subframe
2 - Lower transverse link
3 - Bolt
❑ 5 Nm
4 - Rear left vehicle level send‐
er - G76-
❑ Complete with attach‐
ments
❑ Lever -arrow- must face
outwards
❑ Removing and installing
⇒ page 156
❑ Following renewal, ba‐
sic settings for headlight
must be performed.
Basic setting of headlights
⇒ Vehicle diagnostic tester

5.2 Removing and installing rear left vehicle

level sender - G76-

Note

Removing and installing rear left vehicle level sender - G76- for
adaptive chassis control DCC, front-wheel drive ⇒ page 270

156 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1331-
Perform the following steps:
Removing
– Disconnect connector -1-.
– Remove bolts -2- from lower transverse link.
– Remove bolts -arrows- from subframe.
– Remove rear left vehicle level sender - G76- .
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:
The lever of rear left vehicle level sender - G76- must face outside
of vehicle.
– Perform basic setting of headlights following replacement
⇒ Vehicle diagnostic tester.

Specified torques
Component Specified torque
Rear left vehicle level sender - G76- to lower transverse 5 Nm
link and subframe

5.3 Removing and installing upper trans‐

verse link
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

Perform the following steps:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove coil springs ⇒ page 182 .

5. Assembly overview: transverse link, track rod (front-wheel drive) 157

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unscrew bolt -1-.

– Mark position of eccentric bolt -arrow- in relation to subframe,

for example using a felt-tip pen.
– Unscrew screw -arrow-.
– Remove upper transverse link.
Installing
– Insert upper transverse link into vehicle and hand-tighten
bolts.
Transverse link may be bolted only when dimension “a” has been
attained ⇒ page 136 .

– Tighten new nut -arrow- to specified torque only.

– Observe mark made for position of eccentric bolt -arrow- rel‐
ative to subframe.

– Tighten bolt -1- for upper transverse link.

Note

Ensure that a washer is installed between the bolt and the wheel
bearing housing.

– Install coil spring ⇒ page 182 .

– Install wheel and tighten bolts or nuts ⇒ page 304 .
– Perform wheel alignment ⇒ page 311 .

Specified torques
Component Specified torque
Upper transverse link to wheel bearing housing 130 Nm + 180°further
♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

158 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Component Specified torque

Upper transverse link to subframe 95 Nm
♦ Use new bolts ♦ To tighten nuts, set torque wrench - V.A.G
1332- to 80 Nm.
♦ Tighten threaded connections only when vehicle is in
the normal running position ♦ Applies only in conjunction with insert tool,
18 mm - T10179-

5.4 Removing and installing lower trans‐

verse link
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

Perform the following steps:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove coil springs ⇒ page 182 .
– Remove bolt -arrow- for lower transverse link -1-.

5. Assembly overview: transverse link, track rod (front-wheel drive) 159

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Vehicles with dynamic headlight range control

– Remove bolts -1- from lower transverse link.
Continued for all vehicles
– Mark position of eccentric bolt -arrow- in relation to subframe,
for example using a felt-tip pen.
– Unscrew screw -arrow-.
– Remove lower transverse link.
Installing
– Insert lower transverse link into vehicle and hand-tighten bolts.
Transverse link may be bolted only when dimension “a” has been
attained ⇒ page 136 .

– Tighten new nut -arrow- to specified torque only.

– Observe mark made for position of eccentric bolt -arrow- rel‐
ative to subframe.
Vehicles with dynamic headlight range control
– Install bolts -1- in lower transverse link.
Continued for all vehicles

– Tighten bolt -arrow- for lower transverse link -1-.

– Install coil spring ⇒ page 183 .
– Install wheel and tighten bolts or nuts ⇒ page 304 .
– Perform wheel alignment ⇒ page 311 .

Specified torques
Component Specified torque
Lower transverse link to wheel bearing housing 70 Nm + 180° further
♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Lower transverse link to subframe 95 Nm

♦ Use new bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Rear left vehicle level sender - G76- to lower transverse 5 Nm

link

160 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

5.5 Removing and installing track rod

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

♦ Torque wrench - V.A.G 1332-

Perform the following steps:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove coil springs ⇒ page 182 .
– Remove nut -1- and pull coupling rod -2- from anti-roll bar.
– Remove bolt -arrow- for track rod -3-.

5. Assembly overview: transverse link, track rod (front-wheel drive) 161

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove bolts -arrows- for anti-roll bar clamp.

– Remove nut -arrow- and remove bolt towards rear.

– Remove track rod -1-.
Installing

– Insert track rod -1- into vehicle and hand-tighten bolts.

The track rod may be bolted only when distance “a” has been
attained ⇒ page 136 .
– Tighten new nut -arrow- to specified torque only.

– Tighten bolts -arrows- for anti-roll bar clamp.

162 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Tighten bolt -arrow- for track rod -3-.

Note

Ensure that a washer is installed between the nut and the wheel
bearing housing.

– Connect coupling rod -2- to anti-roll bar and tighten nut -1-.
– Install coil spring ⇒ page 183 .
– Install wheel and tighten bolts or nuts ⇒ page 304 .
– Perform wheel alignment ⇒ page 311 .

Specified torques
Component Specified torque
Track rod to wheel bearing housing 130 Nm + 180° further
♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Track rod to subframe 90 Nm + 90°

♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Anti-roll bar to subframe 25 Nm + 45°

♦ Use new bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Anti-roll bar to coupling rod 40 Nm

♦ Use new bolts

5. Assembly overview: transverse link, track rod (front-wheel drive) 163

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

6 Assembly overview: wheel bearing housing, trailing arm (front-wheel

drive)

1 - Cover
2 - Mounting bracket
3 - Coupling rod
❑ Connects anti-roll bar to
trailing arm and wheel
bearing housing
4 - Bolt
❑ Note tightening se‐
quence
❑ 70 Nm + 90° further
❑ Renew after each re‐
moval
5 - Trailing arm
❑ Removing and installing
⇒ page 174
❑ Repairing ⇒ page 178
6 - Bolt
❑ 8 Nm
7 - Rear right speed sensor -
G44- / rear left speed sensor -
G46-
❑ Can be tested in Guided
Fault Finding using
⇒ Vehicle diagnostic
tester.
❑ Before inserting sensor,
clean inner surface of
hole and coat with lubri‐
cating paste - G 000
650- .
8 - Wheel bearing housing
❑ Removing and installing
⇒ page 165
9 - Bonded rubber bush
❑ Renewing ⇒ page 168
10 - Washer
❑ Chamfer of washer must face outwards.
11 - Nut
❑ 45 Nm
❑ Renew after each removal
12 - Brake disc
13 - Bolt
❑ 8 Nm
14 - Dust cap
❑ Renew after each removal
❑ Pressing off and driving in ⇒ page 171
A proper seal can be achieved only by installing a new grease cap.

164 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

15 - Bolt
❑ Loosen and tighten using bit - T10162 A-
❑ 200 Nm + 90° further
❑ Renew after each removal
16 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing
❑ Removing and installing ⇒ page 171
The wheel bearing and wheel hub are assembled as one unit
This wheel bearing unit is maintenance-free and does not require adjustment. Adjustments and repairs are not
possible!

17 - Bolt
❑ 12 Nm
18 - Cover plate
19 - Bolt
❑ 90 Nm + 90° further
❑ Renew after each removal
20 - Bonded rubber bush
❑ Renewing ⇒ page 178
21 - Bolt
❑ 50 Nm + 90° further
❑ Renew after each removal

6.1 Removing and installing wheel bearing

housing
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

Perform the following steps:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove coil springs ⇒ page 182 .
– Remove wheel bearing unit ⇒ page 171 .
– Take off cover.
– Remove ABS speed sensor out of wheel bearing housing.

6. Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 165
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unscrew screw -arrow-.

– Remove bolt for track rod -1-, upper transverse link -2- and
lower transverse link -3- from wheel housing -4-.
– Remove coupling rod -arrow- from wheel bearing housing.

– Hold wheel bearing housing and unscrew bolts -arrows-.

– Remove coupling rod -1- from trailing arm.
Installing

Threaded connection for trailing arm and wheel bearing housing

may be tightened only after all other components (particularly the
spring and shock absorber) of respective wheel suspension have
been installed. To tighten, wheel suspension must be in extended
position. Only then do trailing arm and wheel bearing housing
move to the necessary position -arrows-.
It is essential to follow specified sequence of work steps below!

166 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Install bolts for track rod -1-, upper transverse link -2- and low‐
er transverse link -3-, but do not tighten.
– Attach coupling rod -arrow- to wheel bearing housing -4- hand-
tight.

– Screw in bolts -arrows- and fit coupling rod -1- to trailing arm.

– Tighten bolt -arrow- for shock absorber.

Threaded connections on wheel bearing housing may be tight‐
ened only when dimension “a” has been obtained ⇒ page 136 .
– Install coil spring ⇒ page 183 .

– Tighten bolt for track rod -1-, upper transverse link -2- and
lower transverse link -3-.
– Tighten nut for coupling rod -arrow-.

6. Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 167
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Tighten bolts -arrow-.

– Fit cover plate.
– Install wheel bearing unit ⇒ page 171 .
– Install ABS speed sensor in wheel bearing housing.
– Install brake disc.
– Attach brake carrier with brake caliper ⇒ Brake systems; Rep.
gr. 46 .
– Install wheel and tighten bolts or nuts ⇒ page 304 .

Specified torques
Component Specified torque
Upper transverse link to wheel bearing housing 130 Nm + 180° further
♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Lower transverse link to wheel bearing housing 70 Nm + 180° further

♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Track rod to wheel bearing housing 130 Nm + 180° further

♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Trailing arm to wheel bearing housing 70 Nm + 90° further

♦ Use new bolts

Coupling rod to wheel bearing housing. 45 Nm

♦ Use new bolts

Splash plate to wheel bearing housing 12 Nm

ABS speed sensor to wheel bearing housing 8 Nm
Shock absorber to wheel bearing housing 180 Nm
♦ Use new bolt

Brake disc to wheel bearing housing. 8 Nm

6.2 Renewing bonded rubber bush for wheel bearing housing

168 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Special tools and workshop

equipment required

♦ Assembly tool - 3346-

♦ Assembly tool - 3350-
♦ Fitting sleeve - 3378-
♦ Follower - 3390-
♦ Torque wrench - V.A.G 1332-
Perform the following steps:
Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove coil springs ⇒ page 182 .
– Remove wheel bearing unit ⇒ page 171 .
– Take off cover.

6. Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 169
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove bolt -arrow- for lower transverse link -1-.

Pressing out bonded rubber bush

– Position tools as shown in figure.

1- Nut - 3346/3-
2- Follower - 3390-
3- Sleeve - 3350-
4- Nut (commercially available)
5- Spindle - 3346/2-
– Pull out bonded rubber bush by turning spindle.
Installing
Pulling in bonded rubber bush

– Position tools as shown in figure.

1- Nut - 3346/3-
2- Press tool - 3346-
3- Bonded rubber bush
4- Fitting sleeve - 3378-
5- Nut (commercially available)
6- Spindle - 3346/2-
– Pull in bonded rubber bush by turning spindle.

Note

♦ Do not use lubricant.

♦ Insert bearing carefully so it does not cant.

– Fit cover plate.

– Install wheel bearing unit ⇒ page 171 .
Threaded connections on wheel bearing housing may be tight‐
ened only when dimension “a” has been obtained ⇒ page 136 .

170 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Tighten bolt -arrow- for lower transverse link -1-.

– Install coil spring ⇒ page 182 .
– Install brake disc.
– Attach brake carrier with brake caliper ⇒ Brake systems; Rep.
gr. 46 .
– Install wheel and tighten bolts or nuts ⇒ page 304 .

Specified torques
Component Specified torque
Lower transverse link to wheel bearing housing 70 Nm + 180° further
♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Splash plate to wheel bearing housing 12 Nm

Brake disc to wheel bearing housing. 8 Nm

6.3 Removing and installing wheel bearing unit

6. Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 171
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Special tools and workshop

equipment required

♦ Hub grease cap puller - VW 637/2-

♦ Fitting sleeve - 3241-
♦ Torque wrench - V.A.G 1332-
♦ Torque wrench - V.A.G 1410-
♦ Insert tool - T10162 A-
Perform the following steps:
Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.

172 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Loosen grease cap from seat by tapping lightly on claw of hub

grease cap puller - VW 637/2- -1-.

– Pry off grease cap.

1- Hub grease cap puller - VW 637/2-
– Remove brake carrier with brake caliper and tie to body with
wire ⇒ Brake systems; Rep. gr. 46 .

Note

Hang brake caliper from body.

– Remove bolt for brake disc and remove brake disc.

– Unscrew bolt -1- using socket - T10162- -2-.

Caution

Do not use an impact driver when removing bolt -1- with socket
- T10162 A- -2-!

– Unscrew bolt -1- using socket - T10162 A- .

– Pull wheel hub/wheel bearing unit -2- from stub axle.

Installing

6. Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 173
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Carefully push wheel hub/wheel bearing unit -2- onto stub

axle.

Caution

Ensure that the wheel hubs/wheel bearing unit does not cant!

– Screw in new bolt -1- and tighten to specified torque.

Note

♦ First tighten bolt to specified torque setting using torque

wrench.
♦ Use a rigid spanner for turning further by angle.

Caution

Do not use an impact driver when tightening bolt -1- with socket
- T10162 A- -2-!

– Drive in new grease cap -1-.

Always renew removed grease caps.
Damaged grease caps may allow moisture to enter the bearing.
Therefore, always use the tool shown in the illustration.
Continue installation in reverse order of removal.
– Install wheel and tighten bolts or nuts ⇒ page 304 .

Specified torques
Component Specified torque
Wheel hub with wheel bearing to wheel bearing housing 200 Nm + 90°
♦ Use new bolt

Brake disc to wheel bearing housing. 8 Nm

6.4 Removing and installing trailing arm with

mounting bracket
Special tools and workshop equipment required

174 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Torque wrench - V.A.G 1332-

♦ Support - T10149-

Perform the following steps:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove coil springs ⇒ page 182 .
– Remove holders -arrows- by pressing out inner pins of rivets.

6. Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 175
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unbolt coupling rod -1- from trailing arm.

– Unscrew bolts -arrows-.

– Remove line -1- from mounting bracket -arrow A-.

– Mark installation position of bearing bracket -2- on body.
– Unscrew bolts -arrows B-.
If the trailing arm is to be renewed, the mounting bracket must be
removed from the longitudinal member.

– Clamp trailing arm in a vice so that mounting bracket -1- lies

against vice -arrow-.
– Unscrew bolt -2-.
The position of the mounting bracket relative to the trailing arm
must then be adjusted ⇒ page 176 .
Determining position of mounting bracket in relation to trailing arm

Measure dimension -a- from middle of bolt to outer edge of

mounting bracket.
Dimension -a- is 57.5 ± 1 mm.
1- Mounting bracket
2- Trailing arm
– Tighten bolt when dimension -a- is set.
Installing
Threaded connection for trailing arm and wheel bearing housing
may be tightened only after all other components (particularly the
spring and shock absorber) of respective wheel suspension have
been installed. To tighten, wheel suspension must be in extended
position. Only then do trailing arm and wheel bearing housing
move to the necessary position -arrows-.

176 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Position: threaded connection between trailing arm and wheel

bearing housing
It is essential to follow specified sequence of work steps below!

– Position trailing arm and mounting bracket on wheel bearing

housing with bolts -arrows- but do not tighten yet.
– Attach coupling rod -1- to trailing arm but do not tighten nut
yet.
– Raise wheel suspension using engine and gearbox jack -
V.A.G 1383 A- until mounting bracket contacts body.

– Tighten bolts -arrows B- on position of old imprint.

– Mount line -1- on mounting bracket -arrows A-.
– Lower wheel suspension again with engine/gearbox jack -
V.A.G 1383 A- .
– Install coil spring ⇒ page 182 .

– Tighten trailing arm bolts -arrows- to prescribed torque. Make

sure components are in required position when doing this
⇒ page 177 .
– Tighten nut for coupling rod -1- on wheel bearing housing.

6. Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 177
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Mount holders -arrows- by pressing in inner pins of rivets.

– Install wheel and tighten bolts or nuts ⇒ page 304 .
– Perform wheel alignment ⇒ page 311 .

Specified torques
Component Specified torque
Trailing arm to wheel bearing housing 70 Nm + 90° further
♦ Use new bolts

Trailing arm to mounting bracket 90 Nm + 90°

♦ Use new bolt

Mounting bracket to body 50 Nm + 90° further

♦ Use new bolts

Coupling rod to trailing arm. 40 Nm

♦ Use new bolts

6.5 Repairing trailing arm

178 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Special tools and workshop

equipment required

♦ Thrust plate - VW 401-

♦ Thrust plate - VW 402-
♦ Removal tool - 3372-
♦ Assembly tool - T10230-
Perform the following steps:
Pressing out bonded rubber bush
– Remove trailing arm ⇒ page 174 .
– Clamp trailing arm in a vice so that mounting bracket -1- lies
against vice -arrow-.
– Unscrew bolt -2-.

6. Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 179
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Fit tools as shown in illustration.

1- Tube - T10230/3-
2- Press tool - T10230/10-
3- Removal tool - 3372-
4- Pressure plate - VW 401-
5- Pressure plate - VW 402-
– Press out bonded rubber bush.
Pressing in bonded rubber bush

Position bonded rubber bush as follows:

1- Make a connecting line between the gap -arrow A- and the
recess -arrow-, e.g. with a straightedge.
2- Locate the bonded rubber bush such that the upper right lug
-1- is to the left of the line.
3- The lower left lug -2- must then be to the right of the con‐
necting line.

Note

Take great care to ensure that the installation position of the bon‐
ded rubber bush is correct relative to the bush in the trailing arm.

– Fit tools as shown in illustration.

1- Tube - T10230/5-
2- Thrust plate - T10230/12- (chamfer must face bonded rub‐
ber bush)
3- Bonded rubber bush
4- Removal tool - 3372-
5- Pressure plate - VW 402-
– Press bonded rubber bush in flush.
– Attach mounting bracket to trailing arm ⇒ page 176 .
– Install trailing arm ⇒ page 176 .

180 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

7 Assembly overview: shock absorber, coil spring (front-wheel drive)

Note

Assembly overview: shock absorber for adaptive chassis control DCC (front-wheel drive) ⇒ page 289

1 - Lower spring seat

❑ End of coil spring turned
to stop
2 - Assembly aid
❑ Not necessary to rein‐
stall once removed
3 - Coil spring
❑ Take different running
gear designs into ac‐
count ⇒ page 322 .
❑ Removing and installing
⇒ page 182

Note

Note information for conversion to

Nivomat under all circumstances
⇒ page 182 .

4 - Upper spring seat

5 - Bolt
❑ 130 Nm + 90° further
❑ Renew after each re‐
moval
6 - Bolt
❑ 50 Nm + 90° further
❑ Renew after each re‐
moval
7 - Shock absorbers
❑ Removing and installing
⇒ page 184
❑ Take different running
gear designs into ac‐
count ⇒ page 322 .

Note

Note information for conversion to

Nivomat under all circumstances
⇒ page 182 .

8 - Washer
9 - Lower transverse link
❑ Removing and installing ⇒ page 159
10 - Wheel bearing housing
❑ Removing and installing ⇒ page 165

7. Assembly overview: shock absorber, coil spring (front-wheel drive) 181

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

7.1 Converting to Nivomat

Observe the following important points when converting the rear
axle to Nivomat
♦ Only convert vehicles with standard running gear. Other run‐
ning gears must not be converted to Nivomat.
♦ The Nivomat shock absorber and the respective coil spring
must be fitted to both sides of the vehicle ⇒ electronic parts
catalogue “ETKA”
Further information for the Nivomat can be found in ⇒ Self-study
programme No. 357 ; The Nivomat .

7.2 Removing and installing coil spring

Special tools and workshop equipment required
♦ Suspension strut clamp - V.A.G 1752-

♦ Spring retainer - V.A.G 1752/3A-

♦ Adapter - V.A.G 1752/9- , not illustrated

Perform the following steps:
Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.

182 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Insert spring compressor -3-.

1- Spring retainer - V.A.G 1752/3A-
2- Adapter - V.A.G 1752/9-
3- Spring compressor - V.A.G 1752/1-

WARNING

Ensure that coil spring is correctly seated in spring retainers -

V.A.G 1752/3A- -2-.

– Compress coil springs until they can be removed.

Note

Use a spanner or a reversible ratchet handle to compress spring

compressor.

Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:
– Check that the lower spring plate is not damaged.
– If necessary, renew lower spring plate.

– Place lower plate onto bottom of coil spring.

End of spring -arrow- must contact stop in lower spring seat.
– Mount spring together with spring plate.
– The spring seat has a lug.

– Insert this pin in holes in lower transverse link -arrow-.

7. Assembly overview: shock absorber, coil spring (front-wheel drive) 183

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Insert upper spring seat into upper end of spring.

– The bead of the spring seat -arrow- must lie against the coil
spring correctly.
– Release tension on coil spring while locating upper spring seat
on lug on body.
– Remove spring compressor .
– Install wheel and tighten bolts or nuts ⇒ page 304 .

7.3 Removing and installing shock absorb‐

ers

Note

Removing and installing shock absorber for adaptive chassis

control DCC (front-wheel drive) ⇒ page 291

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1332-

Perform the following steps:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove rear wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liners .
– Remove coil springs ⇒ page 182 .

184 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove bolts -1- for shock absorber -2-.

– Unscrew screw -arrow-.

– Remove shock absorber.
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:
The shock absorber may be bolted to the wheel bearing housing
only when dimension “a” has been attained ⇒ page 136 .

– Install shock absorber -2- and tighten bolts -1-.

– Tighten bolt -arrow- .

– Install coil spring ⇒ page 182 .
– Install rear wheel housing liner ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liners
– Install wheel and tighten bolts or nuts ⇒ page 304 .

Specified torques
Component Specified torque
Shock absorber to body 50 Nm + 90° further
♦ Use new bolts

Shock absorber to wheel bearing housing 180 Nm

♦ Use new bolt

7. Assembly overview: shock absorber, coil spring (front-wheel drive) 185

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

7.4 Repairing shock absorber

Note

Repairing shock absorber for adaptive chassis control DCC (front-wheel drive) ⇒ page 293

1 - Shock absorbers
❑ Removing and installing
⇒ page 184
❑ Take different running
gear designs into ac‐
count ⇒ page 322 .
2 - Cap
3 - Protective tube
4 - Support ring
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
5 - Buffer stop
❑ For shock absorbers
with support ring
⇒ Item 4 (page 186)
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
6 - Shock absorber mounting
❑ For shock absorbers
with support ring
⇒ Item 4 (page 186)
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
7 - Nut
❑ 25 Nm
❑ Renew after each re‐
moval
❑ Loosening and tighten‐
ing ⇒ page 187
8 - Cover
9 - Shock absorber mounting
❑ For shock absorbers without support ring ⇒ Item 4 (page 186)
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
10 - Buffer stop
❑ For shock absorbers without support ring ⇒ Item 4 (page 186)
❑ Allocation ⇒ Electronic parts catalogue “ETKA”

186 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Dismantling and assembling shock absorber

Special tools and work‐
shop equipment re‐
quired
♦ Torque wrench -
V.A.G 1332-

♦ Shock absorber tool

set - T10001-

Loosening and tighten‐

ing threaded connection
for shock absorber
mounting
1- Commercially
available ratchet
handle
2- Insert - T10001/9-
3- Ratchet wrench -
T10001/11-
4- Insert - T10001/1-

Specified torque
Component Specified torque
Shock absorber mounting to shock absorber 25 Nm
♦ Use new bolts

7. Assembly overview: shock absorber, coil spring (front-wheel drive) 187

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

8 Assembly overview: anti-roll bar (front-wheel drive)

1 - Anti-roll bar
❑ Take different running
gear designs into ac‐
count ⇒ page 322 .
❑ Removing and installing
⇒ page 188
2 - Mountings
❑ Always renew mount‐
ings/bushes on both
sides of vehicle
3 - Clip
4 - Bolt
❑ 20 Nm + 90° further
❑ Tighten evenly
❑ Renew after each re‐
moval
5 - Wheel bearing housing
6 - Nut
❑ 45 Nm
❑ Self-locking
❑ Renew after each re‐
moval
❑ When tightening, coun‐
terhold on multi-point
socket of bolt
⇒ Item 7 (page 188)
7 - Bolt
8 - Coupling rod
❑ Connects anti-roll bar to
trailing arm and wheel
bearing housing
9 - Subframe

8.1 Removing and installing anti-roll bar

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

188 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Removing

Note

The following procedure is for the left side of the vehicle. The
procedure for the right side of the vehicle is identical.

– Remove nut -1- and pull coupling rod -2- from anti-roll bar.

Note

Do not loosen bolt -arrow- for track rod -3-.

– Remove bolts -arrows- for anti-roll bar clamp.

– Remove anti-roll bar.
Installing
– Insert anti-roll bar into vehicle.

– Evenly tighten bolts -arrows- for anti-roll bar clamp.

– Connect coupling rod -2- to anti-roll bar and tighten nut -1-.

8. Assembly overview: anti-roll bar (front-wheel drive) 189

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Specified torques
Component Specified torque
Anti-roll bar to subframe 20 Nm + 90° further
♦ Use new bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Anti-roll bar to coupling rod 45 Nm

♦ Use new bolts

190 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

9 Rear axle in unladen position (four-wheel drive)

Special tools and workshop

equipment required

♦ Engine and gearbox jack - V.A.G 1383 A-

♦ Tensioning strap - T10038-
♦ Support - T10149-

Note

All bolts on running gear components with bonded rubber bushes

may be tightened only when the component is in the unladen po‐
sition (normal position).

Bonded rubber bushes can be twisted only to a limited extent.

Axle components with bonded rubber bushes must therefore be
brought to a position equivalent to the unladen (normal) position
before being tightened.
Otherwise, the bonded rubber bush would be subject to torsion
loading, shortening its service life.

9. Rear axle in unladen position (four-wheel drive) 191

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

To simulate this position on the lifting platform, raise the axle on

one side using the engine and gearbox jack - V.A.G 1383 A- and
support - T10149- .
Before the axle on one side is raised, both sides of the vehicle
must be strapped to the lifting platform arms with tensioning
straps - T10038- .

WARNING

If the vehicle is not strapped down, there is a danger that the

vehicle will slip off the lifting platform!

– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- with a wheel bolt.
Threaded connections may be tightened only when dimension
-a- between the centre of wheel hub and lower edge of wheel
housing, measured before starting work, has been attained.

Measuring dimension -a-

The dimension -a- depends on the ride height of the installed run‐
ning gear:

Running gear 1) Ride height -a- in mm

Standard running gear (G02) 428 ± 10 mm
Standard running gear with 418 ± 10 mm
adaptive chassis control DCC
(G40)
Sports running gear (G03) 393 ± 10 mm
Blue Motion (G40) 418 ± 10 mm
Fully automatic ride height set‐ 418 ± 10 mm
ting (G02+1JH)
Lowered standard running gear 420 ± 10 mm
Mobile service 420 ± 10 mm
ADAC 408 ± 10 mm
1)The type of running gear fitted to the vehicle is recorded on the
vehicle data sticker. The running gear is identified by the PR
number. Which PR No. is allocated to which running gear can be
found here ⇒ page 314 .
– Raise wheel bearing housing using engine and gearbox jack
until dimension -a- is attained.

WARNING

♦ Never raise or lower the vehicle while the engine and

gearbox jack is positioned beneath the vehicle.
♦ Do not leave the engine and gearbox jack under the ve‐
hicle for longer than necessary.

– Tighten respective nuts and bolts.

– Lower wheel bearing housing.
– Pull engine and gearbox jack out from underneath vehicle.
– Remove support - T10149- .

