Service
Workshop Manual
Sharan 1996 >
Edition 04,2014
Service Department. Technical Information Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system
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
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg 0056763920 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
Contents
00 - Technical data ceeee cece eee ee testes eneeeeeeeeeeteneeeees 1
1 Technical data 1
1
1
4.1 Engine number
1.2 Engine data
40 - Removing and installing engine 2
1 Removing and installing engine 2
1.1 Notes on removing 3
12 Securing engine to assembly stand 6
13 Notes on installing 7
1.4 Assembly mountings 9
15 Additional information and assembly work for vehicles with air conditioner 10
13 - Crankshaft group oksopenag 12
1 Dismantling and assembling'éngine . . 12
1.4 Assembly overview - poly V-belt drive 7 12
1.2 Removing and installing poly V-belt - 14
1.3. Assembly overyiéw - toothed belt drive eee we . . .. 18
1.4 Assembly overview - crankcase . 2, 17
2 ‘Sealing flange and flywheel . er wees ieee eee 19
2.1 Assemblyoverview - sealing flanges and flywheel é =e 19
2.2 Renewing crankshaft oil seal - pulley end . . 24
2.3 Removing and installing sealing flange - pulley end nee 3 23
2.4 Removing and installing drive plate tees . % 27
3 Crankshaft 3 29
3.1 Assembly overview - crankshaft g 29
32 Crankshaft dimensions 30
3.3 Checking dowel pin projection out of crankshaft F: 30
4 Pistons and conrods 32
4.1 Assembly overview - pistons and conrods 32
4.2 Piston and cylinder dimensions 3 35
4.3. Checkingipiston projection at TDC 35
15 - Cylinder head, valve gear. . Lf MDG 37
1 Oylinder head 37
1.1 Assembly overview - eylinder head 37
1.2 Removing and installing cylinder head cover 40
1.3. Removing, installing and tensioning toothed belt 42
14 Removing and installing cyiid@enhead Soe 55
1.5 Compression test . 59
2 Valve gear 62
2.1 Assembly overview - valve gear 62
22 Checking valve guides 65
23 Renewing vaive stem seals 65
2.4 Removing and installing camshaft eeeeeeee . . cee .. 7
2.5 Removing and installing camshaft oil seal . cee . a cee 7A
17 - Lubrication 74
1 Engine oil . wees bebe eect eee eee eee . we 74
44 Oilcapacities 74
12 Checking engine oil level 74
2 Parts of lubrication system 75
contanis i @
19-
20 - Fuel supply system
21 - Turbocharging/supercharging
‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
2.1. Assembly overview - oil pump, sump
22 Removing and installing oil sump
3 Olfiter bracket, oil pressure, engine oil cooler and oil supply line
3.4 Assembly overview - oil filter bracket and engine oil cooler: Engine codes ANU, AUY, BVK
3.2. Assembly overview - oil filter bracket and engine oil cooler: Engine codes ASZ, BTB
3.3 Assembly overview - oil supply line to turbocharger
3.4 Removing and installing oil supply line to turbocharger . .
3.5 Checking oil pressure and oll pressure switch age 86 a
Cooling ......
1 Removing and instaling parts of coating syste
1.1. Assembly overview - cooling system, body'€ide: Engine codes ANU, AUY, BVK
1.2 Assembly overview - cooling system, body side: Engine codes ASZ, BTB-
1.3. Assembly overview - cooling system, engine side: Engine codes ANU, AUY, BVK
1.4 Assembly overview - cooling system; engine side: Engine codes ASZ, BTB
1.5 Assembly overview - additional cooler .. . setae
1.6 Coolant hose schematic diagram: Engine code ANU
1.7 Coolant hose schematic diagram: Engine codes AUY, BVK
1.8 Coolant hose schematic diagram: Engine codes ASZ, BTB
1.9 Draining and filling coolant... 5.
4.10 Removing and installing radiator and fan
4.11 Removing and installing coolant pump
1.12 Removing and installing thermostat
1.13 Checking cooling eystem for leaks
1.14 Checking engine oil cooler for leaks
1
14
12
13
14
15
16
17
18
19
1.10
111
1.42
1.13
1.14
1.45
1
14
12
13
14
15
16
17
18
19
Removing and intaling parts of fuel ypply system
Safety precautions when working on fus),supply system
Rules for cleanliness
Assembly overview - fuel tank
Assembly overview - fue iter: Engine codes ANU, AUY, BVK,
Assembly overview - fuel fiter: Engine codes ANU, ASZ, AUY, BTB, BVK
Assembly overview - heat exchanger for fuel cooler ove
Removing and installing fuel cooler: Engine codes ANU, AUY, BVK
Emptying fuel tank... foes
Removing and installing fuel tank
Removing and installing fuel delivery unit
Removing and installing fuel gauge sender
Checking fuel pump. -
Checking tandem pump
Removing and installing tandem pump
Assembly overview - accelerator mechanism
Charge air system with turbocharger.
Safety precautions
Rules for cleanliness
Hose connections with push-on connectors
Assembly overview - turbocharger: Engine code ANU
Assembly overview - turbocharger: Engine codes ASZ, BTB.
Assembly overview - turbocharger: Engine codes AUY, BVK.
‘Assembly overview - charge air cooling: Engine codes ANU, AUY, 8VK
Assembly overview - charge air cooler: Engine codes ASZ, BTB
Checking charge air system for leaks
5
7
80
80
82
83
83
88
88
88.
a9
94
92
94
95
7
98
99
100
103
105
107
109
111
114
114,
115
115
115
eoti7
119
120
122
123
- 125
128
- 130
- 130
132
136
138
- 140
140
141
141
141
142
145
147
149
151
152
Contents 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
4.10 Charge pressure contro! hose routing diagram: Engine code ANU 153
4.11 Charge pressure control hose routing diagram: Engine codes ASZ, AUY, STB, BVK 155
23 - Mixture preparation - injection .... wees cece e eee eee e eee 156
1. Repelring diesel circt injection systern 156
44 Safety precautions 156
1.2 Rules for cleanliness 157
4.3 General notes on injaction 157
1.4 Overview of fitting locations 187
1.5 Assembly overview - intake manifold flap 158
1.6 Assembly overview - air filter 160
1.7 Assembly overview - unit injector 160
1.8 Removing and installing O-rings for unit injector. eee eee . wees 164
1.9 Removing and installing unit injector... . . . . . ee wes 163
2 Engine control unit .. . “ “ neee ween 168
24 Reading and erasing engine control ‘unit fault memory . . . . 168
2.2 Removing and installing engine control unit . eee ee . .. 169
26 - Exhaust system ee .170
4 Removing and instaling parts of exhaust eystem 170
a4 Assembly overview - front exhaust pipe with catalytic converter 170
1.2. Assembly overview - silencers 174
2 Exhaust gas recirculation system 173
24 Assembly overview - exhaust gas recirculation: Engine code ANU 173
22 Assembly overview-- exhaust gas recirculation: Engine codes ASZ, AUY, BTB, BVK 175
23 Checking mechanical exhaust gas recirculation valve 176
28 - Glow plug system : : ATT
1 ‘Checking glow plug system . . . anaes . . seseeenes TT
41.1 Checking glowpiugs °o"% cee cteette ee teteeteeteteeeseserees 178
consents Hii ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
IV contants ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
wy} Technical data
1 Technical data
(VRLO06739; Edition 04.2014)
Engine number and engine code = page 4
Engine data ~ page!
