VW Sharan
The 1.9 TDI PD with 130 PS is the most powerful naturally aspirated diesel in the range and very popular with tuning enthusiasts. It shares all the ATD's weaknesses, but the higher torque (310 Nm) means wear on the camshaft, PD unit injectors, and dual-mass flywheel is significantly more pronounced. Chipping to 150–165 PS is common but massively increases the probability of failure.
Family Load, No Fun
The PD TDI ASZ in the heavy Sharan van is known for piston seizure and soot deposits. 130 hp barely copes with the weight.
Engine Weaknesses 7
In the ASZ, the camshaft drives four PD elements in a 310 Nm engine — the thermal and mechanical load exceeds the weaker variants. First wear signs possible from 70,000–80,000 km. Full replacement ~800–1,200 € in parts.
Symptoms: Clatter on cold start below 40°C oil temperature, rough running at high load, ticking that gets louder with operating time
Like all 1.9 TDI PD engines, the ASZ is an interference engine: a broken timing belt always means engine damage. Official intervals: 90,000 km up to model year 2004, then 120,000 km. Recommendation: replace every 90,000 km, including tensioner rollers and water pump.
Symptoms: Engine no longer starts, loud crack on snapping, no compression at all
The GT1749VA of the ASZ is particularly at risk in chipped vehicles (>140 hp). Infrequent oil changes and short trips lead to failure. Reconditioned exchange turbo: 400–800 € plus fitting. New VW unit: up to 1,500 €.
Symptoms: Power loss in the lower rev range, limp mode, whistling or howling noises, blue or black exhaust smoke
The four PD elements are actuated directly and mechanically by the cams, resulting in higher pressures than the 100 hp ATD. Wear, leaks or electrical faults cause individual cylinders to fail.
Symptoms: Hard rough running, black smoke, power drop, hesitation at part load and acceleration
The ASZ dual-mass flywheel suffers particularly from the high torque (310 Nm) and city driving. Broken or worn arc springs inside lead to failure. Replacement together with the clutch is recommended. Workshop costs 1,500–2,200 €.
Symptoms: Strong vibrations and rattling at idle, clatter in sync with engine speed, gear change problems, transmission shudder on pull-away
As with the ATD, EGR valve, throttle body and intake manifold become coked by soot particles. On the ASZ, swirl flaps are also affected. Cleaning is possible but time-consuming. EGR valve: approx. 120–350 € for the part, 150–300 € labour for cleaning.
Symptoms: Power loss, poor throttle response, increased consumption, engine warning light, black smoke on acceleration
Identical problem to the ATD: the combined fuel and vacuum pump no longer seals due to aged rubber. Diesel or oil escapes, the engine block area around the pump becomes wet. Seal kit repair possible for under 100 €.
Symptoms: Greasy, oily area at the cam cover/pump, diesel smell, slightly spongy brake pedal with severe vacuum loss
Vehicle Weaknesses 7
The Sharan 7M rusts at sills, wheel arches, and door lower edges through dirt accumulation behind trim. Rust is almost always to be expected on vehicles with over 150,000 km and 10+ years.
The manual and electric sliding doors of the Sharan 7M wear at rollers, rails, and locks. Doors no longer close cleanly or are difficult to move.
Defective actuator motors in door locks and corroded wiring harnesses in door grommets lead to partial or complete central locking malfunction.
The Sharan 7M's AC compressor fails at higher mileages. Common causes are a defective drive plate, control valve, or condenser damaged by stone chips. Compressor replacement €700–1,000.
Control arm bushings and ball joints wear prematurely on the heavy Sharan 7M. Rear axle control arms on older examples are prone to corrosion.
The Sharan 7M weighs over 2 tonnes when fully loaded. Brake discs and pads therefore wear significantly faster than on smaller vehicles.
The Sharan 7M's headlight lenses yellow and become opaque, significantly reducing light output. A common failure at MOT inspections.