192 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

10 Overview of rear axle (four-wheel drive)

Note

♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

♦ Always renew self-locking nuts.
♦ Always renew corroded nuts and bolts.
♦ Bonded rubber bushes can be twisted only to a limited extent. Therefore, tighten the bolted connections of
components with bonded rubber bushes only when the wheel bearing housing is raised to unladen position
⇒ page 191 .
♦ Always renew bonded rubber bush on both sides of the vehicle.

I - Assembly overview: sub‐

frame, final drive (four-wheel
drive) ⇒ page 195
II - Assembly overview: trans‐
verse link, track rod (four-
wheel drive) ⇒ page 213

10. Overview of rear axle (four-wheel drive) 193

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

III - Assembly overview: wheel

bearing housing, trailing arm
(four-wheel drive)
⇒ page 225
IV - Assembly overview: shock
absorber, coil spring (four-
wheel drive) ⇒ page 241
IV - Assembly overview: shock
absorber for adaptive chassis
control DCC (four-wheel drive)
⇒ page 296
V - Assembly overview: anti-
roll bar (four-wheel drive)
⇒ page 248

194 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

11 Assembly overview: subframe, final drive (four-wheel drive)

The -arrow- points in direction of travel.

1 - Subframe
2 - Rear bonded rubber bush
❑ Renewing ⇒ page 145
3 - Front bonded rubber bush
❑ Renewing ⇒ page 145
4 - Final drive
❑ Removing and installing
⇒ Rep. gr. 39 ; Remov‐
ing and installing rear fi‐
nal drive
5 - Bolt
❑ 60 Nm + 90° further
❑ Renew after each re‐
moval
6 - Washer
❑ Installed between final
drive and subframe
7 - Washer
❑ Washer must be placed
with holes on lugs of
bonded rubber bush.
8 - Bolt
❑ 60 Nm + 90° further
❑ Renew after each re‐
moval

11.1 Fixing position of subframe

Special tools and workshop equipment required
♦ Locating pins - T10096-

11. Assembly overview: subframe, final drive (four-wheel drive) 195

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Engine and gearbox jack - V.A.G 1383 A-

Perform the following steps:

Installing locating pins - T10096-
– Position engine and gearbox jack - V.A.G 1383 A- underneath
subframe and secure with tensioning strap.

To fix position of subframe, locating pins - T10096- must be

screwed in successively at positions -1- and -2- on both sides of
vehicle.
– Unscrew one hexagon bolt -1- or -2- on both sides.

Note

Only the left side of vehicle is shown to improve clarity.

– Secure position of subframe with locating pins - T10096- .

Note

The locating pins - T10096- may be tightened only to a maximum

of 20 Nm; otherwise the threads of the locating pins may be dam‐
aged.

– Replace securing bolts on subframe with locating pins -

T10096- one after the other on both sides of the vehicle and
tighten to 20 Nm.
The position of the subframe is now fixed.

11.2 Lowering rear axle

Special tools and workshop equipment required

196 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Torque wrench - V.A.G 1332-

♦ Engine and gearbox jack - V.A.G 1383 A-

Perform the following steps:

Lowering subframe with attachments
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheels.
– Unbolt brake calipers on both sides of vehicle and suspend
from body.
– Remove coil springs ⇒ page 242 .
– Remove rear silencer of exhaust system ⇒ Rep. gr. 26 ; Ex‐
haust system; Removing and installing parts of the exhaust
system .
Vehicles with rear left vehicle level sender - G76-
– Disconnect connector -1-.
Continued for all vehicles

11. Assembly overview: subframe, final drive (four-wheel drive) 197

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unclip speed sensor wire from retainer -1- -arrows-.

– Unclip brake lines -1- from bracket -arrow- on left of body.

– Pull retaining clip -2- from subframe -3- and detach brake
hose.

Note

Do not open brake line.

– Remove propshaft ⇒ Propshaft and rear final drive; Rep. gr.

39 .

– Secure vehicle to support arms of lifting platform on both sides

using tensioning straps - T10038- .
1- Tensioning strap - T10038-

WARNING

If the vehicle is not strapped down, it may slip off the lifting
platform.

– Fix position of subframe ⇒ page 195 .

– Carefully lower subframe with attachments about 2 cm.
– Separate connector on Haldex clutch above final drive.

– Unclip brake line on left side -arrow-.

– Unclip brake line above left drive shaft flange.

Note

The clips will be destroyed and must be renewed.

– Lower subframe with attachments about 140 mm.

Installing subframe with attachments
Install in reverse order. During this procedure, observe the fol‐
lowing:
– Install propshaft ⇒ Propshaft and rear final drive; Rep. gr. 39 .
– Fit wheels, torque setting ⇒ page 304 .

198 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Specified torques
Component Specified torque
Subframe to body 70 Nm + 180° further
♦ Use new bolts

11.3 Removing and installing rear axle

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

♦ Engine and gearbox jack - V.A.G 1383 A-

Perform the following steps:

Removing subframe with attachments
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheels.
– Remove coil springs ⇒ page 242 .
– Remove rear silencer of exhaust system ⇒ Rep. gr. 26 ; Ex‐
haust system; Removing and installing parts of the exhaust
system .

11. Assembly overview: subframe, final drive (four-wheel drive) 199

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Vehicles with rear left vehicle level sender - G76-

– Disconnect connector -1-.
Continued for all vehicles

– Unclip speed sensor wire on both sides from bracket -1-

-arrows-.
– Disconnect connectors for rear right speed sensor - G44- and
rear left speed sensor - G46- .

– Unscrew screw -arrow-.

– Unclip brake lines -1- from bracket -arrow- on left of body.

– Pull retaining clip -2- from subframe -3- and detach brake
hose.

Note

Do not open brake line.

– Disconnect connectors of electric parking brake at brake cal‐

iper.
– Remove brake calipers on both sides and tie to body with wire
⇒ Brake systems; Rep. gr. 46 ; Rear brake; Assembly over‐
view - rear brake .

200 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove holders -arrows- by pressing out inner pins of rivets.

– Disconnect connector for rear left vehicle level sender - G76- .

– Secure vehicle to support arms of lifting platform on both sides

using tensioning straps - T10038- .
1- Tensioning strap - T10038-

– Disconnect pendulum support from gearbox by removing bolts

-14-.

– Push engine and gearbox forwards and secure in position with

a suitable piece of wood -A-.

11. Assembly overview: subframe, final drive (four-wheel drive) 201

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Check whether marks (spots of paint) are present on flexible

coupling and final drive flange -arrows-. If no marks are
present, mark positions of flexible coupling and final drive
flange relative to each other -arrows-.

– Unbolt rear propshaft tube with flexible coupling and vibration

damper from rear final drive -arrows-.

Note

To loosen and tighten propshaft, counter-hold on bevel box using

counter-hold tool - T10172- and adapters - T10172/5- . This re‐
quires the assistance of a second mechanic.

– Unscrew bolts for centre bearing -arrows- two turns.

– Support propshaft -A- on tunnel support -1- using a wooden

block.
– Push rear propshaft tube as far as possible in direction of
gearbox.

202 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– When pulling off propshaft, always ensure that bushing

-arrow- is not damaged.
– Separate connector on Haldex clutch above final drive.
– Fix position of subframe ⇒ page 195 .

– Remove line -1- from mounting bracket -arrow A-.

– Mark installation position of bearing bracket -2- on body.
– Unscrew bolts -arrows B-.
– Carefully lower subframe with attachments about 2 cm.

– Unclip brake lines on both sides -arrow-.

Note

The clips will be destroyed and must be renewed.

11. Assembly overview: subframe, final drive (four-wheel drive) 203

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unclip brake line from clips -arrows- above drive shaft flange
on gearbox -1-.

Note

The clips will be destroyed and must be renewed.

– Carefully lower subframe with attachments.

Note

When lowering, ensure sufficient clearance to brake lines, elec‐

trical cables and centring pin to propshaft.

Installing subframe with attachments

Install in reverse order. During this procedure, observe the fol‐
lowing:

Note

Renew the damaged brake line clips on the subframe.

– When connecting propshaft, always ensure that bushing

-arrow- is not damaged.
Attach propshaft to rear final drive ⇒ Propshaft and rear final
drive; Rep. gr. 39 .

Specified torques
Component Specified torque
Subframe to body 70 Nm + 180° further
♦ Use new bolts

Shock absorber to wheel bearing housing 180 Nm

Mounting bracket to body 50 Nm + 90° further
♦ Use new bolts

11.4 Repairing subframe

204 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Special tools and workshop

equipment required

♦ Tensioning strap - T10038-

♦ Locating pins - T10096-
♦ Assembly tool - T10263-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Hydraulic press - VAS 6178- and thrust piece - T10205/13-
♦ Foot pump - VAS 6179-
Pressing out front bonded rubber bush ⇒ page 205
Pressing in front bonded rubber bush ⇒ page 207
Pressing out rear bonded rubber bush ⇒ page 209
Pressing in rear bonded rubber bush ⇒ page 211
Pressing out front bonded rubber bush
– Loosen wheel bolts.
– Raise vehicle.
– Remove rear wheels.
– Remove coil springs ⇒ page 242 .

11. Assembly overview: subframe, final drive (four-wheel drive) 205

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove rear silencer of exhaust system ⇒ Rep. gr. 26 ; Ex‐

haust system; Removing and installing parts of the exhaust
system .
– Disconnect electrical connections between rear axle and
body.
– Remove anti-roll bar ⇒ page 248 .
– Remove track rods ⇒ page 221 .
– Pull out clip -1-.

Note

Do not open brake line.

– Secure vehicle to support arms of lifting platform on both sides

using tensioning straps - T10038- .
1- Tensioning strap - T10038-

– Position engine and gearbox jack - V.A.G 1383 A- underneath

subframe and secure with tensioning strap.

– Remove one hexagon bolt -2- on each side.

Note

Only the left side of vehicle is shown to improve clarity.

To fix position of subframe, locating pins - T10096- must be

screwed in successively at positions -2- on both sides of vehicle.

206 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Secure position of subframe with locating pins - T10096- .

Note

The locating pins - T10096- may be tightened only to a maximum

of 20 Nm; otherwise the threads of the locating pins may be dam‐
aged.

– Replace securing bolts on subframe with locating pins -

T10096- one after the other on both sides of the vehicle and
tighten to 20 Nm.
The position of the subframe is now fixed.
– Lower subframe 10 cm using engine and gearbox jack - V.A.G
1383 A- .
– Mark installation position of bonded rubber bush in relation to
subframe, for example using a felt-tip pen.

– Fit tools as shown in illustration.

1 - Nut - T10263/5-
2 - Washer , from -T10263-
3 - Tube - T10263/6-
4 - Hydraulic press - VAS 6178- and thrust piece - T10205/13-
5 - Nut - T10263/5-
6 - Spindle - T10263/4-
– Take up play in special tools.
– Press out bonded rubber bush.

Note

The outer ring of the bush shears off when the bonded rubber
bush is pressed out. This occurs with a loud bang.

– The bonded rubber bush must be removed from the tube -

T10356/6- once the bush has been pressed out.
– Clamp tube - T10356/6- on the intended surfaces in a vice.
– Insert a screwdriver between tube - T10356/6- and bonded
rubber bush and lever bush out of tube -arrow-. If necessary,
apply a drift to bush and drive out with light hammer blows.
Pressing in front bonded rubber bush
Install in reverse order. During this procedure, observe the fol‐
lowing:

11. Assembly overview: subframe, final drive (four-wheel drive) 207

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Distinguishing features of bonded rubber bushes

I - Front bonded rubber bush
II - Rear bonded rubber bush
The front bonded rubber bushes have two notches on the upper
side -arrows- and differ to the rear slightly in height ⇒ Electronic
parts catalogue “ETKA” .
The bonded rubber bush must be installed in a certain direction;
note mark on subframe.

– Insert bonded rubber bush -1- in subframe so that the nose

and the plate -arrows- face perpendicular to direction of travel.
– Apply thrust piece - T10263/3- -2- so that flattened sides also
face perpendicular to direction of travel.

208 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Set up special tools with bonded rubber bush on subframe as

shown.
1 - Nut - T10263/5-
2 - Press tool - T10263/3-
3 - Bonded rubber bush
4 - Press tool - T10263/2-
5 - Hydraulic press - VAS 6178- and thrust piece - T10205/13-
6 - Nut - T10263/5-
7 - Spindle - T10263/4-
– Take up play in special tools and bonded rubber bush.
– Operate pump to press bonded rubber bush in until collar lies
»flush« on subframe.
– Install track rods ⇒ page 221 .
– Install anti-roll bar ⇒ page 248 .
– Join electrical connections between rear axle and body.
– Install rear silencer of exhaust system ⇒ Rep. gr. 26 ; Exhaust
system; Removing and installing parts of the exhaust system .
– Install coil springs ⇒ page 242 .
– Install wheels and tighten bolts or nuts ⇒ page 304 .
Pressing out rear bonded rubber bush
– Loosen wheel bolts.
– Raise vehicle.
– Remove rear wheels.
– Remove coil springs ⇒ page 242 .
– Remove rear silencer of exhaust system ⇒ Rep. gr. 26 ; Ex‐
haust system; Removing and installing parts of the exhaust
system .

– Pull out clip -1-.

Note

Do not open brake line.

11. Assembly overview: subframe, final drive (four-wheel drive) 209

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Secure vehicle to support arms of lifting platform on both sides

using tensioning straps - T10038- .
1- Tensioning strap - T10038-

– Position engine and gearbox jack - V.A.G 1383 A- underneath

subframe and secure with tensioning strap.

– Remove one hexagon bolt -1- on each side.

Note

Only the left side of vehicle is shown to improve clarity.

To fix position of subframe, locating pins - T10096- must be

screwed in successively at positions -1- on both sides of vehicle.

– Secure position of subframe with locating pins - T10096- .

Note

The locating pins - T10096- may be tightened only to a maximum

of 20 Nm; otherwise the threads of the locating pins may be dam‐
aged.

– Replace securing bolts on subframe with locating pins -

T10096- one after the other on both sides of the vehicle and
tighten to 20 Nm.
The position of the subframe is now fixed.
– Lower subframe 10 cm using engine and gearbox jack - V.A.G
1383 A- .
– Mark installation position of bonded rubber bush in relation to
subframe, for example using a felt-tip pen.

210 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Fit tools as shown in illustration.

1 - Nut - T10263/5-
2 - Washer , from -T10263-
3 - Tube - T10263/6-
4 - Hydraulic press - VAS 6178- and thrust piece - T10205/13-
5 - Nut - T10263/5-
6 - Spindle - T10263/4-
– Take up play in special tools.
– Press out bonded rubber bush by operating the pump.

Note

The outer ring of the bush shears off when the bonded rubber
bush is pressed out. This occurs with a loud bang.

– The bonded rubber bush must be removed from the tube -

T10356/6- once the bush has been pressed out.
– Clamp tube - T10356/6- on the intended surfaces in a vice.
– Insert a screwdriver between tube - T10356/6- and bonded
rubber bush and lever bush out of tube -arrow-. If necessary,
apply a drift to bush and drive out with light hammer blows.
Pressing in rear bonded rubber bush
Install in reverse order. During this procedure, observe the fol‐
lowing:

Distinguishing features of bonded rubber bushes

I - Front bonded rubber bush
II - Rear bonded rubber bush
The front bonded rubber bushes have two notches on the upper
side -arrows- and differ to the rear slightly in height ⇒ Electronic
parts catalogue “ETKA” .
The bonded rubber bush must be installed in a certain direction;
note mark on subframe.

11. Assembly overview: subframe, final drive (four-wheel drive) 211

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Insert bonded rubber bush -1- in subframe so that the nose

and the plate -arrows- face perpendicular to direction of travel.
– Apply thrust piece - T10263/3- -2- so that flattened sides also
face perpendicular to direction of travel.

– Set up special tools with bonded rubber bush on subframe as

shown.
1 - Nut - T10263/5-
2 - Press tool - T10263/3-
3 - Bonded rubber bush
4 - Press tool - T10263/2-
5 - Hydraulic press - VAS 6178- and thrust piece - T10205/13-
6 - Nut - T10263/5-
7 - Spindle - T10263/4-
– Take up play in special tools and bonded rubber bush.
– Carefully operate pump to press bonded rubber bush in until
collar lies »flush« on subframe.
– Install rear silencer of exhaust system ⇒ Rep. gr. 26 ; Exhaust
system; Removing and installing parts of the exhaust system .
– Install coil springs ⇒ page 242 .
– Install rear wheels and tighten bolts or nuts ⇒ page 304 .

Specified torques
Component Specified torque
Subframe to body 70 Nm + 180° further
♦ Use new bolts

212 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

12 Assembly overview: transverse link, track rod (four-wheel drive)

The -arrow- points in direction of travel.

1 - Eccentric bolt
❑ Check wheel alignment
whenever this compo‐
nent is loosened
⇒ page 311 .
❑ Do not turn more than
90° in either direction
(i.e. from minimum to
maximum adjustment
position).
2 - Nut
❑ M12 × 1.5
❑ 95 Nm
❑ Self-locking
❑ Can be loosened and
tightened up to 5 times
for adjustment work.
❑ Renew after each re‐
moval
❑ Always tighten threaded
connections in unladen
position ⇒ page 191
3 - Eccentric washer
❑ Inner hole with lug
4 - Eccentric bolt
❑ Check wheel alignment
whenever this compo‐
nent is loosened
⇒ page 311 .
❑ Do not turn more than
90° in either direction
(i.e. from minimum to
maximum adjustment
position).

Note

The eccentric bolt can also be in‐

stalled facing the rear.

5 - Eccentric washer
❑ Inner hole with lug
6 - Nut
❑ 95 Nm
❑ Self-locking
❑ Can be loosened and tightened up to 5 times for adjustment work.
❑ Renew after each removal
❑ Always tighten threaded connections in unladen position ⇒ page 191

Note

♦ To tighten nuts, set torque

wrench - V.A.G 1332- to 80 Nm.

12. Assembly overview: transverse link, track rod (four-wheel drive) 213
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ This torque setting only applies

in conjunction with 18 mm tool
insert - T10179- .

7 - Subframe
❑ Repairing ⇒ page 204
8 - Bolt
❑ 70 Nm + 180° further
❑ Renew after each removal
9 - Lower transverse link
❑ Removing and installing ⇒ page 219
10 - Nut
❑ 70 Nm + 180° further
❑ Self-locking
❑ Renew after each removal
❑ Always tighten threaded connections in unladen position ⇒ page 191
11 - Bolt
❑ M12 x 1.5 x 75
❑ Renew after each removal
12 - Threaded rivet
❑ M6
13 - Spreader rivet
14 - Stone deflector
15 - Hexagon bolt
❑ 8 Nm
16 - Nut
❑ Self-locking
❑ Renew after each removal
❑ Always tighten threaded connections in unladen position ⇒ page 191
17 - Washer
18 - Bolt
❑ 130 Nm + 180° further
❑ Renew after each removal
❑ Always tighten threaded connections in unladen position ⇒ page 191
19 - Washer
20 - Upper transverse link
❑ Removing and installing ⇒ page 217
21 - Washer
22 - Nut
❑ Self-locking
❑ Renew after each removal
23 - Wheel bearing housing
❑ Removing and installing ⇒ page 226
24 - Washer
25 - Bolt
❑ 130 Nm + 180° further
❑ Renew after each removal

214 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019
❑ Always tighten threaded connections in unladen position ⇒ page 191
26 - Track rod
❑ Forwards closed (left and right track rods differ)
❑ Removing and installing ⇒ page 221
27 - Bolt
❑ 70 Nm + 180° further
❑ Renew after each removal
28 - Bolt
❑ Renew after each removal
❑ Always tighten threaded connections in unladen position ⇒ page 191
29 - Nut
❑ 70 Nm + 180° further
❑ Self-locking
❑ Renew after each removal

12. Assembly overview: transverse link, track rod (four-wheel drive) 215
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

12.1 Assembly overview: rear left vehicle level sender - G76-

Note

♦ Assembly overview: rear left vehicle level sender - G76- for adaptive chassis control DCC, four-wheel drive
⇒ page 271
♦ The rear left vehicle level sender - G76- is only available as a replacement part complete with coupling rod
and upper and lower retaining plates.

1 - Bolt
❑ M5 x 20
❑ 5 Nm
2 - Pop rivet nut
3 - Subframe
4 - Rear left vehicle level send‐
er - G76-
❑ Complete with attach‐
ments
❑ Lever -arrow- must face
outwards
❑ Removing and installing
⇒ page 216
❑ Following renewal, ba‐
sic settings for headlight
must be performed.
Checking basic setting of
headlights ⇒ Vehicle diagnos‐
tic tester

5 - Lower transverse link

12.2 Removing and installing rear left vehicle

level sender - G76-
Special tools and workshop equipment required

216 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Torque wrench - V.A.G 1331-

Note

Removing and installing rear left vehicle level sender - G76- for
adaptive chassis control DCC, four-wheel drive ⇒ page 272

Removing
– Disconnect connector -1-.
– Remove bolts -2- from lower transverse link.
– Remove subframe bolts -3-.
– Remove rear left vehicle level sender - G76- .
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:
The lever of rear left vehicle level sender - G76- must face outside
of vehicle.
– Perform basic setting of headlights following replacement
⇒ Vehicle diagnostic tester.

Specified torques
Component Specified torque
Rear left vehicle level sender - G76- to lower transverse 5 Nm
link and subframe

12.3 Removing and installing upper trans‐

verse link
Special tools and workshop equipment required

12. Assembly overview: transverse link, track rod (four-wheel drive) 217
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Torque wrench - V.A.G 1332-

Perform the following steps:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove coil springs ⇒ page 242 .
– Detach wire -arrow A- for speed sensor from upper suspen‐
sion link.
– Unscrew bolt -1-.

– Mark position of eccentric bolt -arrow- in relation to subframe,

for example using a felt-tip pen.
– Unscrew screw -arrow-.
– Remove upper transverse link -1-.
Installing
– Insert upper suspension link into vehicle and tighten bolts
hand-tight.
Transverse link may be bolted only when dimension “a” has been
attained ⇒ page 192 .

– Tighten new nut -arrow- to specified torque only.

218 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– To do so, use insert tool 18 mm - T10179- .

On use of insert tool 18 mm - T10179- , tighten nuts to 80 Nm.
– Observe mark made for position of eccentric bolt -arrow- rel‐
ative to subframe.

– Tighten bolt -1- for upper transverse link.

Note

Ensure that a washer is installed between the bolt and the wheel
bearing housing.

– Attach wire -arrow A- for speed sensor to upper suspension

link.
– Install coil spring ⇒ page 243 .
– Install wheel and tighten bolts or nuts ⇒ page 304 .
– Perform wheel alignment ⇒ page 311 .

Specified torques
Component Specified torque
Upper transverse link to wheel bearing housing 130 Nm + 180° further
♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Upper transverse link to subframe 95 Nm

♦ Use new bolts ♦ To tighten nuts, set torque wrench - V.A.G
1332- to 80 Nm.
♦ Tighten threaded connections only when vehicle is in
the normal running position ♦ Applies only in conjunction with insert tool,
18 mm - T10179-

12.4 Removing and installing lower trans‐

verse link
Special tools and workshop equipment required

12. Assembly overview: transverse link, track rod (four-wheel drive) 219
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Torque wrench - V.A.G 1332-

Perform the following steps:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove coil spring ⇒ page 242 .
– Remove bolt -arrow- for lower transverse link -1-.

Vehicles with dynamic headlight range control

– Remove bolts -1- from lower transverse link.
Continued for all vehicles
– Mark position of eccentric bolt -arrow- in relation to subframe,
for example using a felt-tip pen.
– Disconnect and lower rear part of exhaust system.
– Unscrew screw -arrow-.
– Remove lower transverse link.
Installing
– Insert lower transverse link into vehicle and hand-tighten bolts.
Transverse link may be bolted only when dimension “a” has been
attained ⇒ page 192 .

220 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Tighten new nut -arrow- to specified torque only.

– Observe mark made for position of eccentric bolt -arrow- rel‐
ative to subframe.
– Reinstall rear section of exhaust system.
Vehicles with dynamic headlight range control
– Install bolts -1- in lower transverse link.
Continued for all vehicles

– Tighten bolt -arrow- for lower transverse link -1-.

– Install coil spring ⇒ page 243 .
– Install wheel and tighten bolts or nuts ⇒ page 304 .
– Perform wheel alignment ⇒ page 311 .

Specified torques
Component Specified torque
Lower transverse link to wheel bearing housing 70 Nm + 180° further
♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Lower transverse link to subframe 95 Nm

♦ Use new bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Rear left vehicle level sender - G76- to lower transverse 5 Nm

link

12.5 Removing and installing track rod

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

12. Assembly overview: transverse link, track rod (four-wheel drive) 221
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Torque wrench - V.A.G 1332-

Perform the following steps:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove coil springs ⇒ page 242 .
– Remove nut -1- and pull coupling rod -2- from anti-roll bar.
– Remove bolt -arrow- for track rod -3-.

– Remove bolts -arrows- for anti-roll bar clamp.

If the upper bolt of the anti-roll bar clamp on the right side of the
vehicle cannot be removed, then additional work must be per‐
formed ⇒ page 222 .
For the right side of the vehicle only (depending on equipment)
Continued for all vehicles

– Secure vehicle to support arms of lifting platform on both sides

using tensioning straps - T10038- .
1- Tensioning strap - T10038-

WARNING

If the vehicle is not strapped down, it may slip off the lifting
platform.

222 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Attach support - T10149- to wheel hub using wheel bolt.

– Raise wheel hub with support - T10149- and engine and gear‐
box jack - V.A.G 1383 A- far enough that bolts of right anti-roll
bar clamp are accessible.
Continuation for both sides of vehicle

– Remove nut -arrow- and remove bolt towards rear.

– Remove track rod -1-.
Installing
– Install track rod on vehicle and tighten bolts hand tight.

Note

Note different versions of track rods: downwards open or forwards

closed.

The track rod may be bolted only when distance “a” has been
attained ⇒ page 192 .

– Insert track rod -1- into vehicle and hand-tighten bolts.

The track rod may be bolted only when distance “a” has been
attained ⇒ page 136 .
– Tighten new nut -arrow- to specified torque only.

– Tighten bolts -arrows- for anti-roll bar clamp.

12. Assembly overview: transverse link, track rod (four-wheel drive) 223
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Tighten bolt -arrow- for track rod -3-.

Note

Ensure that a washer is installed between the nut and the wheel
bearing housing.

– Connect coupling rod -2- to anti-roll bar and tighten nut -1-.
– Install coil spring ⇒ page 243 .
– Install wheel and tighten bolts or nuts ⇒ page 304 .
– Perform wheel alignment ⇒ page 311 .

Specified torques
Component Specified torque
Track rod to wheel bearing housing 130 Nm + 180° further
♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Track rod to subframe 90 Nm + 90° further

♦ Use new nuts and bolts

Anti-roll bar to subframe 20 Nm + 90° further

♦ Use new bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Anti-roll bar to coupling rod 45 Nm

♦ Use new bolts

224 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

13 Assembly overview: wheel bearing housing, trailing arm (four-wheel

drive)
The -arrow- points in direction of travel.

1 - Cover
2 - Mounting bracket
3 - Coupling rod
❑ Connects anti-roll bar to
trailing arm and wheel
bearing housing
4 - Bolt
❑ 90 Nm + 45° further
❑ Observe tightening se‐
quence ⇒ page 236
❑ Renew after each re‐
moval
5 - Trailing arm
❑ Removing and installing
⇒ page 234
❑ Repairing ⇒ page 237
6 - Drive shaft
❑ Assembly overview
⇒ page 251
❑ Removing and installing
⇒ page 253
7 - Multi-point socket head bolt
❑ M14 x 1.5 x 45
❑ 90 Nm + 90° further
❑ Renew after each re‐
moval
8 - Wheel bearing housing
❑ Removing and installing
⇒ page 226
9 - Rear right speed sensor -
G44- / rear left speed sensor -
G46-
❑ Can be tested in Guided Fault Finding using ⇒ Vehicle diagnostic tester.
❑ Before inserting sensor, clean inner surface of hole and coat with lubricating paste - G 000 650- .
10 - Hexagon socket head bolt
❑ M6 × 16
❑ 8 Nm
11 - Bonded rubber bush
❑ Renewing ⇒ page 229
12 - Nut
❑ M12 × 25
❑ 40 Nm
❑ Self-locking
❑ Renew after each removal

13. Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) 225
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

13 - Brake disc
14 - Bolt
❑ 8 Nm
15 - Bolt
❑ 200 Nm + 90° further
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
❑ Renew after each removal
16 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing
❑ Removing and installing ⇒ page 232
The wheel bearing and wheel hub are assembled in one housing.
This wheel bearing unit is maintenance-free and does not require adjustment. Adjustments and repairs are not
possible!