1A Engirie number
The engine number (‘code letters” and “serial number’) can be
found on the joint beiween engine and gearbox.
‘The engine number consists of up to nine characters (alphanu-
meric). The first part (tnaximum 3 characters) makes up the
“engine code’, and the second part (6 characters), the “serial
number’. If more than 999,989 engines with the same engine
code are produced, the first of the six characters is replaced with
a letter.
Inaddition, there isa sticker othe toothed belt guard with “engine
code” and “serial number”
The engine code can also be found divthe vehicle data sticker.
1.2 Engine data
Edition 02.2011 version 14.1
Engine code ANU ASZ AUY BTB BVK
Manufactured oreo | 10.02* | 0600+ | 03.05- | 10.05~
Emissions tuff D3 standard | EU3 stand- | D3 standard EUS stand- | EU4 stand-
ard ard ard
‘Capacity q 19 19 1.9 1.9 19
Output kewet rpm] 66/4000 | 9674000 | asi4000 | 10/4000 | 25/4000
Torque Nm atrpm] 240/1800 | stoite00 | sto/e00 | stoie00 | sto/e00
Bore @mm| 79.5 79.5 79.5 79.5 79.5
Stroke. mm| 95.5 95.5 95.5 95.5 95.5
Compression ratio 18.0 19.0 180 190 12.0
Fuel 2ecordng| DIN EN 590 | DIN EN 590 | DIN EN 580 DIN EN 590 | DIN EN 500
|
Firing order 1-3-4-2 1-3-4-2, 1-3-4-2, 1-3-4-2 1-3-4-2
Catalytic converter yes yes yes yes yes
Exhaust gas recirculation yes yes yes yes yes
| Turbocharging/supercharging yes yes yes yes yes
Charge air cooling yes yes yes yes yes
1. Tochrical data 1 ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 042014
10
1 Removing and installing engine
joving and installing e1
Notes on removing = page 3
‘Securing engine to assembly stand = pagé 6
Notes on installing > page 7
Assembly mountings > page 9
‘Additional information and assembly work for vehicles with air
conditioner = page 10
Special tools and workshop
equipment required
+ Lifting tackle - 20244-
# Support clamp - VW 313-
# Engine and gearbox sup-
port - WW 540-
Engine bracket - T10012-
Workshop hoist - V.A.S
41202/A- oF workshop crane
- VAS 6100-
Drip tray - V.A.G 1308- or
drip tray - VAS 6208-
oe
+
VAG 12028 —— VAG 1308
f
t
2 op 97 10- Removing and insaling engine 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
Torque wrench (5... 50Nm)
-VAG 1331-
@ Torque wrench (40... 200
Nm) -V.AG 1332-
© Engine and gearbox jack -
V.AG 1383/-
© Spring-type clip pliers -
VAS 5024-
Stepladder - VAS 5085-
VAG 1331
Not illustrated 5
Container for removed parts - VAG 1698-
Engine bung set - VAS 6122.
4 Grease - G 000 100: (vehicles with manual gearbox)
# Cable ties
14 Notes on Femoving
The engine is removed fronribelow with the gearbox
- Read fault memories of all Control units before removing
= page 168
VAG 1332
1. Removing and insaling angina 3 @ ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
fw Note
Before carrying out further work, disconnect battery earth
strap. Check whether a coded radio is fited. Obtain anti-theft
coding first itnecessary.
Leave ignition key in ignition lock to prevent steering lock from
engaging.
Itis advisable to remove the front wheels betore beginning
engine removal. The vehicle can then be lowered on hoist until
the brake disc splash plates are just above the floor. This pro-
Vides the most ergonomic working position regarding acces-
sibility of engine compartment components.
4 Allcable ties which are opened or cut through when engine is
‘removed must be replaced in the same position when engine
is installed.
% Some components cannot be removed, or removed only with
‘aiffcully, with the engine installed. Therefore, you should ae-
termine all defective components before removing engine and
renew them while engine is removed.
To prevent damage to removed components, place them in
the container for removed parts - V.A.G 1698-
- Observe rules for cleanliness > page 448
= Allcable ties which are opened or'éut through when engine is
removed must be replaced in the same position when engine
is installed.
= First check whether a codéd radio is fitted. If so, obtain anti-
theft coding,
— With ignition switched if, disconnect earth strap from battery.
= Remove engine cover.
= Remove battery and battery carrier.
— Remove noise insulation + Body Repairs; Rep. gr. 50 ; Exte-
rior; Body = front; Assembly overview - noise insulation (diesel
engine)
~ Remove air filter housing together with intake manifola.
= Disconnect fuel eupply and return lines at diesel fuel fiter.
A WARNING
@ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
© The fuel system is also undér pressure! Before opening
the system, place cloths around) the connections. Then
carefully loosen connection to release the pressure!
\¢ Wear eye and hand protection when petorming any type
of repair work on the fuel system! i
~ Seal ines so that fuel system is not contaminated by dirt
Vehicles with 5-speed manuel gearbox 006
~ Pull pipethose off slave cylinder on gearbox: > 5-speed man-
ual gearbox 006; Rep. or. 30; Assembly overview- hydraulics
and clutch release mechanism
4, 2p. 710. Removing and insaling engine 4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
— Remove selector cables from géarbox: = 5-speed manual
‘gearbox 006; Rep. gr. 34 ; Repairing selector mechanism;
Removing and installing selector cables
Vehicles with 6-speed manual gearbox 02N
Pull pipe/hose off slave eylinder on gearbox: = 6-speed man-
ual gearbox 02N; Rep. gr. 30; Assembly overview- hydraulics
and clutch release mechanism
- Remove selector cables from gearbox: = 6-speed manual
‘gearbox O2N; Rep. gr. 34 : Repairing selector mechanism:
Removing and installing selector cables
Vehicles with four-wheel drive
= Disconnect front propshaft tube from gearbox: > 6-speed
‘gearbox 02N four-wheel drive: Rep. gf. 39 ; Final drive, rear
differential; Removing and installing propshaft
Vehicles with automatic gearbox
— Disconnect selector lever cable from gearbox: + 5-speed au-
tomatic gearbox 08B: Rep. gf. 37 : Repairing selector mech-
anism; Removing and installing’seiector mechanism
Vehicles 06.00
— Bring lock carrier into service position SBody Repairs; Rep.
gr. 50; Exterior; Body - front; Lock carrier Service position
Continuation for all vehicles
— Removing radiator = page 103
- Remove air pipes between turbochargericharge air cooler,
charge air cooler/inlet connection,
— Pull vacuum and breather hoses off engine.