17 - Bolt
❑ M6 x 12
❑ 12 Nm
18 - Cover plate
19 - Bolt
❑ M12 x 1.5 x 80
❑ 90 Nm + 90° further
❑ Renew after each removal
20 - Bonded rubber bush
❑ Renewing ⇒ page 237
21 - Bolt
❑ M10 x 35
❑ 50 Nm + 90° further
❑ Renew after each removal

13.1 Removing and installing wheel bearing

housing
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

Perform the following steps:

Removing
– Loosen drive shaft bolt at wheel hub ⇒ page 252 .

226 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Loosen wheel bolts.

– Raise vehicle.
– Remove wheel.
– Remove coil springs ⇒ page 242 .
– Remove brake carrier with brake caliper and tie to body with
wire ⇒ Rep. gr. 46 .
– Remove ABS speed sensor from wheel bearing housing.
– Unscrew screw -arrow-.

– Unscrew bolts -arrows- and remove splash plate -1-.

– Remove bolt for track rod -1-, upper transverse link -2- and
lower transverse link -3- from wheel housing -4-.
– Unbolt coupling rod from wheel bearing housing -arrow-.

13. Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) 227
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove coupling rod -1- from trailing arm.

– Hold wheel bearing housing and unscrew bolts -arrows-.
– Take out wheel bearing housing.
Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:

Position: threaded connection between trailing arm and wheel

bearing housing
Threaded connection for trailing arm and wheel bearing housing
may be tightened only after all other components (particularly the
spring and shock absorber) of respective wheel suspension have
been installed. To tighten, wheel suspension must be in extended
position. Only then do trailing arm and wheel bearing housing
move to the necessary position -arrows-.
It is essential to follow specified sequence of work steps below!

– Fit trailing arm to wheel bearing housing with bolts -arrows-

but do not tighten yet.
– Attach coupling rod -1- to trailing arm but do not tighten nut
yet.
– Lower wheel suspension again using engine and gearbox jack
- V.A.G 1383 A- and remove support - T10149- from wheel
hub.
– Tighten trailing arm bolts -arrows- to specified torque, ensur‐
ing that components are positioned as required ⇒ page 228 .
– Bolt coupling rod -1- to wheel bearing housing and anti-roll bar.
The threaded connections on the wheel bearing housing may be
tightened only when the dimension between the centre of wheel
hub and lower edge of wheel housing has been attained
⇒ page 192 .
– Install coil spring ⇒ page 243 .
– Attach brake carrier with brake caliper ⇒ Brake systems; Rep.
gr. 46 .
– Tighten drive shaft bolt at wheel hub ⇒ page 252 .
– Install wheel and tighten bolts or nuts ⇒ page 304 .

Specified torques
Component Specified torque
Upper transverse link to wheel bearing housing 130 Nm + 180° further
♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

228 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Component Specified torque

Lower transverse link to wheel bearing housing 70 Nm + 180° further
♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Track rod to wheel bearing housing 130 Nm + 180° further

♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Trailing arm to wheel bearing housing 70 Nm + 90° further

♦ Use new bolts

Coupling rod to wheel bearing housing. 45 Nm

♦ Use new bolts

Splash plate to wheel bearing housing 12 Nm

ABS speed sensor to wheel bearing housing 8 Nm
Shock absorber to wheel bearing housing 180 Nm
Brake disc to wheel bearing housing. 8 Nm
Drive shaft to hub 200 Nm + 90° further
♦ Use new bolt

Volkswagen Technical Site: http://vwts.ru http://vwts.info

13.2 Renewing bonded rubber bush for wheel bearing housing

13. Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) 229
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Special tools and workshop

equipment required

♦ Assembly tool - 3346-

♦ Assembly tool - 3350-
♦ Fitting sleeve - 3378-
♦ Follower - 3390-
♦ Torque wrench - V.A.G 1332-
Perform the following steps:
Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove coil springs ⇒ page 242 .
– Remove brake carrier with brake caliper and tie to body with
wire ⇒ Rep. gr. 46 .

Note

Do not suspend brake caliper by brake hose.

230 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove bolt for brake disc and remove brake disc.

– Unscrew bolts -arrows- and remove splash plate -1-.

– Remove bolt -arrow- for lower transverse link -1-.

Pressing out bonded rubber bush

– Position tools as shown in figure.

1- Nut - 3346/3-
2- Follower - 3390-
3- Sleeve - 3350-
4- Nut (commercially available)
5- Spindle - 3346/2-
– Pull out bonded rubber bush by turning spindle.
Installing
Pulling in bonded rubber bush

13. Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) 231
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Position tools as shown in figure.

1- Nut - 3346/3-
2- Press tool - 3346-
3- Bonded rubber bush
4- Fitting sleeve - 3378-
5- Nut (commercially available)
6- Spindle - 3346/2-
– Pull in bonded rubber bush by turning spindle.

Note

♦ Do not use lubricant.

♦ Insert bearing carefully so it does not cant.

– Fit cover plate.

Threaded connections on wheel bearing housing may be tight‐
ened only when dimension “a” has been obtained ⇒ page 192 .

– Tighten bolt -arrow- for lower transverse link -1-.

– Install coil spring ⇒ page 243 .
– Install brake disc.
– Attach brake carrier with brake caliper ⇒ Brake systems; Rep.
gr. 46 .
– Install wheel and tighten bolts or nuts ⇒ page 304 .

Specified torques
Component Specified torque
Lower transverse link to wheel bearing housing 70 Nm + 180° further
♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Splash plate to wheel bearing housing 12 Nm

Brake disc to wheel bearing housing. 8 Nm

13.3 Removing and installing wheel bearing

unit
Special tools and workshop equipment required

232 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Torque wrench - V.A.G 1332-

♦ Torque wrench - V.A.G 1410-

Perform the following steps:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove coil springs ⇒ page 242 .
– Remove drive shaft ⇒ page 253 .
– Remove brake carrier with brake caliper and tie to body with
wire ⇒ Rep. gr. 46 .

Note

Do not suspend brake caliper by brake hose.

– Remove bolt for brake disc and remove brake disc.

– Unscrew bolts -2-.
– Pull wheel hubs/wheel bearing unit from wheel bearing hous‐
ing.
Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
– Tighten drive shaft bolt at wheel hub ⇒ page 252 .

13. Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) 233
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Specified torques
Component Specified torque
Wheel hub with wheel bearing to wheel bearing housing 70 Nm + 90° further
♦ Use new bolt

Brake disc to wheel bearing housing. 8 Nm

13.4 Removing and installing trailing arm with

mounting bracket
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

♦ Support - T10149-

Perform the following steps:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove coil springs ⇒ page 242 .

234 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove holders -arrows- by pressing out inner pins of rivets.

– Unbolt coupling rod -1- from trailing arm.

– Unscrew bolts -arrows-.

– Remove line -1- from mounting bracket -arrow A-.

– Mark installation position of bearing bracket -2- on body.
– Unscrew bolts -arrows B-.
– Remove trailing arm with mounting bracket.
If the trailing arm is to be renewed, the mounting bracket must be
removed from the longitudinal member.

– Clamp trailing arm in a vice so that mounting bracket -1- lies

against vice -arrow-.
– Unscrew bolt -2-.
The position of the mounting bracket relative to the trailing arm
must then be adjusted ⇒ page 235 .
Determining position of mounting bracket in relation to trailing arm

13. Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) 235
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Measure dimension -a- from middle of bolt to outer edge of

mounting bracket.
Dimension -a- is 57.5 ± 1 mm.
1- Mounting bracket
2- Trailing arm
– Tighten bolt when dimension -a- is set.
Installing
Threaded connection for trailing arm and wheel bearing housing
may be tightened only after all other components (particularly the
spring and shock absorber) of respective wheel suspension have
been installed. To tighten, wheel suspension must be in extended
position. Only then do trailing arm and wheel bearing housing
move to the necessary position -arrows-.

Position: threaded connection between trailing arm and wheel

bearing housing
It is essential to follow specified sequence of work steps below!

– Position trailing arm and mounting bracket on wheel bearing

housing with bolts -arrows- but do not tighten yet.
– Attach coupling rod -1- to trailing arm but do not tighten nut
yet.
– Raise wheel suspension using engine and gearbox jack -
V.A.G 1383 A- and support - T10149- until mounting bracket
contacts body.

– Tighten bolts -arrows B- on position of old imprint.

– Mount line -1- on mounting bracket -arrows A-.
– Lower wheel suspension again using engine and gearbox jack
- V.A.G 1383 A- and remove support - T10149- from wheel
hub.
– Install coil spring ⇒ page 243 .

236 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Mount holders -arrows- by pressing in inner pins of rivets.

– Install wheel and tighten bolts or nuts ⇒ page 304 .
– Perform wheel alignment ⇒ page 311 .

Specified torques
Component Specified torque
Trailing arm to wheel bearing housing 70 Nm + 90° further
♦ Use new bolts

Trailing arm to mounting bracket 90 Nm + 90° further

♦ Use new bolt

Mounting bracket to body 50 Nm + 90° further

♦ Use new bolts

Coupling rod to trailing arm. 40 Nm

♦ Use new bolts

13.5 Repairing trailing arm

13. Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) 237
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Special tools and workshop

equipment required

♦ Thrust plate - VW 401-

♦ Thrust plate - VW 402-
♦ Removal tool - 3372-
♦ Assembly tool - T10230-
Perform the following steps:
Pressing out bonded rubber bush
– Remove trailing arm ⇒ page 234 .
– Clamp trailing arm in a vice so that mounting bracket -1- lies
against vice -arrow-.
– Unscrew bolt -2-.

238 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Fit tools as shown in illustration.

1- Tube - T10230/3-
2- Press tool - T10230/10-
3- Removal tool - 3372-
4- Pressure plate - VW 401-
5- Pressure plate - VW 402-
– Press out bonded rubber bush.
Pressing in bonded rubber bush

– Place trailing arm on a level surface.

– Position trailing arm on a level surface so that dimension -A-
= 113 mm is attained.
– Mark a vertical line on bush of trailing arm -arrows-.

Position the bonded rubber bush on the trailing arm so that the
marked vertical line lies between the raised portions -1-.

Note

Take great care to ensure that the installation position of the bon‐
ded rubber bush is correct relative to the bush in the trailing arm.

13. Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) 239
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Fit tools as shown in illustration.

1- Tube - T10230/5-
2- Thrust plate - T10230/12- (chamfer must face bonded rub‐
ber bush)
3- Bonded rubber bush
4- Removal tool - 3372-
5- Pressure plate - VW 402-
– Press bonded rubber bush in flush.
– Attach mounting bracket to trailing arm ⇒ page 235 .
– Install trailing arm ⇒ page 234 .

240 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

14 Assembly overview: shock absorber, coil spring (four-wheel drive)

Note

Assembly overview: shock absorber for adaptive chassis control DCC (four-wheel drive) ⇒ page 296

1 - Lower spring seat

❑ End of coil spring turned
to stop
2 - Assembly aid
❑ Not necessary to rein‐
stall once removed
3 - Coil spring
❑ Note different running
gear versions
⇒ page 322 , vehicle
data sticker.
❑ Removing and installing
⇒ page 242

Note

Note information for conversion to

Nivomat under all circumstances
⇒ page 242 .

4 - Upper spring seat

5 - Bolt
❑ 180 Nm
❑ Renew after each re‐
moval
6 - Bolt
❑ 50 Nm + 90° further
❑ Renew after each re‐
moval
7 - Shock absorbers
❑ Removing and installing
⇒ page 244
❑ Take different running
gear designs into account ⇒ page 322 .

Note

Note information for conversion to

Nivomat under all circumstances
⇒ page 242 .

8 - Washer
9 - Lower transverse link
❑ Removing and installing ⇒ page 219
10 - Wheel bearing housing
❑ Removing and installing ⇒ page 226

14. Assembly overview: shock absorber, coil spring (four-wheel drive) 241
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

14.1 Converting to Nivomat

Observe the following important points when converting the rear
axle to Nivomat
♦ Only convert vehicles with standard running gear. Other run‐
ning gears must not be converted to Nivomat.
♦ The Nivomat shock absorber and the respective coil spring
must be fitted to both sides of the vehicle ⇒ electronic parts
catalogue “ETKA”
♦ A vehicle alignment check must be performed after exchang‐
ing the shock absorbers and coil springs. The camber on the
rear axle must be set to 1°45'.
Further information for the Nivomat can be found in ⇒ Self-study
programme No. 357 ; The Nivomat .

14.2 Removing and installing coil spring

Special tools and workshop equipment required
♦ Suspension strut clamp - V.A.G 1752-

♦ Spring retainer - V.A.G 1752/3A-

♦ Adapter - V.A.G 1752/9- , not illustrated

Perform the following steps:
Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.

242 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Insert spring compressor -3-.

1- Spring retainer - V.A.G 1752/3A-
2- Adapter - V.A.G 1752/9-
3- Spring compressor - V.A.G 1752/1-

WARNING

Ensure that coil spring is correctly seated in spring retainers -

V.A.G 1752/3A- -2-.

– Compress coil springs until they can be removed.

Note

Use a spanner or a reversible ratchet handle to compress spring

compressor.

Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:
– Check that the lower spring plate is not damaged.
– If necessary, renew lower spring plate.

– Place lower plate onto bottom of coil spring.

End of spring -arrow- must contact stop in lower spring seat.
– Mount spring together with spring plate.
– The spring seat has a lug.

– Insert this pin in holes in lower transverse link -arrow-.

14. Assembly overview: shock absorber, coil spring (four-wheel drive) 243
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Insert upper spring seat into upper end of spring.

– The bead of the spring seat -arrow- must lie against the coil
spring correctly.
– Release tension on coil spring while locating upper spring seat
on lug on body.
– Remove spring compressor .
– Install wheel and tighten bolts or nuts ⇒ page 304 .

14.3 Removing and installing shock absorb‐

ers

Note

Removing and installing shock absorber for adaptive chassis

control DCC (four-wheel drive) ⇒ page 298

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1332-

Perform the following steps:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove rear wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liners .
– Remove coil springs ⇒ page 242 .

244 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove bolts -1- for shock absorber -2-.

– Unscrew screw -arrow-.

– Remove shock absorber.
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:
The shock absorber may be bolted to the wheel bearing housing
only when dimension “a” has been attained ⇒ page 192 .

– Install shock absorber -2- and tighten bolts -1-.

– Tighten bolt -arrow- .

– Install coil spring ⇒ page 243 .
– Install rear wheel housing liner ⇒ General body repairs, ex‐
terior; Rep. gr. 66 .
– Install wheel and tighten bolts or nuts ⇒ page 304 .

Specified torques
Component Specified torque
Shock absorber to body 50 Nm + 90° further
♦ Use new bolts

Shock absorber to wheel bearing housing 180 Nm

14. Assembly overview: shock absorber, coil spring (four-wheel drive) 245
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

14.4 Repairing shock absorber

Note

Repairing shock absorber for adaptive chassis control DCC (four-wheel drive) ⇒ page 300

1 - Shock absorbers
❑ Removing and installing
⇒ page 244
❑ Take different running
gear designs into ac‐
count ⇒ page 322 .
2 - Protective tube
3 - Buffer stop
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
4 - Shock absorber mounting
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
5 - Nut
❑ 25 Nm
❑ Renew after each re‐
moval
❑ Loosening and tighten‐
ing ⇒ page 247
6 - Cover

246 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Dismantling and assembling shock absorber

Special tools and work‐
shop equipment re‐
quired
♦ Torque wrench -
V.A.G 1332-

♦ Shock absorber set -

T10001-

Loosening and tighten‐

ing threaded connection
for shock absorber
mounting
1 - Commercially availa‐
ble ratchet handle
2 - Insert - T10001/9-
3 - Ratchet wrench -
T10001/11-
4 - Insert - T10001/1-

Specified torque
Component Specified torque
Shock absorber mounting to shock absorber 25 Nm
♦ Use new bolts

14. Assembly overview: shock absorber, coil spring (four-wheel drive) 247
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

15 Assembly overview: anti-roll bar (four-wheel drive)

The -arrow- points in direction of travel.

1 - Anti-roll bar
❑ Take different running
gear designs into ac‐
count ⇒ page 322 .
❑ Removing and installing
⇒ page 248
2 - Mountings
❑ Always renew mount‐
ings/bushes on both
sides of vehicle
3 - Clip
4 - Bolt
❑ 20 Nm + 90° further
❑ Tighten evenly
❑ Renew after each re‐
moval
5 - Wheel bearing housing
6 - Nut
❑ 45 Nm
❑ Self-locking
❑ Renew after each re‐
moval
❑ When tightening, coun‐
terhold on multi-point
socket of bolt
⇒ Item 7 (page 188)
7 - Bolt
8 - Coupling rod
❑ Connects anti-roll bar to
trailing arm and wheel
bearing housing
9 - Subframe

15.1 Removing and installing anti-roll bar

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

248 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Perform the following steps:

Removing
– Remove rear wheels.

Note

The following procedure is for the left side of the vehicle. The
procedure for the right side of the vehicle is identical.

– Remove nut -1- and pull coupling rod -2- from anti-roll bar.

Note

Do not loosen bolt -arrow- for track rod -3-.

– Remove bolts -arrows- for anti-roll bar clamp.

If the upper bolt of the anti-roll bar clamp on the right side of the
vehicle cannot be removed, then additional work must be per‐
formed ⇒ page 249 .
For the right side of the vehicle only (depending on equipment)

– Secure vehicle to support arms of lifting platform on both sides

using tensioning straps - T10038- .
1- Tensioning strap - T10038-

15. Assembly overview: anti-roll bar (four-wheel drive) 249

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Attach support - T10149- to wheel hub using wheel bolt.

– Raise wheel hub with support - T10149- and engine and gear‐
box jack - V.A.G 1383 A- far enough that bolts of right anti-roll
bar clamp are accessible.
Continuation for both sides of vehicle
– Remove anti-roll bar.
Installing
– Install anti-roll bar in vehicle.

– Evenly tighten bolts -arrows- for anti-roll bar clamp.

For the right side of the vehicle only (depending on equipment)
– Lower wheel suspension again using engine and gearbox jack
- V.A.G 1383 A- and remove support - T10149- from wheel
hub.
– Remove tensioning strap - T10038- .
Continuation for both sides of vehicle

– Connect coupling rod -2- to anti-roll bar and tighten nut -1-.
– Install wheel and tighten. ⇒ page 304

Specified torques
Component Specified torque
Anti-roll bar to subframe 20 Nm + 90° further
♦ Use new bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Anti-roll bar to coupling rod 45 Nm

♦ Use new bolts

250 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

16 Assembly overview: drive shaft

1 - Outer constant velocity joint

❑ Renew only as com‐
plete unit
❑ Removing ⇒ page 258
❑ Installing: drive onto
shaft to stop using plas‐
tic hammer
2 - Bolt
200 Nm + 90° further
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Renew after each re‐
moval
3 - Drive shaft
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
4 - Clip
❑ Renew after each re‐
moval
❑ Tightening ⇒ page 259
5 - Boot
❑ Check for splits and
chafing
❑ Material: Hytrel (poly‐
ester elastomer)
6 - Clip
❑ Renew after each re‐
moval
❑ Tightening ⇒ page 259
7 - Dished spring
❑ With inner splines
❑ Fitting position ⇒ page 258
8 - Retaining ring
❑ Renew after each removal
❑ Insert in groove in shaft
9 - Boot for constant velocity joint
❑ Material: Hytrel (polyester elastomer)
❑ Without breather hole
❑ Check for splits and chafing
❑ Drive off constant velocity joint with a drift
❑ Coat sealing surface of constant velocity joint with -D 454 300 A2- before installing.
10 - Clip
❑ Renew after each removal
❑ Tightening ⇒ page 259
11 - Locking plate
12 - Multi-point socket head bolt
❑ M8 × 48

16. Assembly overview: drive shaft 251

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019
❑ Pre-tighten diagonally to 10 Nm and then tighten diagonally to specified torque
❑ 40 Nm
❑ Always renew bolts after removing
13 - Retaining ring
❑ Renew after each removal
❑ Remove and install with circlip pliers - VW 161 A- .
14 - Seal
❑ Renew after each removal
❑ Adhesive surface on constant velocity joint must be free of oil and grease!
15 - Inner constant velocity joint
❑ Renew only as complete unit
❑ Pressing off ⇒ page 258
❑ Pressing on ⇒ page 259
❑ Checking ⇒ page 260
16 - Dished spring
❑ With inner splines
❑ Fitting position ⇒ page 258

16.1 Loosening and tightening twelve-point

bolt for drive shaft connection
Special tools and workshop equipment required
♦ Socket, 24 mm - T10361A-

♦ Torque angle wrench - V.A.G 1756 A-

Loosening twelve-point head bolt

– To avoid damage to wheel bearing, do not loosen twelve-point
head bolt using 24 mm socket - T10361A- further than 90° with
vehicle still standing on its wheels.
– Raise vehicle so that wheels are off the ground.

252 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Have second mechanic apply brakes.

– Remove twelve-point head bolt -arrow-.
Fitting twelve-point head bolt
– Renew twelve-point head bolt.

Note

The wheels must not be in contact with the ground when the drive
shaft bolt is tightened; otherwise, the wheel bearing will be dam‐
aged.

– Have second mechanic apply brakes.

– Tighten twelve-point bolt to 200 Nm.
– Lower vehicle onto its wheels.
– Turn twelve-point head bolt 90° further.

16.2 Removing and installing drive shaft

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

♦ Ejector - T10520-

Caution

When removing and installing drive shafts, do not allow them

to hang free and stop against joints due to over bending.

Removing
– Loosen drive shaft bolt at wheel hub ⇒ page 252 .

16. Assembly overview: drive shaft 253

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Caution

Wheel bearings must not be subjected to load after bolt secur‐

ing drive shaft to wheel hub has been loosened.
If wheel bearings are loaded with weight of vehicle, bearing will
be damaged. This reduces the service life of the wheel bearing.
It is not permissible to loosen drive shaft bolt more than 90° if
vehicle is standing on its wheels.
Do not attempt to move the vehicle without the drive shafts
fitted as this would damage the wheel bearing. If a vehicle must
nevertheless be moved, comply with the following:
♦ Install an outer joint instead of the drive shaft.
♦ Tighten outer joint to 120 Nm.

– Remove wheel.
– Remove coil springs ⇒ page 242 .
– Remove bolts -arrows- for lower suspension link -1- and track
rod -2- from wheel bearing housing.

– Unscrew screw -arrow-.

– Loosen drive shaft at gearbox flange.
– Swing wheel bearing housing out and pull drive shaft out of
inner splines.
If the drive shaft cannot be pulled out of the wheel bearing by
hand, use ejector - T10520- .

254 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Before using press tool - T10520- ensure that thrust piece -1- is
inserted.

Using ejector - T10520- :

– To press out drive shaft -3-, secure ejector - T10520- -1- to
wheel hub using 3 wheel bolts -2-.

– It is essential to follow specified sequence.

I - Tighten knurled nut -1- hand-tight.
II - Turn only bolt -2- using a spanner in order to press out drive
shaft with ejector - T10520- .

Note

At the end of the procedure or for pressing out drive shaft further,
the spindle must be moved to its original position in order to apply
the hydraulic force.

– Remove drive shaft.

Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
– Fit inner joint of drive shaft in position and pre-tighten bolts in
diagonal sequence to 10 Nm.
– Tighten multi-point socket head bolts in diagonal sequence to
40 Nm.
– Tighten bolt for drive shaft at wheel hub ⇒ page 252 .
The threaded connections on the wheel bearing housing may be
tightened only when the dimension measured between the centre
of wheel hub and lower edge of wheel housing before work was
started has been attained ⇒ page 192 .

16. Assembly overview: drive shaft 255

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Specified torques
Component Specified torque
Drive shaft to hub 200 Nm + 90° further
♦ Use new bolt

Drive shaft to flange shaft of rear final drive 40 Nm

♦ Use new bolts ♦ Pre-tighten diagonally to 10 Nm

16.3 Dismantling and assembling drive shaft

Special tools and workshop

equipment required

♦ Thrust plate - VW 401-

♦ Thrust plate - VW 402-
♦ Press tool - VW 408 A-
♦ Press tool - VW 411-
♦ Tube - VW 416 B-
♦ Thrust plate - VW 447 H-

256 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Snap ring pliers - VW 161 A-

♦ Torque wrench - V.A.G 1331-
♦ Torque wrench - V.A.G 1332-
♦ Clamp tensioner - V.A.G 1682-
♦ Assembly tool - T10065-

16. Assembly overview: drive shaft 257

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Dismantling
Driving off outer constant velocity joint
– Clamp drive shaft in vice using jaw protectors.
– Fold back boot.
– Drive constant velocity joint off drive shaft using drift -A-.
The drift must be positioned exactly on the triple roller star of the
constant velocity joint.
Driving joint on
– Knock onto shaft with plastic hammer until retaining ring en‐
gages.

Pressing off inner constant velocity joint

– Press off protective boot off joint using a drift.
– Remove retaining ring.
– Remove both clips and slide boot towards outer joint.
Installing

Installation position of dished spring on inner and outer joints

1- Dished spring
– Press joint on to stop.
– Install retaining ring.

258 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Pressing on inner constant velocity joint

Note

Chamfer on internal circumference of ball hub (splines) must face

contact shoulder on drive shaft.

Tighten clip on outer joint

– Position clamp tensioner - V.A.G 1682- as shown in diagram.
Ensure jaws of tensioner lie in corners -arrows B- of ear on O-
type clip.
– Tighten clamp by turning spindle with a torque wrench (do not
cant pliers).

Note

♦ Because a stainless steel boot clamp is required due to the

hard material of the joint boot (compared to rubber), it is pos‐
sible to tighten the clamp only with clamp tensioner - V.A.G
1682- .
♦ Specified torque: 25 Nm.
♦ Use torque wrench -C- with adjustment range 5 … 50 Nm, (e.g.
torque wrench - V.A.G 1331- ).
♦ Ensure that the spindle thread -A- moves smoothly. Lubricate
with MOS2 grease if necessary.
♦ If the thread is tight (e.g. due to dirt), the required clamping
force for the clip will not be attained although the correct torque
is applied.

Tightening clip on small diameter

16. Assembly overview: drive shaft 259

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

16.4 Checking inner constant velocity joint

Removing
The joint is to be dismantled to renew the grease if it is heavily
soiled, and to check the running surfaces and the balls for wear
and damage.
– Swing ball hub and ball cage.
– Press out joint body in direction of arrow.
– Press balls out of cage.

Note

The ball hub and joint body are paired. Do not interchange them.

– Tip ball hub out of ball cage via ball track -arrows-.
– Check joint body, ball hub, ball cage and balls for pitting and
traces of seizing.
Excessive circumferential backlash in the joint is noticeable dur‐
ing load change jolts. In this case the joint must be replaced.
Smoothing and traces of wear of the balls are no reason to renew
the joint.
Installing

– Insert hub into cage via the two chamfers. The hub can be
installed in any position. Press balls into cage.
The ball hub has two different distances between the ball tracks:
a smaller one and a larger one.

– Insert hub complete with cage and balls into joint body, making
sure that a smaller gap -b- faces open side of joint body.
– Also make sure that chamfer on inner circumference of ball
hub is visible after swinging it into place.