= Pull off or disconnect all other electrical connections as nec-
essary from engine and lay to side,
= Remove drive shafts: > Running geer, axles, steering, front
and four-wheel drive: Rep. gr. 40 ; Repairing drive shafts;
Removing and installing drive shafts
Vehicles with air conditioner
= Observe additional information and installation work
= page 10
Continuation for all vehicles
— Remove poly V-belt => page 14
— Unbolt power-assisted steering vane pump and secure to
body with wire; hoses remain connected: = Running gear,
axles, steering, front and four-wheel drive; Rep. gr. 48; Vane
pump, reservoir, hydraulic lines
— Remove front exhaust pipe = page 170
= Insert engine bracket - 710012. in engine and gearbox jack -
VAG 1383 A-
Sharan 1996 >
@
1. Removing and insaling angina 5 @ ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
= Fitengine bracket - 110012. onto cylinder block with securing
nut M10. Specified torque: 40 Nm
= Lift engine and gearbox lightly using engine and gearbox jack
-VAG 1383 A
Remove pendulum support = Running gear, axles, steering,
front and four-wheel drive; Rep. gr. 40 ; Repairing front sus-
pension
= Unscrew right assembly mounting securing bolts -1-.
(F) noe
To remove securing bolts, use stepladcier - VAS S085-
Vehicles » 05.00
— Unscrew left assembly mounting securing bolts -A..
fa) Note
To remove securing bolts, use'stepladler - VAS 5085-.
Vehicles 06,00 =
Unscrew left assembly mounting securing bolts ~A-.
CF noe
To remove securing bolts, use stepladder= VAS 5085-
Continuation for all vehicles
= Carefully lower engine with gearbox.
(8) nove
Engine with gearbox must be guided carefully when lowered to
prevent damage to bodywork.
12 Securing engine to assembly stand
When working on the engine, secure it with engine and gearbox
support - VW_540- to support clamp - VW 313- of the assembly.
stand or to engine and gearbox support - VAS 6085-
6 ep. g710- Removing and insaling engine 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
Procedure
— Unbolt gearbox,
Vehicles with automatic gearbox
Secure torque converter against ‘falling out" after separating
engine from gearbox.
Continuation for all vehicles
— Attach lifting tackle - 2024 A. as follows and lift from engine
and gearbox jack - 1202 A- using workshop crane - VAS 6100-
‘or workshop crane - V.A.G 1383 A
Belt pulley end: 1st hole in hook rail at position 1
Flywheel end: 4th hole in hook rail at position 8
A WARNING
2, =
The hooks and locating pins must be securedwith Yobking pins; pA — st My
a
(a) Note
© The holes marked.tiith 1 ... 4 of the support bar point to the
belt pulley.
¢ The holes in the hook rails are counted up trom the hook.
— Secure engine to support clamp - VW 540- using engine and
‘gearbox support - VW 313-.
(B) ne
First loosen coolant pipe at flywheel end.
1.3 Notes on installing
Procedure
Installation is carried out in the reverse order. When installing,
note the following:
LX _ worwine
When doing any repair work, especially in the engine compart-
iment, pay attention tothe fellowing due tothe cramped candi:
tions:
# Route ail the various lines (e.g. for fuel, hydrautios, act-
vated charcoal filter system, coolant and refrigerant, brake
fuid and vacuum) and electrical wiring in their anginal po-
sitions.
# Ensure that there is sufficient clearance to all moving or
‘hot components
= Check whether dowel sleeves for centring engine/gearbox
have been fitted in cylinder block, insert f necessary.
1. Removing and insaling angina 7 @ ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
- Hook intermediate plate onto sealing flange and slide onto
dowel sleeves -arrows-.
= Clean input shaft splines and lightly grease with grease - G
000 100-
Vehicles with 5-speed manual gearbox 006
= Check clutch and clutch control and install: = 5-speed manual
gearbox 008; Rep. gr. 30 ; Assembly overview - hydraulics
and clutch release mechanism
Vehicles with 6-speed manual gearbox 02N
— Checking and installing clutch and clutch control: > 6-speed
manual gearbox O2N; Rep. gr. 30 ; Assembly overview - hy-
draulics and clutch release mechanism
Continuation for all vehicles
~ Screwin all bolts on assembly mountings by hand approx. 5...
6 turns.
= Align assembly mountings stress-free by rocking
(B) we
‘Specified torques for assembly mountings = page 9
= Install pendulum support > Running gear, axles, steering,
front and four-wheel drive; Rep. gr. 40 : Repairing front sus-
pension
Vehicles with air conditioner
= Install air conditioner compressor > Heating, air conditioning:
Rep. gr. 87 : Removing and installing compressor bracket
Vehicles with 5-speed manual gearbox 006
— Connect pipelhose on slave cylinder and secure with clip: =>
5-speed manual gearbox 006; Rep. gr. 30 ; Assembly over
view- hydraulics and clutch release mechanism.
~ Fitselector cables on gearbox, ifnecessary adjust: = 5-speed
manual gearbox 008; Rep. gr. 34 ; Repairing'selector mech-
anism; Removing and installing selector cables
Vehicles with 6-speed manual gearbox 02N
= Connect pipe/hose on slave cylinder-and secure with clip: =
6-speed manual gearbox 02N: Rep. gr. 30; Assembly over-
view hydraulics and clutch release mechanism.
— Fitselector cables on gearbox, ifnecessary adjust: = 6-speed
manual gearbox O062N: Rep. gr. 34 : Repairing selector
mechanism; Removing and installing selector cables
Vehicles with four-wheel drive
= Install propshaft tube: > 6-speed manual gearbox 02N four
wheel drive: Rep. gr. 39 : Final drive, rear differential; Re-
moving and installing propshaft
Vehicles with air conditioner
= Install air conditioner compressor > Heating, air conditioning;
Rep. gr. 87 ; Removing and installing compressor bracket .
Continuation for all vehicles
= Install drive shafts: > Running geer, axlessteering, front and
four-wheel drive: Rep. gr. 40 : Repairing drive shafts; Remov-
ing and installing drive shafts
8 op. o710- Removing and insaling engine = Install power-assisted steering vane pump with bracket: ="
Running gear, axles, steering, front and four-wheel crive; Res
<&r. 48; Vane pump, reservoir, hydraulic lines.
= Install poly V-belt = page 14
Install air pipes between turbocharger/charge air cooler,
charge air cooler/inlet connection
(B) ne
When instaling ensure that locking lugs engage securely
=page 141
= Install front exhaust pipe = page 170
= Install battery and battery tray.
© Installing radiator = page 103
“Install air filter housing together with intake manifole.
~ Electrica connections and routing = Current flow diagrams,
EleGtrical fault finding and Fitting locations.
= Repleniéh coolant = page 100
= Install noise iféuiation = Body Repairs; Rep, gr'S0 ; Exterior;
Body ont Assembly averven -roseinsllaion esl sr
gine)
Vehicles with automatic gearbox
~ On vehicles with automatic gaarbox the gearbox contrel unit
must also be adapted: = Seif-diaonosis for 5-speed automatic
‘gearbox 098; Repair group 01; Performing self-diagnosis; In-
itiating basic setting
Continuation for all vehicles
— Carry out road test and read all fault memories > page 168
Observe applicable safety precautions during road test
= page 156
Specified torques
(Threaded connection ‘Specified torque|
Bolts, nuts M6 40Nm
MT 45Nm
MB 20Nm
M10 40Nm
M12 60Nm
Deviations
Front exhaust pipe to turbocharger 25.Nm
(a) Note
‘Specified torques for assembly mountings = page 9.
14 Assembly mountings
Specified torques
(Botts oiled)
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
1. Removing and insaling angina 9) @ ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | enginis) - Edition 04.2014
Right assembly mounting
A= 60NmB=55Nm
Vehicles » 05.00
Left assembly mounting on vehicles with manual gearbox:
A= 55 Nm; 8 = 100 Nm; C= 100 Nm; D = 20 Nim '/g turn (90°)
further; E = 80 Nm
Vehicles 06.00
Assembly mounting, left on vehicles with manual gearbox and
automatic gearbox OSB:
A= 60 Nm + Ng tum (90°) further’); B = 90 Nm + '/g turn (90°)
further"; C= 50 Nm + '/q tum (90°) further”; D = 25 Nm
1) Renew securing bolvnut
(@) Note
All threaded holes, where seit-locking bolts are fitted must be
‘cleaned of locking material remnants using @ thread cutting tap.
1.5 Additional information and assembly
work for vehicles with air conditioner
LX warns
The air conditioner refrigerant circuit must not be opened.
10 ep. o.10-Removing and insaling engine 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
fa) Note
.
+
The opening of the refrigerant circuit can only be carried out
Jn workshops, which have trained personnel and the neces-
‘sary range of tools and workshop equipment.
Te prevent damage to condenser or to refrigerant lines/hoses,
ensure that the fines and hoses are not stretched, kinked or
ni
To facilitate removing and installing engine without opening re-
frigerant cireuit:
Remove retaining clamp(s) for refrigerant lines.
Remove poly V-belt = page 14
Remove altemator: = Electrical system; Rep. gr. 27; Re-
moving and installing alternator with poly V-belt
Remove air conditioner compressor = Heating, air condition-
ing; Rep. gf. 87 ; Removing and installing compressor brack-
et
‘Secure air conditioner compressor, to,body ‘So that the tefiig,.
erant lines are not under tension:
1. Removing and instaling engine 11 Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
4 Crankshaft grou
1 Dismantling and assembling engine
(F) now
When working on the engine, secure it with engine and gear-
box support - VW $40- to sypportclamp - VW 313- of the
assembly stand orto engine ap gearbox support - VAS
Finding metal shavings or @large quantity of small metal par-
ticles during engine repair-could indicate that the crankshaft
bearings of conrod bearings are damaged. To prevent this
from causing further darnage, perform the following repairs:
Thoroughly clean oil chgnnels.
Renew engine oll cooler
Renew oil fiter element
eoee
Renew oil spray jets
Assembly overview - poly Vabeit drive > page 12
Removing and installing poly:V-belt = page 14
Assembly overview - toothed Belt drive = page 15
Assembly overview - crankcase & page 17
1A Assembly overview - poly V-belt drive
12. ep.o-.13-Crankshatt group 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
1- Poly V-belt ToS
Mark direction of rota-
ton betore removing |
Check for wear.
Do not kink
Removing and installing
= page 14
2- 40.Nm + 14 tum (90°) fur- é
ther f
3- Belt pulley and vibration WY)
damper
Can only be installed in
one position, holes are
offset.
4-25Nm 2
5-Tensioning element for poly
V-belt
Swing with open-end
spanner to slacken poly
Vibelt > page 14
6 - Alternator
Removing and installing
> Electrical system;
Rep. gr. 27 ; Removing
and installing alternator
with poly V-belt
7 - Bracket for ancillaries
For alternator, power- 4
assisted steering vane %
pump and air condition- %
er compressor %
8-45Nm.
Observe tightening sequence = page.14
9 = Banjo bolt, 30 Nm
10- Seal
Renew.
ooo
14 - Pressure line
12 Vane pump
2 For power-assisted steering
4
5 6 7 8
12.10 CRTeor)
Removing and installing: = Running gear, axles, steering, front and four-wheel drive: Rep. gr. 48 : vane
ump, reservoir, hydraulic lines
13 - Belt pulley
For vane pump.
1.Dismanting and assembiing engine 13 ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
‘Sequence for tightening ancillary bracket to cylinder block
Procedure
— Place ancillary bracket on cylinder block (observe dowel
sleeve between ancillary bracket and cylinder block).
= Tighten ancilary bracket as shown in following tightening se
quence:
1 - Tighten bolt -A- to 45 Nm
2.- Tighten bolt -B- to 45 Nm
3 - Tighten bolt -C- to 45 Nm
4 = Tighten bolt -D- to 45 Nm
5 - Tighten bolt -E- to. 45 Nm
6 - Tighten bolt -F- to.45 Nm
12 Removing and installing poly V-belt
‘Special tools and workshop equipment required
4 Locking pin - T10060-
Removing
® Note
Before removing the poly V-belt mark the Gikeetion of rotation.
When installing belt ensure itis correctly seated im pulleys
~ Mark direction of rotation of poly V-belt.
— Swing tensioning element in direction of arrow using @ 16 mm
‘open jaw spanner until tensioning element can be locked
T10060
14. Rep.o-.13-Crankshat group 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
= Lock tensioner with locking pin - T10060A-
— Remove noise insulation = Body Repairs; Rep. gr. 50; Exte-
rior; Body - front; Assembly overview - noise insulation (diesel
engine)
— Remove poly V-belt
Installing
= Install in reverse order.
fa Note
© Ensure, before installing poly V-belt, that all ancillaries (alter-
‘ato, air conetioner compressor, vane pump) are secured
tightly
‘© When installing poly V-belt, check direction of belt rotation and
‘proper seating of bet in pulleys.
© For vehicles without air conditioning, fit poly V-belt on alterna-
tor last.
For vehicles with air conditioning, ft poly V-belt over air con-
ditoning compressor last
= Fit poly V-belt
‘After completing repairs always
Start engine and check that belt runs properly.
= Install noise insulation = Body Repairs; Rep gr. 50 ; Exterior,
Body «front; Assembly overview - nga insulation (ese en-
sine)
Belt drive routing
Belt drive without air conditionér compressor
Belt drive with air conditionér compressor
1.3 Assembly overview - toothed belt drive
1.Dismanting and assembiing engine 15 @ Sharan 1996 > ao -
4-cyiinder diesel engine (1,9 | engine) -Ecition 04.2014
1 - Toothed belt guard upper
part
2- Toothed belt
Mark direction of rote-
tion before removing,
Check for wear.
Do not kink.
Removing, installing
and tensioning
= page 42
3-20 Nm + '/g turn (45°) fur-
ther
4 Tensioning roller
5 - 100 Nm
6-25Nm
7 - Camshaft pulley
8 - Hub
2 With sender wheel
Use counterhold tool -
710051- to loosen and
tighten.
To remove, use puller -
710052.
Removing an instaling
> page 6;
9-10.Nm
10 - Rear toothed belt guard
11 - Sealing grommet
Renew if damaged,
12- Toothed belt tensioner
Only for vehicles with hydraulic tensioning system
13 - Guide roller
14 Coolant pump
Installed in cylinder block
Check for ease of movement.
D_Note installation position
Removing and installing = page 105
15 - Crankshaft toothed belt pulley
16 - 120 Nm + "/4 turn (90°) further
O Renew.
Use counterhold for toothed belt pulley - 3099- to loosen and tighten
1D Do not additionally oll or grease the threads and shoulder.
Turning further can be done in several stages.
17-15Nm
18-20Nm
19 - Toothed belt guard lower part
20 - Belt pulley and vibration damper
Can only be installed in one position, holes are offset.