260 Rep. gr.42 - Rear suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Swing ball hub into place by swinging hub out of cage as

shown in figure -arrows-.

– Swivel in hub with balls by applying firm pressure to cage

-arrow-.
– Checking function of constant velocity joint
The constant velocity joint is correctly assembled if the ball hub
can be moved by hand backwards and forwards over its entire
range of axial movement.

16. Assembly overview: drive shaft 261

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

43 – Self-levelling suspension
1 Evaluating accident vehicles
A checklist for evaluating running gear of accident vehicles can
be found under ⇒ page 1 .

262 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

2 Components of adaptive chassis control DCC and fitting locations

Caution

Do not interchange the body acceleration senders.

1 - Shock absorber damping

adjustment button - E387-
❑ Location: in front of gear
lever in centre console
❑ Explanations
⇒ page 264
2 - Shock absorber with rear
right shock absorber damper
adjustment valve - N339- .
❑ Removing and installing
front-wheel drive
⇒ page 291
❑ Removing and installing
four-wheel drive
⇒ page 298
3 - Electronically controlled
damping control unit - J250-
❑ Location: on underbody
next to rear left wheel
housing
❑ Removing and installing
⇒ page 273
❑ If the electronically con‐
trolled damping control
unit - J250- is renewed,
the basic setting of the
adaptive chassis control
DCC must be per‐
formed. ⇒ page 274
4 - Body acceleration sender,
rear - G343-
❑ Location: on rear left
shock absorber mount
❑ Removing and installing
front-wheel drive
⇒ page 290
❑ Removing and installing four-wheel drive ⇒ page 297
5 - Shock absorber with rear left shock absorber damper adjustment valve - N338- .
❑ Removing and installing front-wheel drive ⇒ page 291
❑ Removing and installing four-wheel drive ⇒ page 298
6 - Rear left vehicle level sender - G76-
❑ Removing and installing front-wheel drive ⇒ page 270
❑ Removing and installing four-wheel drive ⇒ page 272
❑ If the rear left vehicle level sender - G76- is removed and installed, the basic setting of the adaptive
chassis control DCC must be performed ⇒ page 274
Basic setting of headlights ⇒ Vehicle diagnostic tester

2. Components of adaptive chassis control DCC and fitting locations 263

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

7 - Front left body acceleration sender - G341-

❑ Removing and installing ⇒ page 264
8 - Shock absorber with front left shock absorber damper adjustment valve - N336-
❑ Removing and installing suspension strut ⇒ page 280
❑ Repairing suspension strut ⇒ page 278
9 - Front left vehicle level sender - G78- and front right vehicle level sender - G289-
❑ Removing and installing ⇒ page 268
❑ If the rear left vehicle level sender - G78- and front right vehicle level sender - G289- are removed and
installed, the basic setting of the adaptive chassis control DCC must be performed ⇒ page 274
Basic setting of headlights ⇒ Vehicle diagnostic tester

10 - Shock absorber with front right shock absorber damper adjustment valve - N337-
❑ Removing and installing suspension strut ⇒ page 280
❑ Repairing suspension strut ⇒ page 278
11 - Front right body acceleration sender - G342-
❑ Removing and installing ⇒ page 264

2.1 Shock absorber damping adjustment

button - E387-
The shock absorber damping adjustment button - E387- is located
in front of the gear lever in the centre console.
The shock absorber damping adjustment button - E387- sets the
system to 3 different modes:
♦ Standard
♦ Sport
♦ Comfort
The operating sequence is -Normal- > -Sport- > -Comfort- >
-Normal- > …
In the shock absorber damping adjustment button - E387- , the
fields -Sport- and -Comfort- are back-lit with a yellow function LED
when the selection of the corresponding mode is active.
When -Normal- mode is selected, the shock absorber damping
adjustment button - E387- is not illuminated.

2.2 Removing and installing front left and

right body acceleration senders - G341/
G342-
Special tools and workshop equipment required

264 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Torque wrench - V.A.G 1410-

Removing
– Remove wiper arms ⇒ Rep. gr. 92 ; Wiper system; Removing
and installing wiper arms .
– Remove plenum chamber cover ⇒ Rep. gr. 64 .
– Release connector and pull off.
– Unscrew bolts and remove front left body acceleration sender
- G341- .
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:

Caution

Do not interchange the front body acceleration senders with

the rear body acceleration senders ; assignment in ⇒ Elec‐
tronic parts catalogue “ETKA” .

– Note installation position of front left body acceleration sender

- G341- on bracket.
Retaining lug -1- must engage in recess in front left body accel‐
eration sender - G341- -arrow-.

Note

Make sure to use correct bracket. An “L” is punched into bracket.

Specified torques
Component Specified torque
Front left body acceleration sender - G341- to bracket 5 Nm

2.3 Renewing bracket for front left/right

body acceleration sender - G341/G342-
Special tools and workshop equipment required

2. Components of adaptive chassis control DCC and fitting locations 265

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Torque wrench - V.A.G 1331-

♦ Pin - VW 222 A-

♦ 11 mm drill bit
Removing
– Remove front left and right body acceleration senders - G341/
G342- ⇒ page 264 .
– Unscrew and remove bolts for bracket and remove bracket
from shock absorber turret.
Installing

Caution

Do not interchange the body acceleration senders; assignment

in ⇒ Electronic parts catalogue “ETKA” .

– Clean shock absorber turret.

Front left body acceleration sender - G341-
– Screw front left body acceleration sender - G341- onto brack‐
et.

266 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Note installation position of front left body acceleration sender

- G341- on bracket.
Retaining lug -1- must engage in recess in front left body accel‐
eration sender - G341- -arrow-.

Note

Make sure to use correct bracket. An “L” is punched into bracket.

Front right body acceleration sender - G342-

– Screw front right body acceleration sender - G342- onto brack‐
et.

– Note installation position of front right body acceleration send‐

er - G342- on the bracket.
Retaining lug -1- must engage in recess in front right body accel‐
eration sender - G342- -arrow-.

Note

Make sure to use correct bracket. An “R” is punched into bracket.

Continuation for both sides

– Pull off bonding surface seal on bracket if present and stick on
double-sided adhesive tape.

– Fix bracket using an 11 mm drill bit and drift - VW 222 A- .

Note

The holes in the bracket must line up with the holes in the shock
absorber turret.

– Screw in bolts one after another until finger-tight and then

tighten to specified torque.
– Push plug onto body acceleration sender.

Specified torques
Component Specified torque
Suspension strut to body (suspension turret) 20 Nm + 90°
♦ Use new bolts

2.4 Assembly overview: front left/right vehicle level sender - G78/G289- for
adaptive chassis control DCC

Note

♦ The front left/right vehicle level sender - G78/G289- is only available as a replacement part complete with
coupling rod and upper and lower retaining plates.
♦ Replace with subframe installed.

2. Components of adaptive chassis control DCC and fitting locations 267

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

1 - Subframe
2 - Bolt
❑ M6 x 16
❑ 9 Nm
3 - Front left vehicle level send‐
er - G78- and front right vehicle
level sender - G289-
❑ Complete with attach‐
ments
❑ Lever -arrow- must face
outwards
❑ Removing and installing
⇒ page 268
❑ If the rear left vehicle
level sender - G78- and
front right vehicle level
sender - G289- are re‐
moved and installed, the
basic setting of the
adaptive chassis control
DCC must be performed
⇒ page 274
❑ Following renewal, ba‐
sic settings for headlight
must be performed.
Basic setting of headlights
⇒ Vehicle diagnostic tester

4 - Suspension link
5 - Nut
❑ 9 Nm
❑ Self-locking
❑ Renew after each re‐
moval

2.5 Removing and installing front left/right

vehicle level sender - G78/G289-
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

268 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Removing

Note

♦ To remove front left vehicle level sender - G78- , steering must

be turned to right lock to ensure clearance between suspen‐
sion link and anti-roll bar.
♦ To remove front right vehicle level sender - G289- , steering
must be turned to left lock to ensure clearance between sus‐
pension link and anti-roll bar.

– Detach connector.
– Remove bolt and nut.
– Take out vehicle level sender.
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:

Note

♦ The lever of the vehicle level sender must point towards the
outside of the vehicle.
♦ Thread of vehicle level sender must be screwed into front hole
in suspension link. The retaining lug of the vehicle level sender
must engage in the rear hole in order to ensure the correct
installation position.

– Perform basic setting of adaptive chassis control DCC

⇒ page 274
– Carry out basic setting of headlights ⇒ Vehicle diagnostic test‐
er

Specified torques
Component Specified torque
Bolt to subframe 9 Nm
Nut 9 Nm
♦ Use new bolts

2.6 Assembly overview: rear left vehicle level sender - G76- for adaptive chassis
control DCC

Note

♦ The vehicle level sender is available as a replacement part only complete with coupling rod and upper and
lower retaining plates.
♦ Renewing without removing subframe ⇒ page 270 .

2. Components of adaptive chassis control DCC and fitting locations 269

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

1 - Subframe
2 - Bolt
❑ 5 Nm
3 - Rear left vehicle level send‐
er - G76-
❑ Complete with attach‐
ments
❑ Lever -arrow- must face
outwards
❑ Removing and installing
⇒ page 270
❑ If the rear left vehicle
level sender - G76- is re‐
moved and installed, the
basic setting of the
adaptive chassis control
DCC must be performed
⇒ page 274
❑ Following renewal, ba‐
sic settings for headlight
must be performed.
Basic setting of headlights
⇒ Vehicle diagnostic tester

4 - Lower transverse link

2.7 Removing and installing rear left vehicle

level sender - G76- for adaptive chassis
control DCC, front-wheel drive
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

270 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Removing
– Detach connector.
– Remove bolts.
– Remove rear left vehicle level sender - G76- .
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:
The lever of the vehicle level sender must point towards the out‐
side of the vehicle.
– Perform basic setting of adaptive chassis control DCC
⇒ page 274
– Carry out basic setting of headlights ⇒ Vehicle diagnostic test‐
er

Specified torques
Component Specified torque
Bolt to subframe/lower transverse link 5 Nm

2.8 Assembly overview: rear left vehicle level sender - G76- for adaptive chassis
control DCC, four-wheel drive

Note

♦ The vehicle level sender is available as a replacement part only complete with coupling rod and upper and
lower retaining plates.
♦ Renewing without removing subframe ⇒ page 272 .

2. Components of adaptive chassis control DCC and fitting locations 271

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

1 - Subframe
2 - Bolt
❑ M5 x 20
❑ 5 Nm
3 - Rear left vehicle level send‐
er - G76-
❑ Complete with attach‐
ments
❑ Lever -arrow- must face
outwards
❑ Removing and installing
⇒ page 272
❑ If the rear left vehicle
level sender - G76- is re‐
moved and installed, the
basic setting of the
adaptive chassis control
DCC must be performed
⇒ page 274
❑ Following renewal, ba‐
sic settings for headlight
must be performed.
Basic setting of headlights
⇒ Vehicle diagnostic tester

4 - Lower transverse link

2.9 Removing and installing rear left vehicle

level sender - G76- for adaptive chassis
control DCC, four-wheel drive
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

272 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Perform the following steps:

Removing
– Detach connector.
– Remove bolts.
– Remove rear left vehicle level sender - G76- .
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:
Lever on vehicle level sender must face towards outside of vehi‐
cle.
– Perform basic setting of adaptive chassis control DCC
⇒ page 274
– Carry out basic setting of headlights ⇒ Vehicle diagnostic test‐
er.

Specified torques
Component Specified torque
Bolt to subframe/lower transverse link 5 Nm

2.10 Removing and installing electronically

controlled damping control unit - J250-
Removing
Location: on underbody next to rear left wheel housing
– Switch off all electrical consumers.
– Withdraw ignition key.
Vehicles with keyless entry and start system “Keyless Access”
– Switch off ignition and open driver’s door so that the steering
lock engages.
Continued for all vehicles
Vehicles with 2 seat rows
– Remove luggage compartment floor ⇒ Rep. gr. 70 ; Luggage
compartment trims .
– Fold floor covering to side.
Vehicles with 3rd seat row
– Fold the seat of the left seat of the 3rd row of seats forwards.
– Cut open and fold up carpet at the beads -arrows-.
a - approx. 180 mm
Continued for all vehicles

2. Components of adaptive chassis control DCC and fitting locations 273

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Press retaining lugs -arrows- outwards. Push electronically

controlled damping control unit - J250- -1- out of the bracket.
– Release connector and pull off.
Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
– Attach and lock connector.

– Push electronically controlled damping control unit - J250- into

bracket until lugs -arrows- audibly engage.
– Perform basic setting of adaptive chassis control DCC
⇒ page 274 .

2.11 Removing and installing retainer for

electronically controlled damping con‐
trol unit - J250-
Removing
– Remove electronically controlled damping control unit - J250-
⇒ page 273 .
– Unscrew bolt -arrow- and remove bracket -1-.
Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
– Install electronically controlled damping control unit - J250-
⇒ page 273 .

2.12 Basic setting of adaptive chassis control

DCC
– Connect ⇒ Vehicle diagnostic tester and select “Guided Fault
Finding”.
Running gear

Wheel damping electronic control unit

Function

Basic setting

Follow instructions on screen to perform basic setting.

274 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

2.13 Cable routing left front axle

Note

♦ Always check the cable routing.

♦ Always make sure all cables are correctly hooked into the brackets provided, and are not twisted.

1 - Cable for front left shock

absorber damper adjustment
valve - N336-
❑ Cable must be hooked
into bracket on shock
absorber -arrow-
2 - Cable for front left speed
sensor - G47-
3 - Brake pad wear indicator
wire.

2. Components of adaptive chassis control DCC and fitting locations 275

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

2.14 Cable routing right front axle

Note

♦ Always check the cable routing.

♦ Always make sure all cables are correctly hooked into the brackets provided, and are not twisted.

1 - Cable for front right shock

absorber damper adjustment
valve - N337-
❑ Cable must be hooked
into bracket on shock
absorber -arrow-
2 - Cable for front right speed
sensor - G45-

276 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

2.15 Cable routing rear axle

Note

♦ Always check the cable routing.

♦ Always make sure all cables are correctly hooked into the brackets provided, and are not twisted.

1 - Cable for rear left/right

shock absorber damper ad‐
justment valve - N338/N339-
❑ Cable must be hooked
into bracket on shock
absorber -arrow-
2 - Cable for rear right/left
speed sensor - G44/G46-

2. Components of adaptive chassis control DCC and fitting locations 277

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

3 Assembly overview: suspension strut for adaptive chassis control

DCC

1 - Shock absorber with front

left shock absorber damper
adjustment valve - N336-
❑ Can be renewed sepa‐
rately
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
2 - Buffer stop
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
3 - Protective cover
4 - Coil spring
❑ Removing and installing
⇒ page 280
❑ Observe colour coding
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
Spring allocation via PR No.

These numbers are located on

the vehicle data sticker.
❑ Surface of coil must not
be damaged.
5 - Deep groove ball thrust
bearing
6 - Suspension strut mounting
❑ Note installation posi‐
tion ⇒ page 285
7 - Hexagon nut
❑ 60 Nm
❑ Self-locking
❑ Renew after each re‐
moval
8 - Suspension turret
9 - Bracket
❑ For front left body acceleration sender - G341-
❑ Removing and installing ⇒ page 265
❑ An “L” is punched into bracket

Note

Make sure to use correct bracket.

10 - Front left body acceleration sender - G341-

❑ Removing and installing ⇒ page 264
❑ Note installation position on bracket ⇒ Item 9 (page 278) ⇒ page 279
11 - Bolt
❑ 5 Nm

278 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019
❑ Renew after each removal
12 - Bolt
❑ 20 Nm + 90°
❑ Renew after each removal
13 - Bracket
❑ For front right body acceleration sender - G342-
❑ Removing and installing ⇒ page 265
❑ An “R” is punched into bracket
14 - Front right body acceleration sender - G342-
❑ Removing and installing ⇒ page 264
❑ Note installation position on bracket ⇒ Item 13 (page 279) ⇒ page 279
15 - Nut
❑ 5 Nm
❑ Renew after each removal

Installation position front left body acceleration sender - G341- on

bracket
Retaining lug -1- must engage in recess in front left body accel‐
eration sender - G341- -arrow-.

Note

Make sure to use correct bracket. An “L” is punched into bracket.

Installation position front right body acceleration sender - G342-

on bracket
Retaining lug -1- must engage in recess in front right body accel‐
eration sender - G342- -arrow-.

Note

Make sure to use correct bracket. An “R” is punched into bracket.

3. Assembly overview: suspension strut for adaptive chassis control DCC 279
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

3.1 Removing and installing suspension strut for adaptive chassis control DCC

Special tools and workshop

equipment required

♦ Spreader - 3424-
♦ Torque wrench - V.A.G 1332-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Support - T10149-

♦ Torque wrench - V.A.G 1331-

280 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Ejector - T10520-

Perform the following steps:

Removing
– Loosen drive shaft bolt at wheel hub ⇒ page 84 .

Caution

Wheel bearings must not be subjected to load after bolt secur‐

ing drive shaft to wheel hub has been loosened.
If wheel bearings are loaded with weight of vehicle, bearing will
be damaged. This reduces the service life of the wheel bearing.
It is not permissible to loosen drive shaft bolt more than 90° if
vehicle is standing on its wheels.
Do not attempt to move the vehicle without the drive shafts
fitted as this would damage the wheel bearing. If a vehicle must
nevertheless be moved, comply with the following:
♦ Install an outer joint instead of the drive shaft.
♦ Tighten outer joint to 120 Nm.

– Loosen wheel bolts.

– Raise vehicle.
– Remove wheel.
– Unscrew hexagon nut -arrow- of coupling rod from suspension
strut.
– Detach wire for speed sensor from suspension strut.

3. Assembly overview: suspension strut for adaptive chassis control DCC 281
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unscrew vehicle level sender from suspension link.

– Remove nuts -arrows-

– Pull wheel bearing housing with swivel joint out of suspension
link.
– Pull outer joint of drive shaft out of wheel hub.
If the drive shaft cannot be pulled out of the wheel bearing by
hand, use ejector - T10520- .

Before using press tool - T10520- ensure that thrust piece -1- is
inserted.

Using ejector - T10520- :

– To press out drive shaft -3-, secure ejector - T10520- -1- to
wheel hub using 3 wheel bolts -2-.

282 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– It is essential to follow specified sequence.

I - Tighten knurled nut -1- hand-tight.
II - Turn only bolt -2- using a spanner in order to press out drive
shaft with ejector - T10520- .

Note

At the end of the procedure or for pressing out drive shaft further,
the spindle must be moved to its original position in order to apply
the hydraulic force.

– Secure drive shaft to body with wire.

Caution

Do not allow the drive shaft to hang down under its own weight,
for this would allow the inner joint to bend too far and be dam‐
aged.

– Bolt swivel joint to suspension link again.

– Use wheel bolt to attach engine and gearbox jack - V.A.G 1383
A- with support - T10149- to wheel hub.

WARNING

♦ Do not raise or lower the vehicle while the engine and

gearbox jack - V.A.G 1383 A- is positioned under the ve‐
hicle. The vehicle could slip off the lifting platform.
♦ Do not leave engine and gearbox jack - V.A.G 1383 A-
under vehicle longer than necessary.

– Separate threaded connection between wheel bearing hous‐

ing and suspension strut -arrow-.

3. Assembly overview: suspension strut for adaptive chassis control DCC 283
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Insert spreader -3424- into slot of wheel bearing housing.

– Turn ratchet handle through 90° and detach from spreader -
3424- .
– Press brake disc towards suspension strut by hand.

Note

Otherwise the shock absorber tube can cant in the bore of the
wheel bearing housing.

– Pull wheel bearing housing downwards off shock absorber

tube and lower with engine and gearbox jack - V.A.G 1383 A-
until shock absorber tube is free.
– Secure wheel bearing housing to bracket/subframe with bind‐
ing wire.
– Pull engine and gearbox jack - V.A.G 1383 A- out from under
wheel bearing housing.

WARNING

♦ Do not leave engine and gearbox jack - V.A.G 1383 A-

under vehicle longer than necessary.

– Remove windscreen wiper motor ⇒ Rep. gr. 92 ; Windscreen

wash/wipe system; Removing and installing windscreen wiper
system .

– Remove hexagon bolts -arrows- for upper shock absorber

mounting and remove suspension strut.
Installing

– Use wheel bolt to attach engine and gearbox jack - V.A.G 1383
A- with support - T10149- to wheel hub.
– Place suspension strut on wheel bearing housing and fix sus‐
pension strut in place with the multi-point socket head bolt and
a new nut.
The tip of the multi-point socket head bolt must point in the direc‐
tion of travel.
– Remove spreader - 3424- .

284 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Insert spring plate with one of the two markings -arrows- pointing
in direction of travel.

Left suspension strut

Suspension strut must be inserted so that front left shock absorb‐
er damper adjustment valve - N336- points opposite to direction
of travel.

Right suspension strut

Suspension strut must be inserted so that front right shock ab‐
sorber damper adjustment valve - N337- points in direction of
travel.
Continuation for both sides

– Check installation position of bracket for front left/right body

acceleration sender - G341/G342- .

Note

♦ Use an 11 mm drill bit -1- and drift - VW 222 A- for checking

installation position.
♦ The holes in the bracket must line up with the holes in the
shock absorber tower.

– Remove wire on wheel bearing housing.

3. Assembly overview: suspension strut for adaptive chassis control DCC 285
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Carefully raise wheel bearing housing with the gearbox jack

until bolts for connecting suspension strut to strut turret can be
inserted.
If necessary, use a ladder, e.g. step ladder - VAS 5085- , to insert
the bolts.
– Tighten hexagon bolts for upper shock absorber mounting.
– Detach support - T10149- .

– Tighten threaded connection between wheel bearing housing

and suspension strut -arrow-

286 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unscrew nuts -arrows-.

– Fit drive shaft in wheel hub.
– Fit wheel bearing housing with swivel joint in suspension link.
– Bolt swivel joint to suspension link -arrows-.

Note

Ensure that boot is not damaged or twisted.

– Screw vehicle level sender onto suspension link.

Note

♦ The lever of the vehicle level sender must point towards the
outside of the vehicle.
♦ Thread of vehicle level sender must be screwed into front hole
in suspension link. The retaining lug of the vehicle level sender
must engage in the rear hole in order to ensure the correct
installation position.

– Push plug onto front left/right shock absorber damper adjust‐

ment valve - N336/N337- .
– Tighten drive shaft bolt at wheel hub ⇒ page 84 .

Note

During this step, vehicle must not be standing on its wheels or

wheel bearing will be damaged.

– Install windscreen wiper motor ⇒ Rep. gr. 92 ; Windscreen

wash/wipe system; Removing and installing windscreen wiper
system .
Continue installation in reverse order of removal.
– Fit wheel, torque setting ⇒ page 304 .

Specified torques
Component Specified torque
Suspension strut to wheel bearing housing 70 Nm + 90°
♦ Use new bolts

Suspension strut to body (suspension turret) 20 Nm + 90°

♦ Use new bolts

Swivel joint to cast steel suspension link 60 Nm

♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5

3. Assembly overview: suspension strut for adaptive chassis control DCC 287
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Component Specified torque

Coupling rod to suspension strut 65 Nm
♦ Use new bolts
♦ Counterhold on multi-point socket of joint pin

Drive shaft to hub 70 Nm + 90°

♦ Use new bolt

Vehicle level sender to suspension link 9 Nm

288 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

4 Assembly overview: shock absorber for adaptive chassis control DCC

1 - Lower spring seat

❑ End of coil spring turned
to stop
2 - Coil spring
❑ Take different running
gear types into account
⇒ page 322
❑ Removing and installing
⇒ page 182
3 - Upper spring seat
4 - Bracket
❑ For rear body accelera‐
tion sender - G343-
5 - Body acceleration sender,
rear - G343-
❑ Removing and installing
⇒ page 290
❑ Note installation posi‐
tion on bracket
⇒ Item 4 (page 289)
⇒ page 290
6 - Bolt
❑ 5 Nm
❑ Renew after each re‐
moval
7 - Bolt
❑ 130 Nm + 90° further
❑ Renew after each re‐
moval
8 - Bolt
❑ 50 Nm + 90° further
❑ Renew after each re‐
moval
9 - Shock absorber with rear left/right shock absorber damper adjustment valve - N338/N339-
❑ Removing and installing ⇒ page 291
❑ Take different running gear types into account ⇒ page 322 .
10 - Washer
11 - Lower transverse link
❑ Removing and installing ⇒ page 159
12 - Wheel bearing housing
❑ Removing and installing ⇒ page 165

4. Assembly overview: shock absorber for adaptive chassis control DCC 289
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Installation position rear body acceleration sender - G343- on

bracket
Retaining lug -1- must engage in recess in rear body acceleration
sender - G343- -arrow-.

4.1 Removing and installing rear body ac‐

celeration sender - G343-
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1410-

Perform the following steps:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove wheel housing liner (rear left) ⇒ Rep. gr. 66 .
– Release connector and pull off.
– Unscrew bolts and remove rear body acceleration sender -
G343- .
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:

Caution

Do not interchange the rear body acceleration sender with the

front body acceleration senders ; assignment in ⇒ Electronic
parts catalogue “ETKA” .

290 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Note installation position of rear body acceleration sender -

G343- on the bracket.
Retaining lug -1- must engage in recess in front right body accel‐
eration sender - G342- -arrow-.
– Install wheel housing liner (rear left) ⇒ Rep. gr. 66 .
– Install wheel and tighten bolts or nuts ⇒ page 304 .

Specified torques
Component Specified torque
Rear body acceleration sender - G343- to bracket 5 Nm

4.2 Removing and installing shock absorber

for adaptive chassis control DCC
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

Perform the following steps:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove wheel housing liner ⇒ General body repairs, exterior;
Rep. gr. 66 ; .
Only for left shock absorber
– Unscrew rear left vehicle level sender - G76- from lower trans‐
verse link.
Continuation for both sides
– Remove coil springs ⇒ page 182 .

4. Assembly overview: shock absorber for adaptive chassis control DCC 291
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Disconnect connector and pull cable off shock absorber.

– Remove bolts from shock absorber.

Only for left shock absorber
– Pull rear body acceleration sender - G343- off shock absorber
mount.
Continuation for both sides

– Unscrew screw -arrow-.

– Remove shock absorber.
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:
The shock absorber may be bolted to the wheel bearing housing
only when dimension “a” has been attained ⇒ page 136 .

Note installation position of shock absorber.

The rear left/right shock absorber damper adjustment valve -
N338/N339- must point to the rear outwards to the wheel.
Only for left shock absorber

292 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Put rear body acceleration sender - G343- on shock absorber

mount.
– Place bracket from rear onto shock absorber mount so that
retaining lugs -1- engage in recesses in shock absorber
mount.
– Turn bracket forwards so it makes contact with shock absorber
mount.
Lug -arrow- is used for calibrating bracket for rear body acceler‐
ation sender - G343- .

Continuation for both sides

– Install shock absorber and tighten bolts.

– Tighten bolt -arrow- .

– Push plug onto rear left/right shock absorber damper adjust‐
ment valve - N338/N339- .
– Install coil spring ⇒ page 182 .
Only for left shock absorber
– Screw rear left vehicle level sender - G76- onto lower trans‐
verse link.
Continuation for both sides
– Install wheel housing liner ⇒ General body repairs, exterior;
Rep. gr. 66 .
– Install wheel and tighten bolts or nuts ⇒ page 304 .