16 ep. o-.13-Crankshatt group 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
21-10 Nm + 14 tum (90%) further
22- Cover
Fitted according to version
23 - Toothed belt guard centre part
24-30.Nm
25 -45.Nm
26 - Engine support
27-45.Nm ot 0%
- crankcase
14 Assembly overvie
1- Cylinder block
Removing and installing,
sealing flanges and fly~
Wheelidrive plate
= page 19 g
Removing and installiig
crankshaft g
= page 29 =
2 Dismantting and assem-
bling pistons and con=
rods = page 320
2- Gasket ;
Renew. %
3- Oil filter bracket
Ensure clearance to ad-
jacent components.
2 Dismanting and assem-
bling:
Engine codes ANU,
AUY, BVK = page 80
Engine codes ASZ, BTS
> page 62
4-15 1Nm + Vg turn (80°) fur-
ther
Renew.
O First fit upper left and
lower right bolts and.
then tighten all four bolts
diagonally
5-15Nm.
6 - Engine epeed sender -
G28-
7 Connection
For thermostat.
8-15Nm.
9- O-ring
Renew.
10 - Thermostat
2 Removing and installing = page 107.
1.Dismanting and assembiing engine 17 @ ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
Note installation position > page 107
Checking: heat thermostat in water.
Opening begins at approx. 87 °C.
Ends at approx. 102 °C.
Opening lift at least 7 mm.
14-45Nm
Observe tightening sequence = page 14
12- Bracket for ancillaries
For alternator, power-assisted steering vane pump and air conditioner compressor
13- Oil sump
Clean sealing surface before fitting,
1D Install with silicone sealant - D 176 404 A2~
Removing and installing = page 77
14-15m
18 ep.o-13-Crankshat group 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
2 Sealing flange and, flywheel :
fa Note
¢ When working on the engine, secure it with engine and gear-
box support - VW.540- to support clamp - VW 313- of the
assembly stand af to engine and gearbox support - VAS
6086-
© Repair measures to clutch (vehicles with 5-speed manuel
gearbox 006), — S-speed manual gearbox 006: Rep. gr. 30;
epairing clutch
Repair measures to clutch (vehicles with 6-speed manual
gearbox O2N): = 6-speed manual gearbox: Rep. gr. 30, Re-
airing clutch
Assembly overview - seeling flange and flywheel = page 19
Renewing crankshaft cil seal - belt pulley end > page 24
Removing and installing sealing flange - pulley end
= page 23,
Removing and installing drive plate > page 27 .
24 Assembly overview - sealing flanges and flywheel
‘Sharan 1996 >
@
2 Sealing lange and tywhoot 19 ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
1- Seal
Do not additionally oi
grease the.oil'seal seal-
ing lip. . seal belt pulley end
> page 21
© 2- Sealing flange
=D Must seat on dowel
sleeves,
Removing and instaling
= page 2
G Install with silicone seal-
ant - D 176 404 A2-
3- Gylinder block
Q “Removing and installing
crankshaft
> page 29
1 Dismariting end assem-
bling pistons-and con-
rods = page 32°”
4 - FlywheeV/drive plate
Removing and installing
flywheel, vehicles >
05.00: lock with counter
hold - 3067-
Removing and installing fiywheel, vehicles 06.00 +: lock with counterhold - 3415-
Removing and installing drive plate = page 27
5-60 Nm + 1/4 turn (90°) further
O Renew.
6 - Intermediate plate
Must seat on dowel sleeves.
Do not damage or bend when assembiing
7-15Nm.
8 - Sealing flange with oll seal
Renew complete only.
Do not additionally oil or grease the cil seal sealing lip.
Before installing, remove oil residue from crankshaft journal using a clean cloth,
Use support sleeve supplied when installing
Do not remove support sleeve until sealing flange has been slid onto crankshaft journal
cooog
20 op or-13- Crankshaft group 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
22 Renewing crankshaft oil seal - pulley end
Special tools and workshop
equipment required
© Oil seal extractor - 3203-
© Countethold - 3415- (only
vehicles 06.00»)
© Assembly tool - T10053-
© Torque wrench (5... 50Nm)
“VAG 1331-
@ Torque wrench (40... 200
Nm) - V.AG 1332-
VAG 1331
VAG 1992
Special tools and workshop equipment required
+ Counterhold - 3089- ely vehicles * 05.00)
Removing
~ Remove poly V-belt = page 14’,
— Remove toothed belt > page 42.
2 Sealing lange and tywhneot 21 @ ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
Vehicles » 05.00
— Remove crankshaft toothed belt pulley. To do this, lock tooth-
ed belt pulley using counterhold - 3089-
(B) wwe
When bolting on counterhold, place two washers between tooth-
ed belt pulley and counterhoid.
Vehicles 08.00 *
— Remove charge air pipe = Item 1 (page 150) or
= Item 9 (page 151
= Unbolt charge air pipe bracket from sump
= Item 14 (page 150) or = Item 11 (page 151
— Remove crankshaft toothed belt pulley. To do this, lock tooth-
‘ed belt pulley using counterhold - 3415-
Continuation for all vehicles
- To guide seal extractor, screw centre bolt into crankshaft to
stop by hand.
Screw inner part of oll seal extractor - 3203- two turns (approx.
3 mm) out of outer part and lock using knurled screw.
— Lubricate threaded head of oll seal extractor, place it in posi-
tion and, exerting firm pressure, screw it ino oil seal as far as:
Possible.
= Loosen knurled serew and turn inner part agaitil crankshaft
until the oll eal is pulled out.
Installing
(F re
The oil seal sealing lip must hot be additionally olled or greased.
Remove oil residue from crankshaft journal using clean cloth,
= Fit guide sleeve - T10053/1- onto crankshaft journal,
= Slide oil seal over guide sleeve onto crankshaft journal.
22 op or-13- Crankshaft group 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
Using press sleeve - 110053- , press in onto stop with central
bolt.
Vehicles * 05.00
~ Mala crankshett toothed belt pulley and lock with counterhotd
fa Note
When bolting on counterhold, place two washers between tooth.
ed belt pulley and counterhold.
Vehicles 06.00
= Install crankshaft toothed belt pulley and lock with counterhold
= 3415.
Continuation for all vehicles s
(F) re
© The contact surface between toothed beft pulley and erank-
shaft must be free of oil.
The centre bolt must be renewed.
Thread and shoulder must be free of oil and grease.
= Tighten new centre bolt to 120 Nm and then "/4 turn (80°) tur-
ther (turning further can be done‘in several stages)
Further assembly is basically the reverse of the dismantling se-
quence.
~ How to install and tension toothed belt = page 42.
= Install poly V-belt > page 14
23 Removing and installing sealing flange - pulley end
2 Sealing lange and tywhot 23 @ ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
Special tools and workshop
equipment required
# Counterhold - 3415. (only
vehicles 08.00»)
# Assembly tool - 110053
# Torque wrench (5... 50 Nm)
-VAG 1331-
# Torque wrench (40... 200
Nm) - V.A.G 1332-
VAG 1331
Special tools and workshop equipment required =
+ Counterhoid - 3089: (only vehicles * 05.00)
Not illustrated
Silicone sealant - D 176 404 A.
Hand drill wth plastic brush attachment
Flat scraper
Eye protection
24 op or-13- Crankshaft group 4-cylinder‘diesel engine (1.9 | erigine)- Edition 04.2014
Removing
— Remove poly V-belt = page 14
— Remove toothed belt > page 42 «
Vehicles » 05.00
= Remove crankshaft toothed belt pulley. To do this, lock tooth-
ed belt pulley using counterhold - 309-
[&) note
When bolting on counterhold, place two washers between tooth-
ed belt pulley and counterhold.
Vehicles 06.00 »
- Remove charge air pipe = Item 1 (page 150) or
= Item 9 (page 151
= Unbolt charge air pipe bracket from sump
= or =
- Remove crankshaft toothed belt pulley. To do this, lock tooth-
ed belt pulley using counterhold - 3418.
Continuation for all vehicles
= Drain engine oil
(3) woe
Observe environmental regulations for disposal.
— Remove sump = page 77
= Unbolt front sealing flange.
- Remove sealing flange: if necessary, loosen using light blows
with a rubber headed hammer.
= Remove sealant residue from cylinder block with a flat scraper.
A WARNING
Wear eye protection.
= Use rotating plastic brush to remove sealant residue on seal-
ing flange.
= Clean sealing surfaces. They must be free of oil and grease.
Installing
Note
© Observe expiry date of sealing compound.
¢ The sealing flange must be installed within § minutes of ap-
plying the silicone sealant.
2 Sealing lange and tywhoot 25 ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
= Cutoff tube nozzle at forward marking (Z.of xézzie approx. 3
mm).
= Apply silicone sealing compound, as shown, to clean sealing
‘surface on sump. Sealant bead must be:
#2... 3mm thick,
'# Run bead along inner‘side of bolt holes -arrows-.
fw Note
+ Sealant bead should not be thicker because otherwise excess
sealant can enter sump and plug up strainer in oil pump suc-
tion pipe, as well as drip onto crankshaft oll seal.
Before applying sealant bead, cover sealing surface of oi! seal
with a clesn cloth.
— Apply silicone sealant bead as shown to clean sealing surface
of sealing fiange.
~ Fit sealing flange immediately and lightly tighten all bolts.
i) Note
When fitting sealing flange with @ll seal installed use guide sleeve
= T10053/1-
~ Tighten sealing flange securing bolts diagonally and alternate
ly. Specified torque:15 Nm
= Install sump > page 77
(B) we
‘Sealing compound must dry for approx. 30 minutes after instal-
lation. Only then fil with engine oil.
Vehicles » 05.00
~ Install crankshaft toothed belt pulley and lock with counterhold
fw Note
When bolting on counterhold, place two washers between tooth-
ed belt pulley and counterhoid.
Vehicles 08.00
26 op or-13- Crankshaft group .
.
.
‘Sharan 1996 >
4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
@
= Install crankshaft toothed belt pulley and lock with counterholé
= 3415-
Continuation for all vehicles
(B) woe
The contact surtace between toothed belt pulley and crank-
shaft must be free of oil,
The centre bolt must be renewed.
Thread and shoulder must be free of oll and grease.
= Tighten new centre bolt to 120 Nm and then "4 turn (90°) fur-
ther (turning further can be done in several stages)
Further assembly is basically the reverse of the dismantling se-
quence.
= Install toothed belt and adjust valve timing = page 42
= Install poly V-belt = page 14
24 Removing and installing drive plate
‘Special tools and workshop equipment required
@ Clutch counterhold - VW 558-
‘@ Hexagon bolt M8x45 and two M40 hexagon nuts
© Depth gauge
Loosening and tightening drive plate
= Secure clutch counterhold - VW 558: to drive plate with hex:
agon bolt M8x45. Insert two M10 hexagon nuts between coun-
terhold and drive plate.
Installation position of counterhold: A - To loosen, B - To tighten.
— Loosen drive plate bolts,
Installing drive plate
2 Sealing lange and tywhoot 27 ‘Sharan 1996 >
4-cylinder diesel engine (1,9 hengfieSEtitieno4.2014
~ Fitrive plate using packing plate with recesses ~
— Fit new bolts -3- and'tighten to 30 Nm.
= Check dimension -2- at three points and calculate average.
Specifigation: 19.5... 21.1 mm
(F) now
‘Measure trotgh hole in crive plate toiled surface of einer
If specification is net attained!
— Remove drive plate again and fit-shimp -2-. Tighten bolts -3°
again to 30 Nm.
~ Tighten bolts -3- to 60 Nm and turn 90° (1/4 turn) further (the
additional 1/4 turn can be done in several stages).
28 op or-13- Crankshaft group 20 AO. VK p-¢ylinder diesel engine (1.9 | engine) - Edition 04.2014
3 Crankshaft
(8) nee
© Whee working on the engine, secure it with engine and gear-
‘box support - VW 940- fo support clamp - VW 313- of the
assembly stand or to engine and gearbox support - VAS ;
6085
¢ Before removing crankshaft, ensure that a suitable surface for
storing crankshaft is prepared fo ensure that sender wheel
item 6 (page 30) is not damaged or lies against any other
em,
‘Assembly overview - crankshaft = page 29 g
Crankshatt dimensions = page 30.
Checking fitted pin projection out of crankshaft = page 30 .
3.1. ©, Assembly overview - crankshaft
1 Bearing shélis 1, 2, 4 and 5
2 For beeringécep without
oll groove.
For cylinder block With,
oil groove.
Do not interchange
used bearing shells
(mark).
2-65 Nm + 1g turn (90°) fure
ther
Renew.
Threaded along com.
plete length.
A Tomeasure radialciear-
ance, tighten to 65 Nm
bt not further.
3 - Bearing cap
Bearing cap 1 - belt pul-
ley end
Bearing cap 3 with re-
esses for thrust wash-
ers,
2 Bearing shell retaining
lugs in eylinder block
and bearing caps must
align.
4. Bearing shell 3
For bearing cap without
oll groove
For cylinder block with
oil groove.
5 - Thrust washer
For bearing cap, bear-
ing 3.
Note fixing arrangement
3.Cranksrat 29 @ ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
6 - Sender whee!
For engine speed sender - G28-
Renew if damaged.
Always renew sender wheel f-sééiring bolts ( = it&#W'7.(page 30) ) have been loosened.
Removing and installing’ page 31.
7-10 Nm + 1/4 turn (908) further
O Renew.
8 - Dowel pin
2 Check prdjection from crankshaft > page 30
9 Crankshaft
Axial clearance new: 0.07 ....0.17 mm, wear limit: 0.37 mm.
Check radial clearance using Plastigage; new: 0.03... 0.08 mm; weer limit: 0.17mm.
Do not rotate crankshaft when checking radial clearance.
Q Crankshaft dimensions > page 30.
10 - Thrust'washer 3
1D For dylinder block, bearing 3
3.2 Crankshaft dimensions
[Honing Crankshfaft main Conrod
mension in mn’, "Journal journat
Basic dimension |-0,022 ro.022
54:00 47.80
-0.042. }-0.042
Stage | }-0.022 -0.022
53.75, 47.55,
-0.042 20.042
em 0.022 0.022
Sta) 53.50 47.30
so.002 eft
[Stage Ill }-0.022 }-0.022
bazs e703
-0.042 |-0.042
3.3. Checking dowel pin projection out of
crankshaft
‘Special tools and workshop equipment required
# Depth gauge
Test procedure
Use depth gauge to check fitted pin projection -a- with sender
wheel -1- removed.