Specified torques
Component Specified torque
Shock absorber to body 50 Nm + 90° further
♦ Use new bolts

Shock absorber to wheel bearing housing 180 Nm

♦ Use new bolt

Rear left vehicle level sender - G76- to lower transverse 5 Nm

link

4.3 Repairing shock absorber for adaptive chassis control DCC

4. Assembly overview: shock absorber for adaptive chassis control DCC 293
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

1 - Shock absorber with rear

left/right shock absorber
damper adjustment valve -
N338/N339-
❑ Removing and installing
⇒ page 291
2 - Cap
3 - Protective tube
4 - Buffer stop
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
5 - Shock absorber mounting
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
6 - Nut
❑ 25 Nm
❑ Renew after each re‐
moval
❑ Loosening and tighten‐
ing ⇒ page 295
7 - Cover

294 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Dismantling and assembling shock absorber

Special tools and work‐
shop equipment re‐
quired
♦ Torque wrench -
V.A.G 1332-

♦ Shock absorber tool

set - T10001-

Loosening and tighten‐

ing threaded connection
for shock absorber
mounting
1- Commercially
available ratchet
handle
2- Insert - T10001/9-
3- Ratchet wrench -
T10001/11-
4- Insert - T10001/1-

Specified torque
Component Specified torque
Shock absorber mounting to shock absorber 25 Nm
♦ Use new bolts

4. Assembly overview: shock absorber for adaptive chassis control DCC 295
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

5 Assembly overview: shock absorber for adaptive chassis control DCC

(four-wheel drive)

1 - Lower spring seat

❑ End of coil spring turned
to stop
2 - Coil spring
❑ Note different running
gear versions
⇒ page 322 , vehicle
data sticker.
❑ Removing and installing
⇒ page 242
3 - Upper spring seat
4 - Bracket
❑ For rear body accelera‐
tion sender - G343-
❑ Removing and installing
5 - Body acceleration sender,
rear - G343-
❑ Removing and installing
⇒ page 297
❑ Note installation posi‐
tion on bracket
⇒ Item 4 (page 296)
⇒ page 297
6 - Bolt
❑ 5 Nm
❑ Renew after each re‐
moval
7 - Bolt
❑ 180 Nm
❑ Renew after each re‐
moval
8 - Bolt
❑ 50 Nm + 90° further Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ Renew after each removal
9 - Shock absorbers
❑ Removing and installing ⇒ page 298
❑ Note different running gear versions ⇒ page 322 , vehicle data sticker.
10 - Washer
11 - Lower transverse link
❑ Removing and installing ⇒ page 219
12 - Wheel bearing housing
❑ Removing and installing ⇒ page 226

296 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Installation position rear body acceleration sender - G343- on

bracket
Lug of bracket -1- must engage in recess in rear body acceleration
sender - G343- -arrow-.

5.1 Removing and installing rear body ac‐

celeration sender - G343- (four-wheel
drive)
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1410-

Perform the following steps:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove wheel housing liner (rear left) ⇒ Rep. gr. 66 .
– Release connector and pull off.
– Unscrew bolts and remove rear body acceleration sender -
G343- .
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:

Caution

Do not interchange the rear body acceleration sender with the

front body acceleration senders ; assignment in ⇒ Electronic
parts catalogue “ETKA” .

5. Assembly overview: shock absorber for adaptive chassis control DCC (four-wheel drive) 297
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Note installation position of rear body acceleration sender -

G343- on the bracket.
Lug of bracket -1- must engage in recess in front right body ac‐
celeration sender - G342- -arrow-

Specified torques
Component Specified torque
Rear body acceleration sender - G343- to bracket 5 Nm

5.2 Removing and installing shock absorber

for adaptive chassis control DCC (four-
wheel drive)
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

Perform the following steps:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Remove wheel housing liner ⇒ General body repairs, exterior;
Rep. gr. 66 .
Only for left shock absorber
– Unscrew rear left vehicle level sender - G76- from lower trans‐
verse link.
Continuation for both sides
– Remove coil spring ⇒ page 242 .

298 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Disconnect connector and pull cable off shock absorber

– Remove bolts from shock absorber.

Only for left shock absorber
– Pull rear body acceleration sender - G343- off shock absorber
mount.
Continuation for both sides

– Unscrew screw -arrow-.

– Remove shock absorber.
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:
The shock absorber may be bolted to the wheel bearing housing
only when dimension “a” has been attained ⇒ page 136 .

Note installation position of shock absorber.

The rear left/right shock absorber damper adjustment valve -
N338/N339- must point to the rear outwards to the wheel.
Only for left shock absorber

5. Assembly overview: shock absorber for adaptive chassis control DCC (four-wheel drive) 299
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Put rear body acceleration sender - G343- on shock absorber

mount.
– Place bracket from rear onto shock absorber mounting so that
retaining lugs -1- engage in recesses in shock absorber
mounting.
– Turn bracket forwards so it makes contact with shock absorber
mount.
Lug -arrow- is used for calibrating bracket for rear body acceler‐
ation sender - G343- .

Continuation for both sides

– Install shock absorber and tighten bolts.

– Tighten bolt -arrow- .

– Push plug onto rear left/right shock absorber damper adjust‐
ment valve - N338/N339- .
– Install coil spring ⇒ page 243 .
Only for left shock absorber
– Screw rear left vehicle level sender - G76- onto lower trans‐
verse link.
Continuation for both sides
– Install wheel housing liner ⇒ General body repairs, exterior;
Rep. gr. 66 .
– Install wheel and tighten bolts or nuts ⇒ page 304 .

Specified torques
Component Specified torque
Shock absorber to body 50 Nm + 90° further
♦ Use new bolts

Shock absorber to wheel bearing housing 180 Nm

♦ Use new bolt

Rear left vehicle level sender - G76- to lower transverse 5 Nm

link

5.3 Repairing shock absorber for adaptive chassis control DCC (four-wheel
drive)

300 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

1 - Shock absorber with rear

left/right shock absorber
damper adjustment valve -
N338/N339-
❑ Removing and installing
⇒ page 298
2 - Protective cap
3 - Protective tube
4 - Buffer stop
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
5 - Shock absorber mounting
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
6 - Nut
❑ M10 × 1.0
❑ 25 Nm
❑ Renew after each re‐
moval
❑ Loosening and tighten‐
ing ⇒ page 302
7 - Cover

5. Assembly overview: shock absorber for adaptive chassis control DCC (four-wheel drive) 301
 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Dismantling and assembling shock absorber

Special tools and work‐
shop equipment re‐
quired
♦ Torque wrench -
V.A.G 1332-

♦ Shock absorber set -

T10001-

Loosening and tighten‐

ing threaded connection
for shock absorber
mounting
1 - Commercially availa‐
ble ratchet handle
2 - Insert - T10001/9-
3 - Ratchet wrench -
T10001/11-
4 - Insert - T10001/1-

Specified torque
Component Specified torque
Shock absorber mounting to shock absorber 25 Nm
♦ Use new bolts

302 Rep. gr.43 - Self-levelling suspension

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

44 – Wheels, tyres, vehicle geometry

1 Evaluating accident vehicles
A check list for evaluating running gear of accident vehicles can
be found under ⇒ page 1 .

1. Evaluating accident vehicles 303

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

2 Specified torque for fitting wheels

Wheel bolt to wheel hub for all vehicles
Specified torque: 140 Nm
– Before fitting wheel, protect wheel centring seat against cor‐
rosion ⇒ page 327 .
♦ Install anti-theft wheel bolts with master set for wheel bolts .

304 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

3 Fitting wheel and tyre

3.1 General information

New wheels with a modified contour have been introduced for all
vehicles as of model year 2005.
The tyre fitting unit must be fitted with the tyre fitting head de‐
signed for these wheels.

WARNING

Otherwise there is a danger that the wheel will be damaged.

If the tyre fitting unit has not yet been modified, please contact the
manufacture of the unit.

3.2 Fittings instructions

Warming cold tyres to minimum fitting temperature

Note

This instruction also applies to ultra-high performance tyres (as‐

pect ratio less than or equal to 45 % and speed symbol V or
higher).

WARNING

The minimum fitting temperature of a tyre should be between

15 °C and 30 °C in the core of the tyre.

• To install tyres without damage, it is especially important to

warm the upper part of the sidewall and the inside of the upper
bead to at least 15 °C.
• This internal temperature is referred to as the core tempera‐
ture.
• Rubber is a poor conductor of heat. Therefore, a cold tyre must
be left in an area with the correct temperature for a sufficiently
long period so the inner rubber layers can warm up to at least
15 °C.
• The surface temperature of the tyre during the warming up
phase is no indication of its internal temperature.
• To enable cold tyres to absorb heat from the ambient air as
quickly as possible, they should not be stacked on top of one
another but instead stored individually in order to allow the
warm air to “circulate” around them effectively.
• Tyres must never be placed in front of a radiator or hot air
blower for warming, since this can very quickly lead to critical
surface temperatures.
• Except for warming with warm water or warm ambient air
(max. 50 °C), there is no process available for warming tyres
without damaging the tyre!
• When cold tyres (below 0 °C) are transferred to a warm envi‐
ronment (above 0 °C), a layer of condensation immediately
forms on the surface of the tyre. This layer of condensation

3. Fitting wheel and tyre 305

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

indicates that the tyre is intensively absorbing heat from its

environment through the process of water vapour in the air
condensing out on the tyre surface.
• Once the layer of frost has thawed, condensate water forms.
The condensation should be dried with a cloth so that the fur‐
ther warming process is not delayed due to a temperature drop
caused by evaporation.
Warming times:
♦ Assuming a minimum room temperature of 19 °C and a tyre
temperature of 0 °C or more, a tyre must be kept at a minimum
of 19 °C for at least 2 hours.
♦ Assuming a minimum room temperature of 19 °C and a tyre
temperature of below 0°C, a tyre must be kept at a minimum
of 19 °C for at least 2.5 hours.
Warming recommendations:
♦ If possible, tyres should be stored in the workshop 1 day before
they are fitted (order preparation).
♦ Store on an insulated base, pallet or the like, as high up as
possible
♦ Position the tyres individually to allow the warm air to “circu‐
late” around them effectively
♦ Wipe off condensation
♦ Never heat with a radiator or hot air blower!

306 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

4 Self-sealing tyres “ContiSeal”

♦ New Sharan cars are fitted with self-sealing Continental tyres.
♦ This technology, referred to as ContiSeal, is a system that has
been developed to allow the car to continue to be driven even
if a nail or screw has penetrated the tyre: if screws or nails
penetrate the tyre, a protective layer on the inside of the tyre
running surface immediately seals the resulting holes.
♦ This means no air can escape. The sealing function is effective
for almost all air leaks induced by objects up to 5 millimetres
in diameter.

Note

These may not be fitted in combination with other tyre types, e.g.
run-flat tyres and “normal” tyres.

4.1 Explanation for mobility tyres

♦ ContiSeal is a preventative sealing compound installed by the
manufacturer Continental as an integral component of the pro‐
duction process.
♦ ContiSeal is a self-adhesive, viscous sealing compound that
is applied in an even coat from shoulder to shoulder on the
inside of the running surface.
♦ The sealing compound represents an integral component of
the mobility tyre.
♦ A mobility tyre can be identified by a special logo on the outside
of the sidewall.

Caution

The sealing compound is not intended as a permanent tyre

repair following a puncture.

4. Self-sealing tyres “ContiSeal” 307

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ If a foreign body with a diameter up to 5 mm punctures the

running surface of a mobility tyre, the function of the sealing
compound is to surround the object and to prevent any possi‐
ble air loss by effecting an almost immediate seal.
♦ The sealing compound is designed to seal the majority of
puncture types caused by foreign bodies up to 5 mm in diam‐
eter.
♦ ContiSeal significantly reduces the frequency of flat tyres, but
it is not intended to allow the tyre to be operated with reduced
pressure or when flat (without air).
♦ In all other respects, mobility tyres display the same properties
as tyres without the ContiSeal sealing compound.

4.2 Handling mobility tyres

♦ When handling mobility tyres, take particular care to maintain
cleanliness during work and also when storing tyres.
♦ The sealing compound on the inside of the running surface of
the tyre is not protected and is therefore very susceptible to
any type of contamination.
♦ We recommend storing each tyre individually in a sufficiently
large plastic bag or similar.
♦ As with any other tyre, mobility tyres should be regularly
checked for signs of cuts, penetrations and loss of inflation
pressure.
♦ This inspection should be conducted at least once or twice a
month, and always prior to each long trip.
♦ Penetrations or damage that is not attended to in good time
can lead to a loss of inflation pressure and/or failure of the tyre.
♦ Mobility tyres with damage by cuts and/or penetrations must
be inspected immediately.
♦ It is necessary to decide whether the tyre must be taken out
of use and scrapped.
♦ Removing and installing the mobility tyre involves the same
procedure as a normal tyre.

308 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

5 Tyre pressure monitor display

General information:
The Tyre Pressure Monitoring System is part of the software in
the ABS control unit - J104- . The system is used to detect slow
tyre pressure loss from a wheel. Event memory entries for the
Tyre Pressure Loss Indicator are stored in the ABS control unit -
J104- . The Tyre Pressure Loss Indicator compares the speed
and the rolling circumference of the individual wheels via the ABS
sensors.
After the following work or modifications, the tyre pressure mon‐
itor display button - E492- must be pressed and held until a
confirmation is sounded.
♦ Change in tyre pressure
♦ Changing one or more wheels
♦ Interchanging wheels, e.g. from front to rear
♦ Removing and fitting one or more wheels
A change in a wheel's rolling circumference will be indicated by
the tyre pressure monitor warning lamp - K220- lighting up in the
dash panel insert. A tyre's rolling circumference may change as
a result of:
♦ Insufficient tyre pressure
♦ Structural tyre damage
♦ Uneven load distribution in the vehicle
♦ Increased load on one axle, e.g. due to towing a trailer
♦ Use of snow chains.
♦ Temporary spare wheel installed
♦ Wheel renewal.

5.1 System fault in the ABS system

If a fault in the ABS is displayed by the ESP and TCS warning
lamp - K155- or the traction control system warning lamp - K86- ,
then the tyre pressure loss indicator warning lamp - K220-
-arrow- will also light up. However, no fault will be stored in the
Tyre Pressure Loss Indicator system.
The warning lamp cannot be extinguished by pressing the TPM
button - E492- . In this case, please carry out the following steps:
– Connect ⇒ Vehicle diagnostic tester and select “Guided Fault
Finding” ⇒ Vehicle diagnostic tester.
Running gear

Brake system

01- self-diagnosis-capable system TRW 450

03 - anti-lock braking system ABS/EDL/TCS/ESP

03 - functions

Adapting J104 with tyre pressure monitor display

Follow instructions on screen to perform basic setting.

5. Tyre pressure monitor display 309

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

5.2 Perform basic setting

Basic setting must be performed after every modification to the
wheels.
• Ignition must be switched on.
• Handbrake of vehicle must be applied.
Following each wheel change, the SET button must be actuated
whilst the ignition is switched on and the vehicle is stationary until
an audible signal is sounded. An audible signal confirms that ba‐
sic setting has been performed.
An audible signal confirms that basic setting has been performed.

310 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

6 Vehicle alignment check

Special tools and workshop

equipment required

♦ Wheel alignment computer - V.A.G 1813F- or VW/Audi-ap‐

proved wheel alignment units
♦ Brake pedal depressor - V.A.G 1869/2-
♦ Insert tool, 18 mm - T10179-
♦ Shock absorber tool set - T10001-

6.1 General information

Wheel alignment must be performed only using a VW/AUDI-ap‐
proved wheel alignment unit!
Whenever wheels are aligned, both the front and rear axles must
be measured.
Otherwise, the steering rack may not be centred!
– Carry alignment out with the wheel alignment computer.
All the information on wheel alignment can be found in the wheel
alignment computer.
Current data »updates« are located in VW ServiceNet.

6. Vehicle alignment check 311

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐

ware; Beissbarth
⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐
ware; Hunter
⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐
ware; Corghi
⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐
ware; John Bean

Note

♦ Wheel alignment should not be checked before the vehicle has

completed 2,000 km after the coil springs have settled.
♦ When making adjustments, adhere to the relevant specifica‐
tions as closely as possible.

Wheel alignment is necessary if:

♦ The vehicle does not handle properly.
♦ Vehicle has been involved in an accident and components
have been renewed.
♦ Axle components are removed or renewed.
♦ Tyres wear on one side.
Components have been renewed
Front axle component was Alignment necessary Rear axle component re‐ Alignment necessary
renewed. newed
yes no yes no
Lower suspension link X Lower transverse link X
Bonded rubber bush X 1) Upper transverse link X
for suspension link
Wheel bearing housing X Track rod X
Track rod/track rod ball joint X Wheel bearing housing X
Steering rack X Subframe X
Subframe X Coil spring X
Suspension strut X Shock absorbers X
Anti-roll bar X 1) Anti-roll bar X
Trailing arm X
1) Prerequisite: the positions of the subframe and brackets were
fixed before the parts were removed ⇒ page 13

Components removed and installed

Front axle component re‐ Alignment necessary Rear axle component re‐ Alignment necessary
moved and reinstalled moved and reinstalled
yes no yes no
Lower suspension link X 2) Lower transverse link X
Wheel bearing housing X Upper transverse link X
Track rod/track rod ball X Track rod X
joint
Steering rack X Wheel bearing housing X
Subframe X 2) Subframe X

312 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Front axle component re‐ Alignment necessary Rear axle component re‐ Alignment necessary
moved and reinstalled moved and reinstalled
yes no yes no
Suspension strut X Coil spring X
Anti-roll bar X 2) Shock absorbers X
Anti-roll bar X
Trailing arm X
2) Prerequisite: the positions of the subframe and brackets were
fixed before the parts were removed ⇒ page 13

6.2 Conditions for testing

• Check suspension, wheel bearing, steering and steering link‐
age for excessive play and damage.
• Tread depth difference of no more than 2 mm on one axle.
• Tyres inflated to correct pressures.
• Vehicle unladen.
• Fuel tank must be full.
• Spare wheel and vehicle tools are stowed in correct locations.
• The fluid reservoir for the windscreen/headlight washer sys‐
tem must be full.
• When checking wheel alignment, ensure that sliding plates
and turn tables are not touching end stop.
Please note!
• The test equipment must be properly adjusted and attached
to the vehicle; observe device manufacturer's operating in‐
structions.
If necessary, ask the manufacturer to show you how to use the
wheel alignment machine.
Wheel alignment platforms and wheel alignment units and com‐
puters can lose their calibration over a period of time.
Wheel alignment platforms and alignment units and computers
should be checked and adjusted as necessary during inspection
and maintenance at least once per year!
– Handle these highly sensitive devices carefully and conscien‐
tiously.

6.3 Test preparations

Special tools and workshop equipment required

6. Vehicle alignment check 313

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Brake pedal depressor - V.A.G 1869/2-

The existing lateral runout of the wheel must be compensated for.

Otherwise, the result of the measurement will be incorrect.
If runout compensation is not performed, it is not possible to adjust
toe-in correctly!
Observe information provided by the manufacturer of the wheel
alignment unit.
– Carry out wheel runout compensation.
– Apply brake pedal depressor - V.A.G 1869/2- .
– Use brake pedal depressor to depress brake pedal.

6.4 Wheel alignment specifications

These specifications apply to all engines.
♦ Explanation of PR numbers can be found here ⇒ page 322
The ride height shown in the table refers to dimension -a-.

Front axle Standard running Standard running Sports running Blue Motion
gear gear with adap‐ gear
tive chassis con‐
trol DCC
PR numbers G02 G40 G03 G40
Total toe (without load) 10' ± 10’ 10' ± 10’ 10' ± 10’ 10' ± 10’
Camber (in straight-ahead -28′ ± 30′ -36′ ± 30′ -40′ ± 30′ -36′ ± 30′
position)
Maximum permissible differ‐ max. 30' max. 30' max. 30' max. 30'
ence between sides
Toe-out on turns 1) at 20° left 1°16′ ± 20′ 1°25′ ± 20′ 1°29′ ± 20′ 1°25′ ± 20′
and right steering angle
Caster 7° 22′ ± 30′ 7° 32′ ± 30′ 7° 36′ ± 30′ 7° 32′ ± 30′
Maximum permissible differ‐ max. 30' max. 30' max. 30' max. 30'
ence between sides
Ride height 408 ± 10 mm 398 ± 10 mm 393 ± 10 mm 398 ± 10 mm

314 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

1)
Toe-out on turns can be displayed as a negative value on the
wheel alignment computer, depending on the manufacturer.

Front axle Nivomat Lowered stand‐ Mobile service ADAC

ard running gear
PR numbers G02+1JH G01 G22 G22
Total toe (without load) 10' ± 10’ 10' ± 10’ 10' ± 10’ 10' ± 10’
Camber (in straight-ahead -28′ ± 30′ -34′ ± 30′ -36′ ± 30′ -36′ ± 30′
position)
Maximum permissible differ‐ max. 30' max. 30' max. 30' max. 30'
ence between sides
Toe-out on turns 1) at 20° left 1°16′ ± 20′ 1°23′ ± 20′ 1°25′ ± 20′ 1°25′ ± 20′
and right steering angle
Caster 7° 22′ ± 30′ 7° 29′ ± 30′ 7° 32′ ± 30′ 7° 32′ ± 30′
Maximum permissible differ‐ max. 30' max. 30' max. 30' max. 30'
ence between sides
Ride height 408 ± 10 mm 400 ± 10 mm 398 ± 10 mm 398 ± 10 mm
1)
Toe-out on turns can be displayed as a negative value on the
wheel alignment computer, depending on the manufacturer.

These specifications apply to all engines.

♦ Explanation of PR numbers can be found here ⇒ page 322
Rear axle, front-wheel drive Standard running Standard running Sports running Blue Motion
and 4WD gear gear with adap‐ gear
tive chassis con‐
trol DCC
Camber -1° 20′ ± 30′ -1° 20′ ± 30′ -1° 20′ ± 30′ -1° 20′ ± 30′
Maximum permissible differ‐ max. 30' max. 30' max. 30' max. 30'
ence between sides
Total toe (at specified cam‐ 10′ ± 10′ 10′ ± 10′ 10′ ± 10′ 10′ ± 10′
ber)
Max. permissible deviation max. 20' max. 20' max. 20' max. 20'
from direction of travel
Ride height 428 ± 10 mm 418 ± 10 mm 413 ± 10 mm 418 ± 10 mm

Rear axle, front-wheel drive Nivomat Lowered stand‐ Mobile service ADAC
and 4WD ard running gear
Camber -1° 45′ ± 30′ -1° 20′ ± 30′ -1° 45′ ± 30′ -1° 45′ ± 30′
Maximum permissible differ‐ max. 30' max. 30' max. 30' max. 30'
ence between sides
Total toe (at specified cam‐ 10′ ± 10′ 10′ ± 10′ 10′ ± 10′ 10′ ± 10′
ber)
Max. permissible deviation max. 20' max. 20' max. 20' max. 20'
from direction of travel
Ride height 418 ± 10 mm 420 ± 10 mm 420 ± 10 mm 408 ± 10 mm

Volkswagen Technical Site: http://vwts.ru http://vwts.info

6. Vehicle alignment check 315

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

6.5 Overview - wheel alignment procedure

Always adhere to the following procedure!
– Take note of the information in the wheel alignment unit.

Alignment procedure

Start → Carry out wheel runout com‐ → Bounce springs.

pensation.
↓
Turn steering wheel to ← Measure vehicle height. ← Fit brake pedal depressor - V.A.G
straight-ahead position 1869/2-
and lock in place 1)
↓
Check front axle camber → Is actual value within toler‐ → no
ance?
↓ ↓
↓ ← ← yes Adjusting ⇒ page 317
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle camber → Is actual value within toler‐ → no
ance?
↓ ↓
↓ ← ← yes Adjusting ⇒ page 318
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle toe → Is actual value within toler‐ → no
ance?
↓ ↓
↓ ← ← yes Adjusting ⇒ page 320
↓ ↓
↓ ← ← ← ← ←
↓
Check front axle caster → Is actual value within toler‐ → no
ance?
↓ ↓
↓ ← ← yes Inspect axle components and
body
↓ ↓
↓ ← ← ← ← ←
↓

316 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Check front axle toe → Is actual value within toler‐ → no

ance?
↓ ↓
End ← yes Adjusting ⇒ page 321
↑ ↓
↑ ← ← ← ← ←
1)If steering wheel is not centred, it must be straightened after
wheel alignment is finished. Then carry out basic setting for steer‐
ing angle sender - G85- using ⇒ Vehicle diagnostic tester.

6.6 Correcting front axle camber

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

Note

♦ Camber correction is necessary only after body repairs. Cam‐

ber cannot be adjusted. However, it can be mediated by
shifting the subframe!
♦ Move subframe only to left or right, but never in or opposite to
direction of normal travel!

– Remove noise insulation.

– Loosen bolts -1- for subframe -2- to body on both sides.
The camber adjustment range is limited by the tolerances within
the bores in the brackets and the subframe. If the specified value
is not reached by moving the components, these and the body
must be inspected ⇒ page 1 .
– Now camber may be adjusted to specification by moving sub‐
frame -arrows 3-.
– Tighten new bolts for subframe to body to specified torque plus
extra turn angle.
After shifting the subframe and steering rack, clearance between
the steering column universal joint and the cut-out in the bulkhead
must be checked.

6. Vehicle alignment check 317

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove footwell trim by unscrewing nuts -arrows-.

There must be a clearance of 5 mm all around between universal

joint -1- and aperture in plenum chamber bulkhead -2-.

Specified torques, subframe to body

Bolt Specified torque
M12 x 1.5 x 90 70 Nm + 180° further
♦ Use new bolts

M12 x 1.5 x 100 70 Nm + 180° further

♦ Use new bolts

6.7 Adjusting camber on rear axle

Special tools and workshop equipment required
♦ Ring spanner - T10179-

318 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Loosen upper transverse link nut -A- on subframe.

– Adjust camber by turning hexagon head of eccentric bolt
-arrow-.

Note

The maximum adjustment range is 90° to the left or right of centre.

– Tighten nut -A-.

– To do so, use insert tool 18 mm - T10179- .

Using ring spanner - T10179- , tighten nut to 80 Nm.

– Check camber value again after nut -A- has been tightened.

6. Vehicle alignment check 319

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Specified torques
Component Specified torque
Upper transverse link to subframe (vehicles with front- 95 Nm
wheel drive) ♦ To tighten nuts, set torque wrench - V.A.G
♦ Use new bolts 1332- to 80 Nm.
♦ Tighten threaded connections only when vehicle is in ♦ Applies only in conjunction with insert tool,
the normal running position 18 mm - T10179-

6.8 Adjusting toe at rear axle

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

– Loosen nut -1-.

– Turn eccentric bolt -1- until specification is attained.

– Tighten nut again.

320 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Specified torque
Component Specified torque
Lower transverse link to subframe 95 Nm
♦ Use new bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

6.9 Adjusting front axle toe

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

♦ Insert tool, 24 mm - V.A.G 1332/11-

– Loosen lock nut -3- while counterholding on head of track rod
-2-.
– Pull spring-type clip -1- off boot.
– Adjust toe by turning left and/or right track rod.
To do this, use an open-end spanner on hexagon flats on track
rod.
After turning track rods, ensure that boots are not twisted.
Twisted boots wear out quickly.

– Tighten locknut with tool insert 24 mm - V.A.G 1332/11- while

counterholding track rod ball joint -1-.
– Check toe values again.
It is possible that the value will change slightly when lock nut is
tightened.
However, if the measured toe value lies within the tolerance, the
adjustment is correct.
– Fit spring-type clip to boot.

Specified torques
Component Specified torque
Track rod ball joint to track rod 70 Nm

6. Vehicle alignment check 321

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

6.10 Basic setting of steering angle sensor -

G85-
If steering wheel was realigned, basic settings for steering angle
sensor - G85- must be checked. Carry out basic setting in Guided
fault finding mode using ⇒ Vehicle diagnostic tester.
To do this, select “Select function/component” by pressing
GoTo button.

6.11 Vehicle data sticker

Information on the individual running gear that is fitted is currently
not available on the data sticker.
To find information about the running gear, please search in EL‐
SA/Vehicle-specific notes.
In this example the vehicle is equipped with standard running gear
G02 -arrow-.

322 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

7 Wheels, tyres

7.1 Models with breakdown set

Depending vehicle equipment, the vehicles are equipped with a
tyre mobility set.
Breakdown set is located in luggage compartment. It consists of
a compressor and a bottle of tyre sealant.

7.2 Tyre sealant

The tyre sealant in the bottle has a limited shelf life.
Therefore, the expiry date is indicated on the bottle -arrow-.
Renew tyre sealant if the expiry date is reached (the tyre sealant
must not be older than 4 years).
If the bottle was opened e.g. at a "flat tyre", it must also be re‐
newed.
Observe regulations for disposal.

7.3 Removing a tyre

Tyres which have been filled or sealed using tyre sealant must be
drained before removal.

Caution

♦ Avoid eye and skin contact with tyre sealant.

♦ It is damaging to health and can cause eye irritation and
allergies.
♦ During this work, wear protective gloves and safety gog‐
gles.

– Place the wheel on an even surface.

– Unscrew and remove the valve insert of tyre valve.

7. Wheels, tyres 323

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Use a suitable drill or mill to carefully drill a hole in shoulder

area of tyre.
– Hold wheel over a suitable container and drain sealant.
– Remove tyre from rim.
– Clean wheel rim with, for example, a moist cloth.

7.4 Fitting a new tyre

• Ensure that the wheel rim is clean.
– Insert new tyre valve with -VAS 6459- -1-.
– Unscrew and remove valve insert.
– Inflate tyre to approx. 3 - 4 bar. The bead of the tyre must slip
audibly over the hump of the rim.
– Screw in valve insert.
– Check tyre pressure to make sure prescribed pressure has
been reached.
– Balance wheel.

7.5 Tyre sealant disposal

♦ Tyre sealant or residue must not be mixed or disposed of with
other fluids.
♦ Excess tyre sealant must be collected and stored in a plastic
container. The plastic container can be disposed of through
the disposal system along with the breakdown set (when the
expiry date is exceeded)
♦ The items can be returned or disposed of through the existing
workshop disposal system.
♦ Contact the service provider or the waste disposal officer of
the sales centre or importer.

324 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

8 Instructions for changing or fitting

wheels

WARNING

Perform the checks and follow the instructions listed below.

This is important to ensure that the wheel bolts and the wheels
are properly secured.

– Check to ensure that contact surfaces -arrows- on brake disc

are free of corrosion and dirt.
If necessary, clean contact surfaces using e.g. pneumatic brush
grinder set - VAS 6446- ⇒ Volkswagen ServiceNet; Workshop
Equipment, Catalogue .

– Check to ensure that contact surface -arrow- on centring seat

of brake disc are free of corrosion and dirt.

– Check to ensure that contact surface -arrow- on inner side of

wheel (rim) and also centring seat of rim are free of corrosion
and dirt.
– The lug seats* in the holes for the wheel bolts and the threads
of the wheel bolts must also be free of corrosion and dirt, oil
or grease.
*The lug seat is the curved surface of a section of a sphere cut
by a plane.

8. Instructions for changing or fitting wheels 325

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Check whether the wheel bolts can be easily screwed in by

hand. The thread of the wheel bolts must not come into contact
with the bore in the brake disc -arrow-.
If the thread of the wheel bolt touches the hole -arrow-, turn the
brake disc relative to the wheel hub accordingly.
If necessary, remove dirt and corrosion, oil or grease from the
contact surfaces, threads in the wheel hub and/or wheel bolts as
necessary.

WARNING

Damaged, badly corroded or difficult to remove wheel bolts

must be renewed.

8.1 Fitting wheels

– Preserving wheel centring seat ⇒ page 327 .
1- When fitting the wheel, pull in all wheel bolts uniformly by
hand.
2- Tighten diagonally to 30 Nm.
3- Lower vehicle onto the floor and tighten all wheel bolts with
the torque wrench to the prescribed torque in diagonal se‐
quence ⇒ page 304 .

WARNING

Do not use an impact screwdriver to screw in the bolts.

326 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

9 Protecting wheel centring seat

against corrosion
Applies to alloy and steel wheels
When changing a wheel, wheel centring seat should be waxed
using wax spray to prevent corrosion between wheel centring seat
and rim ⇒ Electronic parts catalogue “ETKA” .
– Remove wheel.
– Thoroughly clean wheel centring seat on wheel hub and the
centring ring of the wheel rim.
– Apply wax to centring area -arrow- with a brush.
Ensure that only centring ring -arrow- but not contact surface of
wheel rim has been waxed. Otherwise, the brakes will be soiled,
which would reduce the braking efficiency.

WARNING

Wheel bolts, contact surfaces of wheel hub and wheel rim and
wheel hub threads must not be waxed. Never treat wheel se‐
curing bolts with lubricant or corrosion protection materials!

– Install wheel and tighten bolts or nuts ⇒ page 304 .

9. Protecting wheel centring seat against corrosion 327

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

10 Vibration due to wheels/tyres - cau‐

ses and rectification
Causes of rough running ⇒ page 328
Balancing wheels ⇒ page 328
Conduct a road test before balancing wheels ⇒ page 328 .
Balance wheels on stationary wheel balancer ⇒ page 329 .
Vibration control system - VAS 6230 A- ⇒ page 332
Finish balancer ⇒ page 332
Radial and lateral run-out on wheels and tyres ⇒ page 333
Checking radial and lateral run-out on wheels and tyres with tyre
gauge - V.A.G 1435- ⇒ page 333
Checking radial and lateral run-out on wheel rim ⇒ page 334
Matching ⇒ page 335
Flat spots caused by storage or handling ⇒ page 336

10.1 Causes of rough running

Rough running can have a number of different causes. It can also
be caused by tyre wear. Tyre wear caused by driving is not always
evenly spread across the entire running surface of the tyre. This
causes slight imbalances which affect the smooth running of a
wheel which was previously exactly balanced.
Minor imbalances will not be felt at the steering wheel, but that
does not mean that they are not there. They increase wear on the
tyre and thus reduce the tyre service life.
Recommendation
To ensure
• optimal safety,
• smoothest possible running and
• even wear
throughout a tyre's service life, we recommend having the wheels
and tyres balanced at least twice during the tyre's service life.

10.2 Balancing wheels

Before you start balancing the wheels, the following requirements
must be met.
• Tyre inflation pressure must be OK.
• The tyre tread must not exhibit one-sided wear and should be
at least 4 mm deep.
• The tyre must not show any signs of damage, for example
cuts, piercing, foreign bodies, etc.
• The wheel suspension, steering and steering linkage, includ‐
ing the shock absorbers, must be in perfect condition.
• You must have conducted a road test.

10.3 Conducting a road test before balancing

wheels
If a customer brings a vehicle to the workshop complaining about
“vibration”, a road test is essential prior to balancing the wheels.

328 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ This will give you information about the nature of the rough
running.
♦ You will be able to determine the speed range in which rough
running occurs.
– Raise the vehicle on a lifting platform immediately after the
road test.
– Mark the positions of the tyres on the vehicle.
Tyre position Marked with …
Front left tyre FL
Front right tyre FR
Rear left tyre RL
Rear right tyre RR
– Remove wheels.
– Balance wheels.

10.4 Balancing wheels on stationary wheel

balancing machine
• Road test has been carried out ⇒ page 328 .
Clamp wheel into wheel balancing machine

Note

When balancing tyres, please remember that cleanliness is ab‐

solutely essential, as is the case in any other repair work you carry
out. Only then can you attain a flawless result!

Dirt and rust in the area of the contact surfaces and centre of the
wheel distort the result.
– Clean contact surface, centring element and inside of wheel
using e.g. pneumatic brush grinding set - VAS 6446- ⇒ Volks‐
wagen ServiceNet; Workshop Equipment, Catalogue before
clamping wheel on wheel balancing machine!

Note

It is very important that the correct tools for centring and clamping
the wheels are used on the wheel balancing system. Before com‐
mencing any work, find out about the respective centring system
for wheel balancing machines ⇒ Volkswagen ServiceNet; Work‐
shop Equipment, Catalogue .

10. Vibration due to wheels/tyres - causes and rectification 329

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Attach the wheel (together with tyre) to the wheel balancing

machine.

330 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Note

♦ To clamp the wheel in place, use centring system for wheel

balancing machines - VAS 5271- , for example.
♦ This ensures that the wheel is 100% centred and that the
wheel will be clamped without damage!
♦ The wheel cannot be centralised 100% with conical clamping
elements on the wheel balancing machine.
♦ A deviation of 0.1 mm from the centre results in an imbalance
of 10 g at the wheel/rim.

Procedure for balancing wheels and tyres

– Allow the wheel (together with tyre) to rotate on the wheel bal‐
ancing machine.
– Check that the indicator lines on the sidewalls of the tyre near
the wheel rim flange run evenly.
– Check tyre profile with wheel/tyre rotating.

Note

If one-sided wear, flat spots from braking or severely washed out

spots are apparent, balancing cannot achieve smooth running. In
this case, the tyre must be renewed.

– Check true running of the wheel/tyre. If the wheel and tyre do

not run true although there are no flat spots, radial or lateral
runout may be the cause.
– Check the wheel for radial or lateral run-out ⇒ page 333 .
– If radial and lateral runout are within the specified tolerance,
balance the wheel and tyre.

Note

♦ More than 60 g of weight per tyre should not be used.

♦ If more weight is required, you may be able to achieve smooth‐
er running by "matching" the tyre and rim. Matching tyres
⇒ page 335 .
♦ The wheel balancer display should indicate 0 g.
♦ As an alternative to match mounting, you could use the vibra‐
tion control system - VAS 6230 A- ⇒ page 332 .

– Bolt wheel onto vehicle.

– First, hand-tighten the lowest wheel bolt to about 30 Nm.
– Then, tighten the remaining wheel bolts diagonally to about 30
Nm. This process centres the wheel on the hub.
– Lower vehicle onto its wheels.
– Now use the torque wrench to firmly tighten the wheel bolts
diagonally to the prescribed torque.
Carrying out road test
– After balancing the wheels and tyres, carry out a road test.

10. Vibration due to wheels/tyres - causes and rectification 331

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

If you detect vibration during the road test, it may be due to tol‐
erance in the wheel centring.
In unfavourable circumstances, the component tolerances of
wheels and hubs could cumulate. This too can lead to vibration.
This can be alleviated using a finish balancer. ⇒ page 332

10.5 Vibration control system - VAS 6230 A-

Using the vibration control system - VAS 6230 A- you can perform
more functions than just stationary balancing.
A special feature of this system is the testing of the radial force of
the wheel and tyre while rolling.
A roller presses against the wheel with a force of about 635 kg.
This simulates the vertical tyre force against the road surface
during travel.
Radial and lateral runout in the wheel and tyre and differences in
the stiffness of the tyre cause the vertical force of the wheel to
vary.
The -VAS 6230 A- detects and stores the position of the maximum
measured radial force in the tyre. Then the position of the smallest
distance between the wheel rim flange and the centre of the rim
is measured.

10.6 Finish balancer

Note

♦ Before working with a finish balancer , the mechanic needs to

have been instructed by the manufacturer of the balancer.
♦ To balance the wheels, set the wheels of the driven axle on
the sensor platforms (only the front wheels of a front-wheel
drive vehicle, all four wheels of an all-wheel drive vehicle).

If you determine a residual imbalance greater than 20 grams

when balancing the wheels, you should rotate the mounting po‐
sition of the wheel on the hub.
– Mark the point at which the imbalance is indicated.
– Then, unbolt the wheel and rotate its position on the hub so
that the marking points downwards.

Note

The hub must not rotate during this procedure.

– First, hand-tighten the lowest wheel bolt to about 30 Nm.

– Then, tighten the remaining wheel bolts diagonally to about 30
Nm. This process ensures that the wheel is centred properly
on the hub.
– Check whether the imbalance is less than 20 g using the finish
balancer.

332 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Note

The imbalance should always be less than 20 grams before you

change the balance weight.

– Loosen the wheel bolts again if necessary.

– Rotate wheel again by one or two wheel bolt holes in relation
to wheel hub.
– Tighten wheels using the method described above.

Note

Do not try to reduce the imbalance using balancing weights until

the imbalance is less than 20 g.

– Balance wheels if imbalance is less 5 g.

– Tighten wheel bolts to specified torque if you have not already
done so.

WARNING

Always tighten wheel bolts to specified tightening torque using

a torque wrench!

10.7 Radial and lateral runout of wheels and

tyres
Radial and lateral runout occur when the wheel and tyre do not
run absolutely true.
For technical reasons, 100% true running is not possible.
Therefore, the manufacturers of these components allow a pre‐
cisely determined tolerance.
Mounting the tyre in an unfavourable position on the wheel can
cause the maximum allowed tolerance for wheel with tyre to be
exceeded.
The table shows the maximum permissible tolerances for a wheel
with mounted tyre.
Tolerances for radial and lateral runout of wheels with tyres
Wheel with tyre Radial runout (mm) Lateral runout (mm)
Passenger cars 0.9 1.1
(1.3 in vicinity of lettering)

10.8 Checking radial and lateral runout on

wheels and tyres with tyre gauge - V.A.G
1435-
Checking lateral run-out
– Preload tyre gauge approx. 2 mm.

10. Vibration due to wheels/tyres - causes and rectification 333

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Fit tyre gauge to side wall of tyre.

– Turn wheel slowly.
– Make a note of the smallest and largest deflection of the indi‐
cator needle.

Note

If the difference is greater than 1.3 mm, the lateral runout is too
great.

In this case, you can reduce lateral runout by match mounting the
tyre ⇒ page 335 .
Extreme values on the tyre gauge due to small irregularities in the
rubber may be disregarded.
Checking radial runout
– Preload tyre gauge approx. 2 mm.

– Fit tyre gauge to running surface of tyre.

– Turn wheel slowly.
– Make a note of the smallest and largest deflection of the indi‐
cator needle.

Note

If the difference is greater than 1 mm, the radial runout is too great.

In this case, you can reduce radial runout by match mounting the
tyre ⇒ page 335 .

10.9 Checking radial and lateral run-out on

wheel rim
– Attach the disc wheel to the wheel balancing machine .
– Use the centring system for wheel balancing machines - VAS
5271- .
– Preload tyre gauge approx. 2 mm.
– Turn disc wheel slowly.
– Make a note of the smallest and largest deflection of the indi‐
cator needle.
S - Lateral runout
H - Radial runout
– Compare the measured values with the specifications in the
table ⇒ page 335 .

Note

Extreme values on the tyre gauge due to small irregularities may

be disregarded.

334 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Specifications for radial and lateral runout on wheel rim

Wheel Radial runout (mm) Lateral runout (mm)
Steel wheel 0.5 0.5
Alloy wheel 0.5 0.8

Note

If the measured value exceeds the specification, acceptably

smooth running cannot be attained.

10.10 Matching
General information
When radial or lateral runout of the disc wheel and tyre coincide,
the imbalance of the wheel is amplified by the tyre.
For technical reasons, 100% true running is not possible
⇒ page 333 .
Before match mounting the used wheels which are fitted on the
vehicle, run the tyres warm. This will eliminate any flat spots
caused by storage or handling, ⇒ page 336 .
Procedure for match mounting
– Let air out of tyre.
– Press tyre beads off wheel rim flanges.
– Apply tyre assembly paste all around the tyre beads.
– Rotate tyre by 180° in relation to disc wheel.
– Inflate tyre to approx. 4 bar.
– Attach the wheel (together with tyre) to the wheel balancing
machine.
– Check wheel for true running and for radial and lateral runout .

Note

♦ If the specified values for radial and lateral runout are not ex‐
ceeded, the wheel can be balanced to 0 g. Specified values
appear on ⇒ page 333 .
♦ If the radial and lateral runout is not within the specifications,
the tyre must be rotated again.

– Let air out and press tyre beads off the wheel rim flanges.
– Rotate tyre by 90° in relation to disc wheel (quarter of a turn).
– Inflate tyre again to 4 bar and check true running.

Note

♦ If the specified values for radial and lateral runout are not ex‐
ceeded, the wheel can be balanced to 0 g.
♦ If the radial and lateral runout are not within the specified val‐
ues, the tyre must be rotated again.

10. Vibration due to wheels/tyres - causes and rectification 335

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Press tyre off wheel rim flange again as described above.

– Rotate tyre by 180° in relation to disc wheel (half a turn).
If the radial and/or lateral runout are still not within the specified
values, check the disc wheel for radial and/or lateral runout:
⇒ page 334 .
If the measured values for radial and lateral runout of the wheel
are within the specified values, the tyre has an unacceptably high
radial or lateral runout. In this case, the tyre must be renewed.

Note

♦ After fitting the tyres there will be fitting lubricant between the
tyres and the rim flanges.
♦ You should therefore avoid severe braking and acceleration
manoeuvres for the first 100 or 200 km driven. The tyres may
otherwise rotate on the rims and the work will have been in
vain.

10.11 Flat spots caused by storage or handling

What is a flat spot?
The terms flat area and flats are also used for the term flat spot.
Flat spots caused by storage or handling also cause vibration in
the same way as incorrectly balanced wheels do. It is important
that flat spots on the tread are identified as such.
Flat spots caused by storage or handling cannot be balanced and
they can reoccur at any time due to various circumstances. Flat
spots caused by storage or handling can be eliminated without
complicated special tools. Assuming it is not a flat spot caused by
full-on braking ⇒ Wheel and Tyre Guide - Series; Rep. gr. 44 ;
Rolling noises due to tyres, locked brake flat spots .

Note

Flat spots caused by hard braking cannot be repaired. Such tyres

must be renewed.

Reasons for flat spots caused by storage or handling:

♦ The vehicle has been left standing in one place without being
moved for several weeks.
♦ The tyre inflation pressure is too low.
♦ The vehicle was placed in a paint shop drying booth after being
painted.
♦ The vehicle was parked with warm tyres in a cool garage or
similar for a long period of time. In this case, a standing flat
spot may even occur overnight.
Eliminating flat spots caused by storage or handling
♦ Flat spots caused by storage or handling cannot be eliminated
from the tyre using workshop equipment.
♦ Flat spots caused by storage or handling can be removed only
by running the tyres warm.
♦ The method described below is not recommended in cold and
wintry weather.

336 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Requirements and conditions:

– If necessary, check tyre pressure and correct.
– If possible, drive the vehicle onto a motorway.
– Traffic and road conditions permitting, drive a 20 to 30 km
stretch at a speed of 120 to 150 km/h (where legally permis‐
sible).

WARNING

♦ Do not endanger yourself or other road users during this

road test.
♦ Observe the highway code and speed limitations in force
when performing the road test.

– Jack up the vehicle immediately after the trip.

– Unbolt wheels from vehicle.
– Balancing wheels on stationary wheel balancer ⇒ page 329 .

10. Vibration due to wheels/tyres - causes and rectification 337

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

11 Adaptive cruise control

⇒ “11.1 Calibrating adaptive cruise control”, page 338

11.1 Calibrating adaptive cruise control

Before adjusting the adaptive cruise control (ACC) system, check
the sensor, its bracket and its securing elements for damage, ex‐
ternal influence and secure seating. Repair any damaged parts if
necessary.
Before adjusting the adaptive cruise control (ACC) system, read
out the event memory and rectify any faults found.
The “measured misalignment-angle value” of the ACC control unit
indicates whether or not the sensor is out of adjustment.
Use only a wheel alignment machine and adjusting devices ap‐
proved by VW/AUDI to adjust the adaptive cruise control (ACC)
system.
Correct adjustment is an essential prerequisite for the perfect
functioning of the adaptive cruise control (ACC) system.

Note

♦ Re-adjustment is required when:

♦ The rear axle toe setting has been adjusted.
♦ The adaptive cruise control unit - J428- has been removed and
reinstalled.
♦ The front bumper support has been removed and installed.
♦ The front bumper support has been loosened or moved.
♦ The misalignment angle is greater than –0.8° to +0.8°.
♦ The vehicle has been brought into the service position.

Special tools and workshop equipment required

♦ Setting device - VAS 6430- or setting device, basic kit - VAS
6430/1-

♦ ACC reflector mirror - VAS 6430/3-

♦ Wheel alignment computer

338 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Note

♦ Before driving vehicle onto wheel alignment platform, make

sure there is sufficient space between vehicle and setting de‐
vice - VAS 6430- . The distance between ACC reflecting mirror
- VAS 6430/3- and the sensor must be 120 cm ± 2.5 cm.
♦ If available space is not adequate, move vehicle backwards
onto alignment platform as required to achieve space re‐
quired.
♦ If the position of the ACC reflecting mirror - VAS 6430/3- on
alignment beam is changed during the adjustment work, the
setting of setting device - VAS 6430- must always be checked
(e.g. spirit levels, individual toe values on adjusting beam,
etc.).

• Before starting adjustment, read out event memory and rectify

any faults.
Adjustment procedure described here is based on setting device
- VAS 6430- .
The following setting sequence is to be adhered to:
1- Establish a distance of 120 cm ± 2.5 cm between the ACC
reflecting mirror - VAS 6430/3- fitted in the middle and the
sensor in the radiator grille.
2- Install ACC reflector mirror - VAS 6430/3- centred on align‐
ment beam.
3- Adjust adaptive cruise control unit - J428- .
If wheel alignment has just been carried out, the steps described
under “Setting without preceding wheel alignment” do not have to
be carried out.
Setting without preceding wheel alignment
– Press button to select ACC calibration in wheel alignment
computer.
– Observe testing preconditions for wheel alignment
⇒ page 313 .
– Drive car onto wheel alignment platform.
– Connect battery charger ⇒ Electrical system; General infor‐
mation; Rep. gr. 27 ; Charging battery .
– Connect ⇒ Vehicle diagnostic tester. (Route diagnostic cable
through open window.)

Note

During the setting procedure, make sure that all the car doors
remain closed and that the car's exterior lighting is switched off.

– Move front wheels to straight-ahead position.

– Mount quick-release clamps on rear wheels.
– Mount measurement transducers on rear wheels.
– Carry out wheel run-out compensation at rear wheels.

11. Adaptive cruise control 339

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Setting with or without preceding wheel alignment

– Position ACC setting device - VAS 6430- in the middle and
parallel at a distance -a- from the ACC reflector mirror - VAS
6430/3- fitted in the middle to the VW emblem in the radiator
grille.
a - 120 cm ± 2.5 cm
– Remove dirt, if there is any, from the sensor lens.
a - 120 cm ± 2.5 cm

Note

ACC setting device - VAS 6430- is not allowed to be moved on

alignment beam.

– Mount measurement transducers -1- of front wheels on align‐

ment beam.

– In the area -A-, move position -2- on rotary knob so that it co‐
incides with marking on mirror (the number 2 on the rotary
knob must point towards the vehicle).

340 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Use adjusting screws -1-, -2- and -3- to bring spirit levels -A-
and -B- to - VAS 6430/3- horizontal.
– Adjust mirror -4- by means of crank handle -arrow- in such a
way that the laser beam contacts the centre of the sensor lens.

– Position the mirror on side of the alignment beam so that the

laser beam contacts the centre of the sensor lens -1-.

– Level spirit levels -2- of the measurement transducer -1-.

11. Adaptive cruise control 341

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Turn fine adjuster screw -5- until display on wheel alignment

computer is within tolerance.

– Level spirit levels -2- of the measurement transducer -1-.

– Now, use laser beam -3- of -VAS 6430/3- to check again
whether spirit levels are horizontal and laser beam hits centre
of sensor lens.

Note

The alignment of - VAS 6430/3- must be repeated if the laser

beam does not coincide with the sensor lens.

– Press ⇒ Vehicle diagnostic tester GoTo button and select Se-

lect function/component function.

Selection on ⇒ Vehicle diagnostic tester for setting adaptive

cruise control unit - J428- :
– On the screen, click the following buttons one after the other:
♦ Running gear (Rep. Gr. 01; 40 - 49)
♦ 13 - Proximity control
♦ 01 - Onboard-diagnostic capable system
♦ 13 - Proximity control
♦ 13 - Adaptive cruise control, functions
♦ 13 - Calibration
Follow instructions on screen to set the control unit.

342 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Designation of adjuster screws of adaptive cruise control unit -

J428- -3-
1- Adjuster screw 1
2- Adjuster screw 2

WARNING

The ACC setting is not accepted until “Final control diagnosis

is completed” is displayed in the ⇒ Vehicle diagnostic tester.

Installing Volkswagen emblem

– Insert tabs -1- of Volkswagen emblem into recesses of radiator

grille -arrows-.

– Fold Volkswagen emblem -1- upwards, and push it completely

downwards onto edge -arrow- in radiator grille.

– Push uppermost tab -arrow- of Volkswagen emblem down‐

wards.
– Push Volkswagen emblem -1- in -direction of arrow- until tabs
can be heard to engage.

11. Adaptive cruise control 343

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

12 Front camera for driver assist sys‐

tems - R242-

Note

The following situations can cause the camera function to be im‐

paired by sustained poor visibility of the lane marker lines:

♦ The field of view of the camera is contaminated or iced over.

In this case, clean the affected area.
♦ The field of view of the camera is fogged over.
The camera’s viewing window must be cleaned manually if there
is heavy soiling on the inside of the windscreen in the field of view
of the camera. To do this, the control unit and lens hood must be
removed and the windscreen cleaned using cleaning solution.
Removing the control unit and lens cover ⇒ Rep. gr. 94 .
Correct calibration is a basic precondition for the driver assistance
system's -242- front camera to function without faults.
The driver assistance system's -242- front camera must be reca‐
librated if:
♦ “No or incorrect basic setting/adaption” entry stored in the
event memory.
♦ The front camera for driver assist systems - R242- was re‐
newed.
♦ Windscreen has been renewed or removed.
♦ Rear axle toe has been adjusted.
♦ Modifications having an effect on the body height have been
made to the car's running gear.
♦ The vehicle level senders have been reprogrammed on vehi‐
cles with damper control.

Note

♦ Before calibrating the front camera for driver assist systems,

read out event memory and rectify faults as necessary.
♦ The geometrical driving axis of the car must be measured in
order to calibrate the driver assistance system's front camera.
It is used as a reference position for the setting device - VAS
6430- .
♦ Calibration of the driver assistance system's front camera
must only be performed only using VW/AUDI approved wheel
alignment equipment!
♦ Calibration of the driver assistant system's front camera is
permitted only with the setting device - VAS 6430- !

12.1 Adjusting front camera for driver assis‐

tance system R242
Special tools and workshop equipment required

344 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Setting device - VAS 6430-

♦ Wheel alignment computer

♦ ⇒ Vehicle diagnostic tester

Note

♦ The front camera for driver assist systems - R242- must be

correctly located in the holder.
♦ The field of view of the camera must be clean and clear.
♦ Before driving the vehicle onto the wheel alignment platform,
make sure there is sufficient space between the midpoint of
the hub of the front wheels and the setting device - VAS 6430- .
♦ The distance between the setting device - VAS 6430- and the
centre point of the hub of the front wheels must be 1500 mm
± 25 mm.
♦ If the available space is not adequate, move the vehicle back‐
wards on the alignment platform as required.
♦ The calibration board must be positioned centrally on the set‐
ting device.
♦ The event memory must be read before starting calibration.
Any memory entries must be deleted.

– Note testing preconditions for wheel alignment ⇒ page 313 .

– Drive car onto wheel alignment platform.
– Connect battery charger ⇒ Electrical system; general infor‐
mation; Rep. gr. 27 .
– Connect ⇒ Vehicle diagnostic tester to vehicle. (Route diag‐
nostic cable through open window.)

Note

During the calibration procedure, make sure that all the car doors
remain closed and that the car's outside lighting is switched off.

– Move front wheels to straight-ahead position.

– Select calibration run for front camera for driver assist systems
-R242- on wheel alignment computer.
– Mount quick-release clamps on all four wheels.
– Mount measuring transducers on wheels.
– Perform wheel runout compensation on rear wheels.
– Bounce springs.

12. Front camera for driver assist systems R242 345

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Measure ride height at all four wheels and make a note of it.

Note

♦ Setting device - VAS 6430- is not allowed to be moved on

alignment beam.
♦ Wheel alignment platform must be in the lowermost levelled
position for next work step.