1- Sender wheel
2+ Securing bolt
3 - Projection of dowel pin -3- out of crankshaft a =
5...3.0mm
30 op. 9:15- Crankshaft group 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
Removing and installing sender wheel
— Renew sender wheel -2- each time bolts -1- are loosened
Specified torque: 10 Nm + 80° (1/4 turn)
(B) woe
The second time the bolts are tightened, the contact points in the
sender whee! for the countersunk heads are deformed so far that
the bolt heads seat on the crankshaft -3-,-arrows- and the sender
wheel is loose under the bolts.
3.Cranksnat 31 ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
4 Pistons and conrods
(B) woe
When working on the engine, secure it with engine and gear-
‘box support - VW 840- to support clamp - VW 313- of the
assembly stand or to engine and gearbox support - VAS
6095-.
4 Allbearing and running surfaces must be oiled before assem
oy.
Assembly overview - pistons and conrods = page 32
Piston and cylinder dimensions = page 35
Checking piston projection at TOC = page 35
44 Assembly overview - pistons and conrods
1 - Piston rings
Offset gaps by 120°.
O_ Use piston ring pliers to
remove and install
Q “TOP" faces towards
piston crown.
Checking ring gap
= page 33,
Checking ring-to-groove
clearance = page 34 .
2-Piston
With combustion cham-
ber.
Mark installation posi-
tion and cylinder num-
ber.
Installation position and
allocation of piston to
cylinder = page 35
‘Arrow on piston crown
Points to belt pulley end,
Install using piston ring
clamp.
If piston skirts cracked, |
renew piston,
Checking piston projec-
tion at TE
= page 35
3- Piston pin
1D Ifdiffcult to remove,
heat piston to 60 °C.
Remove and install us-
ing drift VW 222A.
4 Circlip
5 - Conrod
Renewas set only.
Mark cylinder allocation -A- with coloured pen.
o
oooesn
32 kop. 9:15- Crankshaft group 4-cylinder diesélengine (1.9 | engine) - Edition 04.2014
installation position: Marking -B- faces towards pulley end
6 --Bearing shell
©. Note installation position,
Note version: Upper bearing shell (towards piston) is made of a more weer resistant material. Identifi-
cation: Black line on bearing surface in area of joint
Do not interchange used bearing shells.
Insert bearing shells centrally
Check for secure seating.
Axial clearance, wear limit: 0.37 mm
Check radial clearance with Plastigage; wear limit: 0.08 mm.
Do not rotate crankshaft when checking radial clearance.
7 - Cylinder block §
© Q_ Checking cylinder bores > page 34
@ Piston and cylinder dimensions > page 35
8 - Conrod bearing cap
2 Note installation position.
9- Oil sprayjet
For pistoivggoling.
10-25 Nm
Insert without sealant.
14 - Conrod bolt, 30 Nm + '/4 turn (90°) further
Renew.
2 Oilthreads and contact surface.
Use old bolt for measuring radial clearance.
ooocoen od
Checking piston ring gap
‘Special tools and workshop equipment required
Feeler gauges
— Insert ring at right angles from above and push down into cyl
inder approx. 15 mm from bottom end of cylinder.
Piston ring New ‘Wear limit
dimensions in mm
‘1st compression ring 0.20 ...0.40 4.0
[2nd compression ring 0.20 ... 0.40 4.0
[Oil soraper ring 0.25 0.50 1.0
4. Pistons and conrods 33, @ ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
Checking ring-to-groove clearance
‘Special tools and workshop equipment required
# Foeler gauges
= Clean ring groove before checking.
Piston ring New Wear limit
dimensions in mm.
‘1st compression ring 0.06 ...0.09) 0.25 0.
[2nd compression ring 0.05 ... 0.080 0.25
[Oil scraper ring (0.03 00.06. 0.15
Checking cylinder bores
‘Special tools and workshop edulpment required
Insice caliper 50 ... 100 mm
— Take measurements at 3 positions ih both lateral direction
-A- and longitudinal direction -B.. Difference between actual ‘
{and nominal diameter max. 0.10 mm,
34 0p. :15- Crankshaft group 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
fa) Note
Cylinder bores must not be measured when cylinder block is
mounted on a repair stand with engine support bracket - VW 540-
as measurements may then be incorrect.
Piston installation position and allocation of piston to cylinder
Piston in cylinders 1 and 2:
Larger inlet valve recess -arrows- towards flywheel.
Piston in cylinders 3 and 4:
Larger inlet valve recess -arrows- towards belt pulley end.
¢ New piston allocation to cylinders 's shown by a coloured
‘marking on piston crown.
© Piston for cylinders 1 and 2: marked 1/2
¢ Piston for cylinders 3 and 4: marked 3/4
42 Piston and cylinder dimensions
Honing dimension Piston Cylinder bore Z
Basic dimension __mm| 7947. 7951
Stage | mm| 79.72 79.76
‘Stage Il m9 FO9PeN 4 80.01
43 GH8cking piston projection at TDG
Special todls and workshop equipment required
‘@ Measuring bridge - VW 382/7-
4. Pistons and conrods 35 @ ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
# End dimension plate - VW 385/17-
+ Dial gauge
4.3.1 Test procedure
Piston projection at TDC must be measured on all pistone when
installing new pistons or a short engine. Install the appropriate
cylinder head gasket depending upon piston projection, accord
ing to following table:
(Ene
Turn engine clockwise to measure piston projection at TDC.
Piston projection Identification
Holesinotches
0.91 mm... 4.00 mm
4.01 mm... 1.10 mm
4.41 mm ... 1.20 mm
4.3.2 Cylinder head gasket identification
# Part No. = -arrow 1-
# Production control code
# Holes = -arrow 3
Installation position: identifiation faces upwards.
(Fro :
If different values are determined during the projection measure-
ment, use the largest dimension for selecting the gasket.
arrow 2- (disregard)
vw 385/17
36 op. 9:15- Crankshaft group Sharan 1996 >
4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
Cylinder head, valve ge
1 Cylinder head
(F) ne
¢ When instaling an exchange cylinder head with fitted cam-
shaft, the contact surfaces betiveen the bucket tapoets and
the cam must be oiled before installing the cylinder head cov-
er
The plastic protectors fitted to protact the open valves must be
removed only immediately before the cylinder head is fitted.
© Ifthe cylinder head is replaced, all the coolant in the system
must also be renewed.
Assembly overview - cylinder head = page 37
Removing and installing cylinder head cover > page 40
Removing, installing and tensioning toothed belt > page 42
Removing and installing cylinder head = page 55
Compression test = page 59
14 Assembly overview - cylinder head
1. Cylnderheas 37 ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
1 - Toothed belt guard upper
part
2- Toothed belt
Mark direction of rote-
tion before removing,
Check for wear.
Do not kink.
Removing, installing
and tensioning
= page 42
3-10Nm
O Renew.
4-25Nm
5 - 100 Nm
6 - Camshaft pulley
7 -Hub
With sender wheel
Use counterhold tool -
T10051- to loosen and
tighten
1D To remove, use puller -
710052.