– Align setting device - VAS 6430- at a right angle to lengthways

axis of car.

– Turn setting device - VAS 6430- upwards so that alignment

beam is parallel to middle of measurement transducers on
front wheels, in order to perform a correct measurement with
distance measuring unit -1-.
1- Distance measuring unit with tape measure and socket pin
– Position setting device - VAS 6430- at distance -a- of 1500 mm
± 25 mm from midpoint of hub of front wheels to beam of set‐
ting device - VAS 6430- .

Caution

♦ Distance -a- of 1500 mm ± 25 mm must be measured on

both sides of vehicle and adjustment device - VAS 6430-
must then be aligned.
♦ Distance -a- must be same on both sides of car.
♦ To guarantee correct calibration, setting device - VAS
6430- must be at right angle to lengthways axis of car.

– Mount measurement transducer -1- of front wheels onto set‐

ting device - VAS 6430- .

– Measure height value -a- between standing surface of setting

device - VAS 6430- and wheel support surface on wheel align‐
ment platform and enter value in wheel alignment computer.

346 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unscrew clamping bolt -arrow-, place measuring bar -1- on

floor.

– Use crank -1- to set calibration panel - VAS 6430/4- to nominal

height -2- indicated by wheel alignment computer and make a
note.

When nominal height has been reached, measuring bar -1- must
be moved upwards slightly and secured with clamping screw
-arrow-.

12. Front camera for driver assist systems R242 347

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Use adjuster screw -1- to level spirit level -A-.

– Move setting device - VAS 6430- sideways -arrows B- until

display on wheel alignment computer is within tolerance.

– Screw down adjuster screws -2- and -3- slightly to secure set‐
ting device - VAS 6430- against rolling away.

348 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Turn fine adjuster screw -1- until display on wheel alignment

computer is within tolerance.

– Use adjuster screw -1- to level spirit level -A-.

– Use adjuster screws -2- and -3- to level spirit level -B-.

12. Front camera for driver assist systems R242 349

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unscrew clamping bolt -arrow-, place measuring bar -1- on

floor.

– Check nominal height -2- again and correct if necessary.

When nominal height has been reached, measuring bar -1- must
be moved upwards slightly and secured with clamping screw
-arrow-.
Concluding work is carried out via ⇒ Vehicle diagnostic tester.
– Switch on ignition.
– On ⇒ Vehicle diagnostic tester, select “Guided Fault Finding”.
Body (Rep. Gr. 01;27;50…97)

Electrical system (Rep. Gr. (01, 27, 90…97)

01_Self-diagnosis capable systems

Front camera for driver assistance system -R242-

Camera for driver assistance systems, functions

A5 - Calibrating the control unit (Rep. Gr. 44)

Follow instructions on screen to perform calibration.

Note

The next step in Guided fault finding is to measure the body

height.

350 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Enter the noted standing height.

12. Front camera for driver assist systems R242 351

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

48 – Steering
1 Evaluating accident vehicles
A check list for evaluating running gear of accident vehicles can
be found under ⇒ page 1 .

352 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

2 General repair instructions

To achieve the desired results when performing repairs on the
steering rack it is important to work with the greatest possible care
and cleanliness, and to use proper tools in good condition. Also
note the basic rules on safety when performing repair procedures.
A number of general notes on the individual repair procedures,
which can otherwise be found in the relevant sections of the
workshop manual, are summarised here. They apply for this par‐
ticular workshop manual.
For a description of the design and function of the “APA” steering
system, see ⇒ Self-study programme No. 399 ; Electromechan‐
ical Steering with Parallel-axis Drive .
For a description of the design and function of the electrome‐
chanical steering system, see ⇒ Self-study programme No. 317 ;
Electromechanical Power-assisted Steering with Double Pinion .

2.1 Steering rack

♦ Thoroughly clean all unions and the adjacent areas before
disconnecting.
♦ When installing the steering rack, make sure that dowel
sleeves between bracket and steering rack are seated cor‐
rectly.
♦ Place removed parts on a clean surface and cover them to
prevent them from getting dirty. Use sheeting and paper for
this purpose. Use lint-free cloths only.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing.
♦ Use only the grease and sealants with specified part numbers.
♦ If repair work cannot be performed immediately, cover new
parts which have been removed from their packing.

2.2 Gaskets and seals

♦ Always renew seals and gaskets.
♦ When seals have been removed, check contact surface on
housings or shafts for burrs and damage and rectify as nec‐
essary.
♦ Completely remove all residue from liquid sealants from the
sealing surfaces, making sure that no residual sealant gets
into the steering rack housing.

2.3 Nuts and bolts

♦ Loosen and tighten bolts and securing nuts for covers and
housings diagonally.
♦ Avoid canting sensitive parts, such as servo motor with control
unit. Loosen and tighten them diagonally in stages.
♦ Specified torques given are for unlubricated nuts, bolts and
screws.
♦ Always renew self-locking bolts and nuts.

2. General repair instructions 353

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

2.4 Electrical components

You have certainly felt an electric shock when you have touched
something metallic. This is due to the electrostatic charge of the
human body. This charge can cause malfunctions if you touch the
electric steering rack and steering column components.
– Before working on electrical components, touch an earned
object, such as a water pipe or a lifting platform. Do not directly
touch connector contacts.

2.5 Guided fault-finding, vehicle self-diag‐

nosis and test instruments
♦ Before performing repair work on the electromechanical steer‐
ing rack, determine the cause of damage as precisely as
possible using the ⇒ Vehicle diagnostic tester in “Guided Fault
Finding”, “Vehicle Self-Diagnosis” and “Test Instruments” op‐
erating modes.

354 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

3 Assembly overview - airbag and steering wheel

1 - Steering column
❑ Removing and installing
⇒ page 358
2 - Steering wheel
❑ Removing and installing
⇒ page 355
❑ Different versions possi‐
ble. Refer to ⇒ Electron‐
ic parts catalogue
3 - Bolt
❑ 30 Nm + 90°
❑ Renew after each re‐
moval

3.1 Removing and installing airbag and

steering wheel
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

3. Assembly overview - airbag and steering wheel 355

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Perform the following steps:

Removing

WARNING

The following conditions must be met before starting work on

the electrical system and removing the steering wheel:
♦ Earth strap must be disconnected from battery ⇒ Rep. gr.
27 ; Battery; Disconnecting and reconnecting the battery .
♦ The wheels must be in straight-ahead position.
Failure to comply with these precautions may lead to subse‐
quent failure of the airbag system!

– Move steering column to middle height position.

– Remove airbag module ⇒ General body repairs, interior; Rep.
gr. 69 ; Passenger protection .
– Turn wheels to straight-ahead position.

Note

The steering wheel must be removed/installed in the middle po‐

sition (wheels facing straight ahead).

– Remove bolt -1-.

– Mark position of steering wheel/steering column with a felt-
tipped pen.
– Pull steering wheel -2- off steering column.
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:
Make sure that the wheels are pointing straight ahead before fit‐
ting the steering wheel.
– When installing a steering wheel that has been removed,
make sure that the markings on the steering column and steer‐
ing wheel are in line.
– When installing a new steering wheel (without marking), the
steering wheel must be mounted in middle position (steering
wheel spoke must be horizontal and wheels in straight posi‐
tion).
– Install steering wheel.
– Installing airbag module ⇒ General body repairs, interior; Rep.
gr. 69 ; Passenger protection .
– Carry out road test.
– If the steering wheel is skewed, the steering wheel must be
removed again and fitted onto the splines of the steering col‐
umn.
Specified torque

Component Specified torque

Bolt for steering wheel 30 Nm + 90°
♦ Use new bolt

356 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

3. Assembly overview - airbag and steering wheel 357

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

4 Assembly overview: steering column, left-hand drive

Note

♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

♦ Always renew self-locking nuts.
♦ Always renew corroded nuts and bolts.

1 - Assembly carrier with

mounting bracket
2 - Steering column
❑ Removing and installing
⇒ page 358
3 - Bolt
❑ 20 Nm
❑ Observe tightening se‐
quence ⇒ page 365
4 - Bolt
❑ 20 Nm
❑ Observe tightening se‐
quence ⇒ page 365
5 - Crash bar for brake pedal
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
6 - Crash bar for clutch pedal
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
7 - Bolt
❑ 30 Nm
❑ Renew after each re‐
moval

4.1 Removing and installing steering col‐

umn, left-hand drive vehicle
Special tools and workshop equipment required

358 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Torque wrench - V.A.G 1331-

♦ Torque wrench - V.A.G 1332-

4. Assembly overview: steering column, left-hand drive 359

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Perform the following steps:

Removing

Note

♦ Before starting work, check to see if a knee airbag is fitted.

♦ If “AIRBAG” appears on trim under steering column, this
means a knee airbag is installed.
♦ If a knee airbag is installed then it must be renewed ⇒ General
body repairs, interior; Rep. gr. 69 ; Airbag; Removing and in‐
stalling knee airbag .

Only the complete steering column is supplied as a replacement

part. A repair is not possible.
Steering lock housing can be transferred ⇒ Electrical system;
Rep. gr. 94 ; Ignition switch and lock cylinder .

WARNING

The following conditions must be met before starting work on

the electrical system and removing the steering wheel:
♦ Mechanic must electrostatically discharge himself/herself.
This can be done by touching earthed metal such as a
water pipe, a heating pipe, metal girders or a lifting plat‐
form ⇒ page 354 .
Failure to comply with this precaution may lead to subsequent
failure of the electronic steering column lock control unit -
J764- !
♦ Disconnect earth strap from battery ⇒ Electrical system;
Rep. gr. 27 ; Battery; Disconnecting and reconnecting the
battery .
♦ The wheels must be in straight-ahead position.
Failure to comply with these precautions may lead to subse‐
quent failure of the airbag system!

– Turn wheels to straight-ahead position.

– Pull down lever on side of steering column.
– Swing steering column down as far as possible and pull out.
– Press lever on side of steering column back up.
– Remove airbag module ⇒ General body repairs, interior; Rep.
gr. 69 ; Airbag; Removing and installing driver airbag module .
– Remove steering wheel ⇒ page 355 .
– Remove steering column trim ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments, covers and trims; Removing and
installing steering column trim .
– Remove steering column switch ⇒ Electrical system; Rep. gr.
94 ; Steering column switch; Removing and installing steering
column switch .
Vehicles with ignition/starter switch

360 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Disconnect connector -1-.

Vehicles with keyless entry and start system “Keyless Access”

– Disconnect connector -1-.
– Unclip cable from holder on electronic steering column lock
control unit - J764- -arrow-.
Continued for all vehicles
– Remove footwell vent ⇒ Rep. gr. 80 ; Repairing heating; Re‐
moving and installing vents

– Remove nut -arrow- and pull earth cable off steering column.

– Press lugs -arrow- of the cable guide -1- inwards on both sides
and pull cable guide -1- out of the guide on the steering col‐
umn.

4. Assembly overview: steering column, left-hand drive 361

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unscrew securing nuts -arrows- and remove footwell trim -1-.

– Unscrew bolt -arrow- from universal joint -1- and pull off uni‐
versal joint in -direction of arrow-.

Caution

The following work must not be performed while the universal

joint is separated from the steering rack:
♦ Switch on ignition
♦ Turn steering mechanism
♦ Turn steering column
These points must absolutely be heeded because otherwise,
irreparable damage may be caused.

Vehicles with manual gearbox

– Remove left bolt -1- and remove crash bar for clutch pedal
-2-.

Vehicles with dual clutch gearbox or automatic gearbox

– Remove left bolt for steering column.
Continued for all vehicles

362 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove right bolt -1- and remove crash bar for brake pedal
-2-.

– Unscrew bolts -1- and hold steering column when doing this.

– Lower steering column -1- slightly and carefully pull column

out of guides on mounting bracket -arrow-.

Caution

Take great care to ensure the steering column is handled and

transported correctly ⇒ page 367 .

Installing

– Hook steering column -1- with cut-out into guide on mounting

bracket -arrow-.
The correct installation position of the steering column relative to
the mounting bracket is guaranteed only in this way.

Note

When installing steering column, adhere strictly to bolting se‐

quence.

4. Assembly overview: steering column, left-hand drive 363

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Fix steering column in position with bolts -1-.

– Fit crash bar for brake pedal -2- and secure with bolt -1-.

Vehicles with dual clutch gearbox or automatic gearbox

– Fix steering column in position with bolt.

Vehicles with manual gearbox

– Fit crash bar for clutch pedal -2- and secure with bolt -1-.
Continued for all vehicles

364 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Tighten bolts -1-, -2-, -3- and -4- one after the other to the
specified torque.

– Install cable guide -1- beneath steering column.

The lugs -arrow- must latch into the guide on both sides.

– Fit earth cable on steering column -arrow-.

– Position universal joint -1- in direction of -arrow- onto steering

pinion.
– Insert new hexagon bolt -arrow- and tighten.

4. Assembly overview: steering column, left-hand drive 365

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Insert footwell trim -1- and secure with bolts -arrows-.

Vehicles with ignition/starter switch

– Connect connector -1-.

Vehicles with keyless entry and start system “Keyless Access”

– Connect connector -1-.
– Clip cable into holder on electronic steering column lock con‐
trol unit - J764- -arrow-.
Vehicles with knee airbag
– Install knee airbag ⇒ General body repairs, interior; Rep. gr.
69 ; Airbag; Removing and installing knee airbag .
Continued for all vehicles
– Install footwell vent on driver's side ⇒ Rep. gr. 80 ; Repairing
heating; Removing and installing vents
– Install steering column switch ⇒ Electrical system; Rep. gr.
94 ; Steering column switch; Removing and installing steering
column switch .
– Install steering column trim ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments, covers and trims; Removing and
installing steering column trim .
– Install steering wheel ⇒ page 355 .
– Install driver airbag module ⇒ General body repairs, interior;
Rep. gr. 69 ; Airbag; Removing and installing driver airbag
module .
– Carry out basic setting for steering angle sender - G85- using
⇒ Vehicle diagnostic tester.

Specified torques
Component Specified torque
Universal joint to steering rack 30 Nm
♦ Use new bolt

Steering column to mounting bracket 20 Nm

366 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

4.2 Handling and transporting steering col‐

umn

WARNING

♦ Adherence to proper steering column handling is essen‐

tial.
♦ Improper handling of steering column may damage the
steering column, leading to safety risks.

Proper steering column handling and transport

♦ Use both hands to transport steering column.
♦ Hold steering column upper jacket tube and in area of upper
universal joint.

Improper handling of steering column

Transportation using the clamping lever leads to primary steering
column damage.

4. Assembly overview: steering column, left-hand drive 367

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Improper handling of steering column with safety risks

Following methods of handling will damage universal joint bushes
and lower steering column bearing:
♦ Transporting steering column with one hand on jointed shaft.
♦ Bending joints more than 90°.

4.3 Checking steering column for damage

Visual check
– Check all steering column parts for damage.
Checking function
– Check that steering column turns smoothly and easily.
– Check whether steering column can be moved in the longitu‐
dinal direction and vertically.

368 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

5 Assembly overview: steering column, right-hand drive

Note

♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

♦ Always renew self-locking nuts.
♦ Always renew corroded nuts and bolts.

1 - Bolt
❑ 20 Nm
2 - Assembly carrier
3 - Anti-vibration brace
4 - Bolt
❑ 20 Nm
❑ Observe tightening se‐
quence ⇒ page 375
5 - Crash bar for brake pedal
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
6 - Bolt
❑ 20 Nm
❑ Observe tightening se‐
quence ⇒ page 375
7 - Bolt
❑ 30 Nm
❑ Renew after each re‐
moval
8 - Crash bar for clutch pedal
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
9 - Bolt
❑ 20 Nm
10 - Bolt
❑ 20 Nm
11 - Steering column
❑ Removing and installing
⇒ page 369
12 - Mounting bracket

5.1 Removing and installing steering col‐

umn, right-hand drive vehicle
Special tools and workshop equipment required

5. Assembly overview: steering column, right-hand drive 369

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Torque wrench - V.A.G 1331-

♦ Torque wrench - V.A.G 1332-

Perform the following steps:

Removing
Only the complete steering column is supplied as a replacement
part. A repair is not possible.
Steering lock housing can be transferred ⇒ Electrical system;
Rep. gr. 94 ; Ignition switch and lock cylinder .
Vehicles with knee airbag
– Remove knee airbag ⇒ General body repairs, interior; Rep.
gr. 69 ; Airbag; Removing and installing knee airbag .
Continued for all vehicles

WARNING

The following conditions must be met before starting work on

the electrical system and removing the steering wheel:
♦ Mechanic must electrostatically discharge himself/herself.
This can be done by touching earthed metal such as a
water pipe, a heating pipe, metal girders or a lifting plat‐
form ⇒ page 354 .
Failure to comply with this precaution may lead to subsequent
failure of the electronic steering column lock control unit -
J764- !
♦ Disconnect earth strap from battery ⇒ Electrical system;
Rep. gr. 27 ; Battery; Disconnecting and reconnecting the
battery .
♦ The wheels must be in straight-ahead position.
Failure to comply with these precautions may lead to subse‐
quent failure of the airbag system!

370 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Turn wheels to straight-ahead position.

– Pull down lever on side of steering column.
– Swing steering column down as far as possible and pull out.
– Press lever on side of steering column back up.
– Remove airbag module ⇒ General body repairs, interior; Rep.
gr. 69 ; Airbag; Removing and installing driver airbag module .
– Remove steering wheel ⇒ page 355 .
– Remove steering column trim ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments, covers and trims; Removing and
installing steering column trim .
– Remove steering column switch ⇒ Electrical system; Rep. gr.
94 ; Steering column switch; Removing and installing steering
column switch .
Vehicles with ignition/starter switch
– Disconnect connector -1-.

Vehicles with keyless entry and start system “Keyless Access”

– Disconnect connector -1-.
– Unclip cable from holder on electronic steering column lock
control unit - J764- -arrow-.
Continued for all vehicles

– Remove nut -arrow- and pull earth cable off steering column.

5. Assembly overview: steering column, right-hand drive 371

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Press lugs -arrow- of the cable guide -1- inwards on both sides
and pull cable guide -1- out of the guide on the steering col‐
umn.

– Unscrew bolt -1-.

– Push up footwell trim -2- in -direction of arrow- and remove.

– Remove bolt -1- for universal joint and pull universal joint -2-
off steering rack.

Caution

The following work must not be performed while the universal

joint is separated from the steering rack:
♦ Switch on ignition
♦ Turn steering mechanism
♦ Turn steering column
These points must absolutely be heeded because otherwise,
irreparable damage may be caused.

372 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Vehicles with manual gearbox

– Remove left bolt -1- and remove crash bar for clutch pedal
-2-.

Vehicles with dual clutch gearbox or automatic gearbox

– Remove left bolt -1- for steering column.
Continued for all vehicles

– Remove right bolts -1- and remove crash bar for brake pedal
-2-.

– Unscrew bolts -1- and hold steering column when doing this.

5. Assembly overview: steering column, right-hand drive 373

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Lower steering column -1- slightly and carefully pull column

out of guides on mounting bracket -arrow-.

Caution

Take great care to ensure the steering column is handled and

transported correctly ⇒ page 377 .

Installing

– Hook steering column -1- with cut-out into guide on mounting

bracket -arrow-.
The correct installation position of the steering column relative to
the mounting bracket is guaranteed only in this way.

Note

When installing steering column, adhere strictly to bolting se‐

quence.

– Fix steering column in position with bolts -1-.

– Fit crash bar for brake pedal -2- and secure with bolts -1-.

374 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Vehicles with dual clutch gearbox or automatic gearbox

– Fix steering column in position with bolt -1-.

Vehicles with manual gearbox

– Fit crash bar for clutch pedal -2- and secure with bolt -1-.
Continued for all vehicles

– Tighten bolts -1-, -2-, -3- and -4- one after the other to the
specified torque.

– Install cable guide -1- beneath steering column.

The lugs -arrow- must latch into the guide on both sides.

5. Assembly overview: steering column, right-hand drive 375

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Fit earth cable on steering column -arrow-.

– Fit universal joint -2- onto steering rack pinion and tighten bolt
-1-.

– Install footwell trim -2- and secure with bolt -1-.

Vehicles with ignition/starter switch

– Connect connector -1-.

376 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Vehicles with keyless entry and start system “Keyless Access”

– Connect connector -1-.
– Clip cable into holder on electronic steering column lock con‐
trol unit - J764- -arrow-.
Vehicles with knee airbag
– Install knee airbag ⇒ General body repairs, interior; Rep. gr.
69 ; Airbag; Removing and installing knee airbag .
Continued for all vehicles
– Install steering column switch ⇒ Electrical system; Rep. gr.
94 ; Steering column switch; Removing and installing steering
column switch .
– Install steering column trim ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments, covers and trims; Removing and
installing steering column trim .
– Install steering wheel ⇒ page 355 .
– Install driver airbag module ⇒ General body repairs, interior;
Rep. gr. 69 ; Airbag; Removing and installing driver airbag
module .
– Carry out basic setting for steering angle sender - G85- using
⇒ Vehicle diagnostic tester.

Specified torques
Component Specified torque
Universal joint to steering rack 30 Nm
♦ Use new bolt

Steering column to mounting bracket 20 Nm

5.2 Handling and transporting steering col‐

umn

WARNING

♦ Adherence to proper steering column handling is essen‐

tial.
♦ Improper handling of steering column may damage the
steering column, leading to safety risks.

5. Assembly overview: steering column, right-hand drive 377

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Proper steering column handling and transport

♦ Use both hands to transport steering column.
♦ Hold steering column upper jacket tube and in area of upper
universal joint.

Improper handling of steering column

Transportation using the clamping lever leads to primary steering
column damage.

Improper handling of steering column with safety risks

Following methods of handling will damage universal joint bushes
and lower steering column bearing:
♦ Transporting steering column with one hand on jointed shaft.
♦ Bending joints more than 90°.

5.3 Checking steering column for damage

Visual check
– Check all steering column parts for damage.
Checking function
– Check that steering column turns smoothly and easily.

378 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Check whether steering column can be moved in the longitu‐

dinal direction and vertically.

5. Assembly overview: steering column, right-hand drive 379

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

6 Electromechanical steering rack,

LHD vehicle

6.1 Assembly overview - electromechanical steering rack for LHD vehicle

Caution

The following work must not be performed while the universal

joint is separated from the steering rack:
♦ Switch on ignition
♦ Turn steering mechanism
♦ Turn steering column
These points must absolutely be heeded because otherwise,
irreparable damage may be caused.

1 - Universal joint
2 - Bolt
❑ 30 Nm
❑ Renew after each re‐
moval
3 - Power steering rack
❑ With power steering
control unit - J500-
❑ With electromechanical
power steering motor -
V187-
❑ With steering torque
sender - G269-
❑ Can be tested in guided
fault finding using ⇒ Ve‐
hicle diagnostic tester
❑ Removing and installing
⇒ page 381

Note

Any entries in the event memory

must be deleted before renewing
the steering rack ⇒ Vehicle diagnos‐
tic tester.

4 - Wheel bearing housing

5 - Nut
❑ Tighten to 100 Nm, then
loosen (turn back) 180°
and retighten to 100 Nm
❑ Self-locking
❑ Renew after each re‐
moval
Volkswagen Technical Site: http://vwts.ru http://vwts.info

380 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

6 - Subframe
7 - Bolt
❑ 50 Nm + 90° further
❑ Renew after each removal
8 - Heat shield
9 - Torx bolt
❑ 6 Nm
❑ Self-tapping
10 - Wire

6.2 Removing and installing steering rack, left-hand drive vehicle

Special tools and workshop

equipment required

♦ Ball joint puller - T10187-

♦ Torque wrench - V.A.G 1331-
♦ Torque wrench - V.A.G 1332-
♦ Engine and gearbox jack - V.A.G 1383 A-

6. Electromechanical steering rack, LHD vehicle 381

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Removing

Note

Any entries in the event memory must be deleted before renewing

the steering rack ⇒ Vehicle diagnostic tester.

– Connect ⇒ Vehicle diagnostic tester and start “Guided Fault

Finding”.
Follow instructions on screen.
– Turn steering wheel to straight-ahead position and remove ig‐
nition key so that the steering lock engages.
Vehicles with keyless entry and start system “Keyless Access”
– Switch off ignition and open driver’s door so that the steering
lock engages.
Continued for all vehicles
– Disconnect battery ⇒ Rep. gr. 27 ; Battery; Disconnecting and
reconnecting battery .
– Unscrew securing nuts -arrows- and remove footwell trim -1-.

– Unscrew bolt -arrow- from universal joint -1- and pull off uni‐
versal joint in -direction of arrow-.

Caution

The following work must not be performed while the universal

joint is separated from the steering rack:
♦ Switch on ignition
♦ Turn steering mechanism
♦ Turn steering column
These points must absolutely be heeded because otherwise,
irreparable damage may be caused.

– Loosen wheel bolts.

– Raise vehicle.
– Remove front wheels.
– Remove lower noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Assembly overview - noise insulation .

382 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Loosen nut on track rod ball joint but do not remove complete‐
ly.

Caution

To protect thread, leave nut screwed a few turns onto joint pin.

– Push track rod ball joint off wheel bearing housing and remove
nut.
1- Ball joint puller - T10187-

– Unscrew nuts -arrows-.

– Pull suspension link out of swivel joint and turn wheel bearing
housing outwards to relieve suspension link.

– Detach exhaust system bracket from subframe -arrows-.

– Disconnect pendulum support from gearbox by removing bolts

-14-.

6. Electromechanical steering rack, LHD vehicle 383

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unscrew bolts -5- and -6- for steering rack.

– Fix position of subframe and brackets ⇒ page 13
– Separate connector for extended service intervals on oil sump.

– Position engine and gearbox jack - V.A.G 1383 A- -1- under

subframe

– Remove bolts -9- and -10- and lower subframe with bracket
slightly. In the process, observe electrical wiring.

384 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Unscrew bolts -arrows- and remove heat shield -1- above

steering rack.

– Remove cable guide from subframe -arrow-.

– Unclip all remaining cable clips on steering rack.

– Separate connectors -1- and -2- from steering rack.

– Lower subframe carefully with engine/gearbox jack - V.A.G
1383 A- .
– Lift off steering rack from subframe and remove to right.

– Position steering rack as shown in diagram.

This prevents damage to the control unit -1-.
Installing
Install in reverse order.

6. Electromechanical steering rack, LHD vehicle 385

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Renew seal -1-.

– Slide seal -1- over collar of steering rack -2- so that rubber lip
makes contacts with collar all round -arrows-.
– Make sure that seal -1- is firmly seated.
– Coat seal with lubricant e.g. soft soap from above.

– Always make sure that intermediate plate -1- is inserted be‐

tween subframe -2- and body.

– Check that white pressure diaphragm -arrow- is clean and un‐

damaged.
– Clean pressure diaphragm carefully if necessary.

Note

Renew steering rack if pressure diaphragm is damaged.

386 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Plug in connectors -1- and -2- so they audibly engage

Threaded sleeve of steering rack must be located in subframe
hole.

Note

♦ Coat seal on steering rack with suitable lubricant, e.g. soft

soap, before installing steering rack.
♦ After fitting the steering rack to the universal joint ensure that
the seal is not kinked against the assembly plate on the steer‐
ing rack. The opening to the footwell must be sealed correctly.
Otherwise, this can result in water leaks and/or noise.
♦ Ensure sealing surfaces are clean.

Before inserting subframe bolts, position steering rack on sub‐

frame and insert bolts for steering rack and anti-roll bar.
– Attach lower noise insulation ⇒ Rep. gr. 50 ; Assembly over‐
view - noise insulation .
– Bolt universal joint to steering rack.
– Connect battery ⇒ Rep. gr. 27 ; Battery; Disconnecting and
reconnecting battery .
– Carry out basic setting for steering angle sender - G85- using
⇒ Vehicle diagnostic tester.
If new steering rack has been installed, adapt electromechanical
power steering using ⇒ Vehicle diagnostic tester.
– Adapt electromechanical power-assisted steering using ⇒ Ve‐
hicle diagnostic tester.
Running gear (repair group 01; 40...49)

Electromechanical power steering

01 - self-diagnosis-capable system (APA-BS)

Electromechanical steering system

Function

Adapting electromechanical steering

Follow instructions on screen.

After installation, position of steering wheel must be checked dur‐
ing road test.
If steering wheel is crooked or a new steering rack was installed,
wheels must be aligned.
– Check wheel alignment ⇒ page 311 .

Specified torques
Component Specified torque
Subframe to body 70 Nm + 180°
♦ Use new bolts

Heat shield to subframe 6 Nm

♦ Bolt M6 is self-locking

Steering box to subframe 50 Nm + 90°

♦ Use new bolts

6. Electromechanical steering rack, LHD vehicle 387

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Component Specified torque

Universal joint to steering rack 30 Nm
♦ Use new bolt

Heat shield to steering rack 6 Nm

♦ Bolt M6 is self-locking

Track rod ball joint to wheel bearing housing Tighten to 100 Nm, then loosen (turn back) 180°
♦ Use new bolts and retighten to 100 Nm

Exhaust system bracket to subframe

⇒ Engine; Rep. gr. 26

Specified torques for pendulum support to gearbox

Bolt Specified torque
M10 × 35 50 Nm + 90° further
♦ Use new bolt

M10 × 75 50 Nm + 90° further

♦ Use new bolt

388 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

7 Electromechanical steering rack,

RHD vehicle

7.1 Assembly overview - electromechanical steering rack for RHD vehicle

Caution

The following work must not be performed while the universal

joint is separated from the steering rack:
♦ Switch on ignition
♦ Turn steering mechanism
♦ Turn steering column
These points must absolutely be heeded because otherwise,
irreparable damage may be caused.

1 - Universal joint
2 - Bolt
❑ M8 x 35
❑ 30 Nm
❑ Renew after each re‐
moval
3 - Wire
4 - Shield
5 - Torx screw
❑ 6 Nm
❑ Self-tapping
6 - Power steering rack
❑ With power steering
control unit - J500-
❑ With electromechanical
power steering motor -
V187-
❑ With steering angle
sender - G85-
❑ With steering torque
sender - G269-
❑ Can be tested in guided
fault finding using ⇒ Ve‐
hicle diagnostic tester
❑ Removing and installing
⇒ page 390

Note

Any entries in the event memory

must be deleted before renewing
the steering rack ⇒ Vehicle diagnos‐
tic tester.

7. Electromechanical steering rack, RHD vehicle 389

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

7 - Left wheel bearing housing

8 - Nut
❑ M12 × 1.5
❑ Tighten to 100 Nm, then loosen (turn back) 180° and retighten to 100 Nm
❑ Self-locking
❑ Renew after each removal
9 - Bolt
❑ M10 x 70
❑ 50 Nm + 90° further
❑ Renew after each removal
10 - Subframe
11 - Right wheel bearing housing

7.2 Removing and installing steering rack, RLD vehicle

Special tools and workshop

equipment required

♦ Torque wrench - V.A.G 1331-

♦ Torque wrench - V.A.G 1332-

390 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

♦ Engine and gearbox jack - V.A.G 1383 A-

♦ Ball joint puller - 3287 A-
Removing

Note

Any entries in the event memory must be deleted before renewing

the steering rack ⇒ Vehicle diagnostic tester.

– Connect ⇒ Vehicle diagnostic tester and start “Guided Fault

Finding”.
Follow instructions on screen.
– Turn steering wheel to straight-ahead position and remove ig‐
nition key so that the steering lock engages.
Vehicles with keyless entry and start system “Keyless Access”
– Switch off ignition and open driver’s door so that the steering
lock engages.
Continued for all vehicles
– Disconnect battery ⇒ Rep. gr. 27 ; Battery; Disconnecting and
reconnecting battery .
– Unscrew bolt -1-.
– Push up footwell trim -2- in -direction of arrow- and remove.

– Remove bolt -1- for universal joint and pull universal joint -2-
off steering rack.

Caution

The following work must not be performed while the universal

joint is separated from the steering rack:
♦ Switch on ignition
♦ Turn steering mechanism
♦ Turn steering column
These points must absolutely be heeded because otherwise,
irreparable damage may be caused.

– Loosen wheel bolts.

– Raise vehicle.
– Remove front wheels.
– Remove lower noise insulation ⇒ Rep. gr. 50 ; Assembly
overview - noise insulation .

7. Electromechanical steering rack, RHD vehicle 391

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Loosen nut on track rod ball joint but do not remove complete‐
ly.

Caution

To protect thread, leave nut screwed a few turns onto joint pin.

– Push track rod ball joint off wheel bearing housing and remove
nut.
1- Ball joint puller - T10187-

– Unscrew nuts -arrows-.

– Pull suspension link out of swivel joint and turn wheel bearing
housing outwards to relieve suspension link.

– Detach exhaust system bracket from subframe -arrows-.

– Disconnect pendulum support from gearbox by removing bolts

-14-.

392 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove bolts -arrows- from heat shield.

– Remove heat shield from subframe.

– Unscrew bolts -5- and -6- for steering rack.

– Fix position of subframe ⇒ page 13 .
– Separate connector for extended service intervals on oil sump.

– Position engine and gearbox jack - V.A.G 1383 A- -1- under

subframe

7. Electromechanical steering rack, RHD vehicle 393

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Remove bolts -9- and -10- and lower subframe with bracket
slightly. Observe electrical wiring.

– Unscrew bolts -arrows- and remove heat shield -1- above

steering rack.

– Remove cable guide from subframe -arrow-.

– Unclip all remaining cable clips on steering rack.

– Separate connectors from steering rack.

– Lower subframe carefully using engine and gearbox jack -
V.A.G 1383 A- .
– Lift off steering rack from subframe and remove to right.

394 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Position steering rack as shown in diagram.

This prevents damage to the control unit -1-.
Installing
Install in reverse order.

– Renew seal -1-.

– Slide seal -1- over collar of steering rack -2- so that rubber lip
makes contacts with collar all round -arrows-.
– Make sure that seal -1- is firmly seated.
– Coat seal with lubricant e.g. soft soap from above.

7. Electromechanical steering rack, RHD vehicle 395

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Always make sure that intermediate plate -1- is inserted be‐

tween subframe -2- and body.
Threaded sleeve of steering rack must be located in subframe
hole.

Note

♦ Coat seal on steering rack with suitable lubricant, e.g. soft

soap, before installing steering rack.
♦ After fitting the steering rack to the universal joint, make sure
that the seal is not kinked when lying against the assembly
plate and that the opening to the footwell is correctly sealed.
Otherwise, this can result in water leaks and/or noise.
♦ Ensure sealing surfaces are clean.

Before inserting subframe bolts, position steering rack on sub‐

frame and insert bolts for steering rack and anti-roll bar.
– Attach lower noise insulation ⇒ Rep. gr. 50 ; Assembly over‐
view - noise insulation .
– Bolt universal joint to steering rack.
– Connect battery ⇒ Rep. gr. 27 ; Battery; Disconnecting and
reconnecting battery .
– Carry out basic setting for steering angle sender - G85- using
⇒ Vehicle diagnostic tester.
If new steering rack has been installed, adapt electromechanical
steering using ⇒ Vehicle diagnostic tester.
– Adapt electromechanical power-assisted steering using ⇒ Ve‐
hicle diagnostic tester.
Running gear (repair group 01; 40...49)

Electromechanical power steering

01 - Onboard-diagnostic capable system

Electromechanical steering system

Function

Adapting electromechanical steering

Follow instructions on screen.

Note

If parking aid 2 is fitted in the vehicle, the power steering control

unit - J500- must be recoded ⇒ Vehicle diagnostic tester.

After installation, check position of steering wheel during road

test.
If steering wheel is crooked or a new steering rack was installed,
wheels must be aligned.
– Check wheel alignment ⇒ page 311 .

396 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Specified torques
Component Specified torque
Subframe to body 70 Nm + 180°
♦ Use new bolts

Heat shield to subframe 6 Nm

♦ Bolt M6 is self-locking

Steering box to subframe 50 Nm + 90°

♦ Use new bolts

Universal joint to steering rack 30 Nm

♦ Use new bolt

Heat shield to steering rack 6 Nm

♦ Bolt M6 is self-locking

Track rod ball joint to wheel bearing housing Tighten to 100 Nm, then loosen (turn back) 180°
♦ Use new bolts and retighten to 100 Nm

Exhaust system bracket to subframe

⇒ Engine; Rep. gr. 26

Specified torques for pendulum support to gearbox

Bolt Specified torque
M10 × 35 50 Nm + 90° further
♦ Use new bolt

M10 × 75 50 Nm + 90° further

♦ Use new bolt

7. Electromechanical steering rack, RHD vehicle 397

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

8 Repairing electromechanical steer‐

ing rack, LHD vehicle
Currently, no repairs can be performed on steering racks.

8.1 Assembly overview: electromechanical steering rack, LHD vehicle

1 - Right track rod ball joint

❑ Marked with “A”
⇒ page 403
❑ Removing and installing
⇒ page 405
❑ Checking: ⇒ page 409
❑ Fitting position
⇒ page 409
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
2 - Nut
❑ 70 Nm
3 - Clip
4 - Boot
❑ Must not be twisted after
toe setting has been ad‐
justed.
❑ Removing and installing
⇒ page 406
5 - Clip
❑ Renew
6 - Track rod
❑ 100 Nm
❑ Removing and installing
⇒ page 401
7 - Long bonded rubber bush
❑ Left rear with centring.
❑ Renewing ⇒ page 399
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
8 - Power steering rack
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
❑ Removing and installing ⇒ page 381
9 - Long bonded rubber bush
❑ Rear right
❑ Renewing ⇒ page 399
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
10 - Short bonded rubber bush
❑ Front left and right.
❑ Renewing ⇒ page 399
❑ Allocation ⇒ Electronic parts catalogue “ETKA”

398 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

11 - Locking plate
12 - Left track rod ball joint
❑ Marked with “B” ⇒ page 412
❑ Removing and installing ⇒ page 405
❑ Checking: ⇒ page 409
❑ Fitting position ⇒ page 409
❑ Allocation ⇒ Electronic parts catalogue “ETKA”

8.2 Renewing bonded rubber bushes for

power-assisted steering rack
Special tools and workshop equipment required
♦ Assembly tool - T10390-

Carry out the following work:

Removing

Note

♦ Always renew bonded rubber bushes in pairs per side of the

vehicle.
♦ Removal and installation are described for only one bonded
rubber bush. The procedure for the second bonded rubber
bush is similar.
♦ Always note allocation of bonded rubber bush to power-as‐
sisted steering rack ⇒ page 400 .

– Remove power steering rack ⇒ page 381 .

8. Repairing electromechanical steering rack, LHD vehicle 399

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Fit tools from above as shown in illustration.

1- Nut - T10390/3-
2- Tube - T10390/1-
– Pull out bonded rubber bush.

Allocation of bonded rubber bush to power-assisted steering rack

1- Short bonded rubber bush for front left
2- Short bonded rubber bush for front right
3- Long bonded rubber bush for rear right
4- Long bonded rubber bush for rear left with centring
Installing
– Note allocation of bonded rubber bush to power-assisted
steering rack ⇒ page 400 .
– Coat exterior of bonded rubber bush with soapy water.

– Position the bonded rubber bushes so that the flattened areas

point inwards in parallel -arrows-.

Note

Always draw in bonded rubber bush from above from direction of

steering shaft.

400 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Fit tools as shown in illustration.

1- Nut - T10390/3-
2- Bonded rubber bush
3- Tube - T10390/2-
– Draw bonded rubber bush in to stop until rubber lip has folded
over edge -arrow-.

Note

After releasing assembly tool - T10390- , bonded rubber bush

slides back slightly.

– Place lock plate -1- onto bonded rubber bushes so that edges
and flattened areas engage.
– Secure lock plate -1- in position with a cable tie -2-.

Note

Tighten cable tie as securely as possible so that lock plate does

not slip when installing power-assisted steering rack.

– Install power steering rack ⇒ page 381 .

– Remove cable tie from steering rack.

8.3 Removing and installing track rod

8. Repairing electromechanical steering rack, LHD vehicle 401

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Special tools and workshop

equipment required

♦ Ball joint puller - 3287 A-

♦ Hose clip pliers - V.A.G 1275-
♦ Torque wrench - V.A.G 1332-
♦ Open end spanner insert, AF 38 mm - V.A.G 1923-
♦ Locking pliers for Phaeton steering rack - VAS 6199-
Carry out the following work:
Removing
– Turn steering wheel to straight-ahead position.
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Clean outside of steering rack in vicinity of boot.

402 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Loosen nut on track rod ball joint but do not remove complete‐
ly.

Caution

To protect thread, leave nut screwed a few turns onto joint pin.

– Open clips and push boot back.

– Unscrew track rod.

1- Open-end spanner attachment - V.A.G 1923-
2- Torque wrench - V.A.G 1332-

Note

♦ If the steering rack shows signs of corrosion, damage, wear or

soiling, renew the complete steering rack.
♦ Likewise, if there is no film of grease on the steering rack, the
steering rack must be renewed.

Installing track rod

Carry out installation in the reverse sequence, noting the follow‐
ing:

Caution

Do not grease steering rack.

– Make sure that correct track rod ball joint is installed on each
side.
I - Track rod ball joint on right marked with an “A”
II - Track rod ball joint on left marked with a “B”
– Turn steering wheel to straight-ahead position.
– Thread new clamps and rubber boot onto track rod.

8. Repairing electromechanical steering rack, LHD vehicle 403

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Screw track rod into track rod ball joint until dimension -a- is
attained.
Dimension -a- = 367 mm ± 1 mm

– Tighten track rod.

1- Open-end spanner attachment - V.A.G 1923-
2- Torque wrench - V.A.G 1332-
– Lightly lubricate sealing surface between boot and track rod
with grease - G 052 168 A1- (from repair kit Fuchs Renolit
JP1619).

– Push rubber boot -2- onto track rod -1-, making sure that boot
is correctly positioned.
– Secure spring-type clip on rubber boot using hose clip pliers -
V.A.G 1275- .
– Lightly lubricate sealing surface between boot and steering
rack with grease - G 052 168 A1- (from repair kit Fuchs Renolit
JP1619).
– Push rubber boot onto steering rack housing as far as it will
go.

– Install new clip, as shown in figure, with locking pliers for

Phaeton steering rack - VAS 6199- .
– Install wheel and tighten bolts or nuts ⇒ page 304 .
– Check wheel alignment ⇒ page 311 .
– If both track rods have been exchanged, basic setting must be
carried out for steering angle sender - G85- ⇒ Vehicle diag‐
nostic tester.
– Then carry out basic setting of steering ⇒ Vehicle diagnostic
tester.

Specified torques
Component Specified torque
Track rod to steering rack 100 Nm
Track rod ball joint to track rod 70 Nm
Track rod ball joint to wheel bearing housing Tighten to 100 Nm, then loosen (turn back) 180°
♦ Use new bolts and retighten to 100 Nm

404 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

8.4 Removing and installing track rod ball

joint
Special tools and workshop equipment required
♦ Ball joint puller - T10187-

♦ Torque wrench - V.A.G 1332-

Carry out the following work:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Loosen nut -1-.
– Mark position of track rod ball joint on track rod.
– Loosen nut -2- on track rod ball joint but do not remove com‐
pletely.

Caution

To protect thread, leave nut screwed a few turns onto joint pin.

– Push track rod off wheel bearing housing and remove nut.
1- Ball joint puller - T10187-
– Unscrew track rod ball joint from track rod.
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:

8. Repairing electromechanical steering rack, LHD vehicle 405

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Make sure that correct track rod ball joint is installed on each
side.
I - Track rod ball joint on right marked with an “A”
II - Track rod ball joint on left marked with a “B”
– Screw track rod ball joint onto track rod as far as previously
applied mark and secure with lock nut.
– Insert track rod ball joint into wheel bearing housing.
– Bolt track rod ball joint with new nut.
– Install front wheel and tighten ⇒ page 304 .
– Check wheel alignment ⇒ page 311 .

Specified torques
Component Specified torque
Track rod ball joint to track rod 70 Nm
Track rod ball joint to wheel bearing housing Tighten to 100 Nm, then loosen (turn back) 180°
♦ Use new bolts and retighten to 100 Nm

8.5 Removing and installing bellows

406 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Special tools and workshop

equipment required

♦ Hose clip pliers - V.A.G 1275-

♦ Torque wrench - V.A.G 1332-
♦ Insert tool, 24 mm - V.A.G 1332/11-
♦ Locking pliers for Phaeton steering rack - VAS 6199-
Carry out the following work:
Removing

Note

♦ If boot is defective, moisture and dirt will enter steering rack.

There must be a palpable film of grease in the area of the teeth
on the steering rack. If there is no film of grease, the steering
rack must be renewed.
♦ The steering rack must be renewed:
♦ In the event of corrosion.
♦ In the event of damage.
♦ In the event of excessive wear
♦ In the event of soiling on the steering rack.

8. Repairing electromechanical steering rack, LHD vehicle 407

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Turn steering wheel to straight-ahead position.

– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Mark position of nut on track rod.
– Remove track rod ball joint ⇒ page 405 .
– Clean outside of steering rack in vicinity of boot.
No dirt must be allowed to enter the steering rack through a de‐
fective rubber boot during this operation.
– Open hose clips.
– Pull boot off steering rack housing and track rod.

Note

♦ If the steering rack shows signs of corrosion, damage, wear or

soiling, renew the complete steering rack.
♦ Likewise, if there is no film of grease on the steering rack, the
steering rack must be renewed.

Installing

Caution

Do not grease steering rack.

– Turn steering wheel to straight-ahead position.

– Thread new clamps and rubber boot onto track rod.
– Lightly lubricate sealing surface between boot and track rod
with grease - G 052 168 A1- (from repair kit Fuchs Renolit
JP1619).
– Push rubber boot -2- onto track rod -1- as shown in figure.
– Secure spring-type clip on rubber boot using hose clip pliers -
V.A.G 1275- .
– Lightly lubricate sealing surface between boot and steering
rack with grease - G 052 168 A1- (from repair kit Fuchs Renolit
JP1619).
– Push rubber boot onto steering rack housing to stop.

408 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Install new clip, as shown in figure, with locking pliers for

Phaeton steering rack - VAS 6199- .
– Screw in track rod ball joint up to mark made during removal
and install ⇒ page 405 .
– Install front wheel and tighten ⇒ page 304 .
– Check wheel alignment ⇒ page 311 .
– If both track rods have been exchanged, basic setting must be
carried out for steering angle sender - G85- ⇒ Vehicle diag‐
nostic tester.
– Then carry out basic setting of steering ⇒ Vehicle diagnostic
tester.

Specified torques
Component Specified torque
Track rod ball joint to track rod 70 Nm

8.6 Checking play, security and boots of

track rod ends
– Check play by moving track rods and wheels with the vehicle
raised (wheels hanging free). Clearance: zero clearance
– Check attachment.
– Check boots are not damaged and are seated correctly.

8.7 Allocation of track rod ball joints

I - Right track rod ball joint is marked with -A-.
II - Left-hand track rod ball joint is marked with -B-

8. Repairing electromechanical steering rack, LHD vehicle 409

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

9 Repairing electromechanical steer‐

ing rack, RHD vehicle
Currently, no repairs can be performed on steering racks.

9.1 Assembly overview: electromechanical steering rack, RHD vehicle

1 - Right track rod ball joint

❑ Marked with “A”
⇒ page 412
❑ Removing and installing
⇒ page 414
❑ Checking: ⇒ page 418
❑ Fitting position
⇒ page 418
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
2 - Nut
❑ 70 Nm
3 - Clip
4 - Boot
❑ Must not be twisted after
adjusting toe.
❑ Remove steering rack to
renew.
5 - Clip
❑ Renew
6 - Track rod
❑ 100 Nm
❑ Removing and installing
⇒ page 411
❑ Replacement parts are
supplied pre-adjusted.
7 - Power steering rack
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Removing and installing
⇒ page 390
8 - Left track rod ball joint
❑ Marked with “B” ⇒ page 412
❑ Removing and installing ⇒ page 414
❑ Checking: ⇒ page 418
❑ Fitting position ⇒ page 418
❑ Allocation ⇒ Electronic parts catalogue “ETKA”

410 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

9.2 Removing and installing track rod

Special tools and workshop

equipment required

♦ Ball joint puller - 3287 A-

♦ Hose clip pliers - V.A.G 1275-
♦ Torque wrench - V.A.G 1332-
♦ Open end spanner insert, AF 38 mm - V.A.G 1923-
♦ Locking pliers for Phaeton steering rack - VAS 6199-
Carry out the following work:
Removing
– Turn steering wheel to straight-ahead position.
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Clean outside of steering rack in vicinity of boot.

9. Repairing electromechanical steering rack, RHD vehicle 411

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Loosen nut on track rod ball joint but do not remove complete‐
ly.

Caution

To protect thread, leave nut screwed a few turns onto joint pin.

– Open clips and push boot back.

– Unscrew track rod.

1- Open-end spanner attachment - V.A.G 1923-
2- Torque wrench - V.A.G 1332-

Note

♦ If the steering rack shows signs of corrosion, damage, wear or

soiling, renew the complete steering rack.
♦ Likewise, if there is no film of grease on the steering rack, the
steering rack must be renewed.

Installing track rod

Carry out installation in the reverse sequence, noting the follow‐
ing:

Caution

Do not grease steering rack.

– Make sure that correct track rod ball joint is installed on each
side.
I - Track rod ball joint on right marked with an “A”
II - Track rod ball joint on left marked with a “B”
– Turn steering wheel to straight-ahead position.
– Thread new clamps and rubber boot onto track rod.

412 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Screw track rod into track rod ball joint until dimension -a- is
attained.
Dimension -a- = 367 mm ± 1 mm

– Tighten track rod.

1- Open-end spanner attachment - V.A.G 1923-
2- Torque wrench - V.A.G 1332-
– Lightly lubricate sealing surface between boot and track rod
with grease - G 052 168 A1- (from repair kit Fuchs Renolit
JP1619).

– Push rubber boot -2- onto track rod -1-, making sure that boot
is correctly positioned.
– Secure spring-type clip on rubber boot using hose clip pliers -
V.A.G 1275- .
– Lightly lubricate sealing surface between boot and steering
rack with grease - G 052 168 A1- (from repair kit Fuchs Renolit
JP1619).
– Push rubber boot onto steering rack housing as far as it will
go.

– Install new clip, as shown in figure, with locking pliers for

Phaeton steering rack - VAS 6199- .
– Install wheel and tighten bolts or nuts ⇒ page 304 .
– Check wheel alignment ⇒ page 311 .
– If both track rods have been exchanged, basic setting must be
carried out for steering angle sender - G85- ⇒ Vehicle diag‐
nostic tester.
– Then carry out basic setting of steering ⇒ Vehicle diagnostic
tester.

Specified torques
Component Specified torque
Track rod to steering rack 100 Nm
Track rod ball joint to track rod 70 Nm
Track rod ball joint to wheel bearing housing Tighten to 100 Nm, then loosen (turn back) 180°
♦ Use new bolts and retighten to 100 Nm

9. Repairing electromechanical steering rack, RHD vehicle 413

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

9.3 Removing and installing track rod ball

joint
Special tools and workshop equipment required
♦ Ball joint puller - T10187-

♦ Torque wrench - V.A.G 1332-

Carry out the following work:

Removing
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Loosen nut -1-.
– Mark position of track rod ball joint on track rod.
– Loosen nut -2- on track rod ball joint but do not remove com‐
pletely.

Caution

To protect thread, leave nut screwed a few turns onto joint pin.

– Push track rod off wheel bearing housing and remove nut.
1- Ball joint puller - T10187-
– Unscrew track rod ball joint from track rod.
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:

414 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Make sure that correct track rod ball joint is installed on each
side.
I - Track rod ball joint on right marked with an “A”
II - Track rod ball joint on left marked with a “B”
– Screw track rod ball joint onto track rod as far as previously
applied mark and secure with lock nut.
– Insert track rod ball joint into wheel bearing housing.
– Bolt track rod ball joint with new nut.
– Install front wheel and tighten ⇒ page 304 .
– Check wheel alignment ⇒ page 311 .

Specified torques
Component Specified torque
Track rod ball joint to track rod 70 Nm
Track rod ball joint to wheel bearing housing Tighten to 100 Nm, then loosen (turn back) 180°
♦ Use new bolts and retighten to 100 Nm

9.4 Removing and installing bellows

9. Repairing electromechanical steering rack, RHD vehicle 415

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

Special tools and workshop

equipment required

♦ Hose clip pliers - V.A.G 1275-

♦ Torque wrench - V.A.G 1332-
♦ Insert tool, 24 mm - V.A.G 1332/11-
♦ Locking pliers for Phaeton steering rack - VAS 6199-
Removing boot

Note

If boot is defective, moisture and dirt will enter steering rack.

There must be a palpable film of grease in the area of the teeth
on the steering rack. If there is no film of grease, the steering rack
must be renewed. Also renew steering rack if there are signs of
corrosion, damage or wear to the steering rack.

– Turn steering wheel to straight-ahead position.

– Remove wheel.
– Clean outside of steering rack in vicinity of boot.

416 Rep. gr.48 - Steering

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

No dirt must be allowed to enter the steering rack through a de‐

fective rubber boot during this operation.
– Mark position of nut -arrow 3- on track rod.
– Loosen nut -arrow 3-, counterholding on track rod ball joint
-arrow 2-.
– Loosen spring-type clamp -arrow 1- on boot using hose clip
pliers - V.A.G 1275- and push onto track rod.
– Remove clamp and pull boot from steering rack housing.
– Now turn track rod out of track rod ball joint.
– Pull boot with spring-type clip off track rod.

Note

♦ If the steering rack shows signs of corrosion, damage, wear or

soiling, renew the complete steering rack.
♦ Likewise, if there is no film of grease on the steering rack, the
steering rack must be renewed.

Installing boot

Caution

Do not grease steering rack.

– Turn steering wheel to straight-ahead position.

– Thread new clamps and rubber boot onto track rod.
– Screw in track rod to mark made during removal.

– Tighten lock nut -3- to specified torque while counterholding

track rod ball joint -2-.
– Lightly lubricate seal point between boot and track rod with
grease - G 052 168 A1- (from repair kit Fuchs Renolit JP1619).

– Push rubber boot -2- onto track rod -1- as shown in figure.
– Secure spring-type clip on rubber boot using hose clip pliers -
V.A.G 1275- .
– Lightly lubricate seal point between boot and steering rack with
grease - G 052 168 A1- (from repair kit Fuchs Renolit JP1619).
– Push rubber boot onto steering rack housing to stop.

9. Repairing electromechanical steering rack, RHD vehicle 417

 Sharan 2011 ➤ , Sharan 2016 ➤
Running gear, axles, steering - Edition 02.2019

– Install new clamp, as shown in figure, with locking pliers for

Phaeton steering rack - VAS 6199- .
Continue installation in reverse order of removal.
Wheel alignment must be checked following installation.
– Check wheel alignment ⇒ page 311 .
– If both boots have been exchanged, basic setting must be
carried out for steering angle sender - G85- using ⇒ Vehicle
diagnostic tester.
– Then carry out basic setting of steering ⇒ Vehicle diagnostic
tester.

Specified torques
Component Specified torque
Track rod ball joint to track rod 70 Nm

9.5 Checking play, security and boots of

track rod ends
– Check play by moving track rods and wheels with the vehicle
raised (wheels hanging free). Clearance: zero clearance
– Check attachment.
– Check boots are not damaged and are seated correctly.

9.6 Allocation of track rod ball joints

I - Right track rod ball joint is marked with -A-.
II - Left-hand track rod ball joint is marked with -B-

418 Rep. gr.48 - Steering