Removing and installing
page 67
8 - Rear toothed belt guard
9 - Sealing grommet . 2
Q Renewifdamaged, 34331932 31 20 30 29 28 27
10-Hall sender-G40- %,
For camshaft positién. 3 NiS-048
To remove, unbutton
sealing grommet = Item 9 (page 36) from rear toothed belt guard, 4
11 - Cylinder head bolt
O Renew.
2 Observe sequence when loosening and tightening = page 55 5
Before installing, place washers in cylinder head = item 4 (pace 62)
12 - Cylinder head cover
Before fiting,:thoroughly clean sealing surface of cylinder head with clean cloth.
Removing and installing > page 40
13 - Preseure regulating valve
For crankcase ventilation.
14- Crankcase breather hose
To intake manifold between air filter housing and turbocharger
15-Cap
Renew seal if damaged. “. >
16 - Seal “
Renew if damaged. Pee °
17-10Nm
With spacer sleeve and seal
Renew seal if damaged.
13 14 15 16 17
38 R09. 9:15- Cyindor head, valve goar 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
Observe tightening sequence > page 40
18 - Gasket for cylinder head cover
Renew if damaged.
Before fitting gasket, seal transition points of bearing cap 1 and 5 to cylinder head with sealant - AMV.
174 004 01 > page 40
19-20 Nm
20 - Lifting eye
24 - Unit injector
Removing and installing + page 163 .
22-10. Nm
23 - Central connector
For unit injector - N240 -. -243-
24 - From brake servo
25 - Tandem pump
For fuel and vacuum supply.
Removing and installing = page 126
Must not be dismantled.
26 - Supply line
From fuel fter:
Engine codés’ANU, AUY, BVK: \tth fupl cooler at underbody = Item 14 (page 119)
Epgitie codes ANU, ASZ, AUY, BTB, BUK:without fuel cooler at underbody = Item 1 (page 119
White or with white marking
Check for secure seating
Secure with spring-type clips.
27 - Return line
2 To fuel fier (engine codes ANU, AUY, BVK: with fuel cobler at underbody) = item 40 (page 118)
To heat exchanger (engine codes ANU, ASZ, AUY, BTB, VK: without fuel cooler at underbody)
> Item 10 (page 121 5
Blue or with blue marking.
Check for secure seating
Secure with spring-type clips. 3
28 - Gasket :
Renew,
29- Bolt
30- Cylinder head
Removing and installing > page 55
a After renewing, renew entire coolant.
'31.- Cylinder head gasket
@. Renew.
Note marking = page 40
2 After'renewing, renew entire coolant,
32- Glow plug "
2 45Nm
Cheek > page 178
33- Tensioning roller
34-20 Nm + Vig tum (45°) further
1. Cylnderheas 39 @ ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
Checking cylinder head for distortion
‘Special tools and workshop equipment required
# Straight edge
+ Feeler gauges
Max. permissible distortion: 0.1 mm,
(F ne
Reworking diesel cylinder heads is not permissible:
Cylinder head gasket identification
4 Part No. = -arrow 1+
# Production control code = -arrow 2~(disregard)
# Holes = -arrow 3-
+ Installation position: identification faces upwards.
fi Note
Different thicknesses of cylinder head gasket are fitted depending
on the piston projection. When renewing gasket, install new gas-
ket with same identification.
12 Removing and installing cylinder head
cover
Special tools and workshop equipment required
Torque wrench (6... 60. Nm) - VAG 1334.
VAG 1331
40 0p. or.15- Cynder noad. valve gear 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
© Spring-type clip pliers - VAS 5024 A-
VAS 5024 A
@ Sealant - AMV 174 004 01-
Removing
= Observe rules for cleanliness = page 115
= Remove engine cover.
— Remove upper toothed belt guard.
= Disconnect crankcase breather hose at union of rear intake
manifold.
~ Remove cylinder head cover.
Installing
Install in reverse order. In the process, note the following:
A WARNING
When doing any repair work, especially in the engine compart-
iment, pay attention tothe following dui tothe cramped cond!
8:
# Route al the various lines (e.g. for fil, drut, act.
Vale charcoal fer system) cootantandrefigerant brake
ful ‘and vacuum) and electrical wiring in.their original po-
Stone
¢ Ensure that there is sufficient cleargnce to all moving or
hot components.
Note
¢ Renew cylinder head cover if damaged.
© Renew cylinder head cover gasket and bolt seal if damaged
or leaking. s
= Clean sealing surfaces. They must be free of oil and grease.
1.Cyindorheas 41 ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
= Place a drop of sealant - AMV 174 004 01- (2 approx, S¥iin)
-arrows- on edges of both sealing surfaces of bearing’cap and
cylinder head at front of engine.
— Place a drop of sealant - AMV 174-004 01- (7 approx. 5 mm)
-ar;rows- on edges of both sealing surfaces of bearing cap and
cylinder head at rear of engine,
(CF) noe
+ Observe expity date of sealing compound.
Cylinder head cover must be installed Within 5 minutes of ap-
plying sealant.
= Install cylinder head cover immediately and tighten al'secur-
ing bolts hand-tight in illustrated sequence.
= Tighten securing bolts in illustrated sequence. Specified tor-
que: 10 Nm
Further assembly is basically the reverse of the dismantling se-
quence,
13 Removing, installing and tensioning toothed belt
42 Rep or.15- Cynder head. valve gear 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
‘Special tools and workshop
equipment required
© Support bracket - 10-2228
with legs -10-222A/5- (ve-
hicles * 05.00) or
-10-222A14- and
-10-222A15- (vehicles
06.00 *),
Locking pin - 3359-
@ Pin wrench - 3387- or hex-
agon wrench
Locking plate -T10008- ©
(vehicles with hydraulicten-
sioning system) 5
© Crankshaft stop - 110050-
@ Locking pin-T10115-
For vehicles with oval crankshaft pulley
¢ Crankshaft stop - T10100-
1.Cylnderheas 43 @ ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
Special tools and workshop
equipment required
Torque wrench (5..50Nm) | WAG 1991
=VAG 1331
# Torque wrench (40,
200 Nm) - V.A.G 1332-
# Spring-type clip pliers -
VAS 5024 A-
Dill bit @ 4 mm (vehicles
with hydraulic tensioning
system)
1.3.1 Removing
If the toothed belt is renewed during a:repair measure, enter this
inthe service schedule of vehicle wallet.
— Observe rules for cleanliness > page 15
— Remove noise insulation = Body Repaifs: Rep. gr. 50 : Exte-
rior; Body - front; Assembly overview - noise insulation (diesel
engine)
= Remove air fiter housing together with intake Manifold
- Remove poly V-belt = page 14
- Remove poly V-belt tensioning device from ancillary bracket:
VAG 1332
eee
44 0p. or.15- Cynder noad. valve gear 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
Vehicles * 05.00
— Install spindles -A. in installation position as illustrated and fit
support bracket 10-222 with legs 10-2228/5.
10-222 A,
= “Secure legs 10-222A/5 with body bolts -arrows-
Vehicles 08.00 »
- Separate the plug connector between turbotharger and
charge air cooler by pulling the securing clamp arrow.
- Remove air duct trim.
— Remove 10 mm bolts -arrows- and pull trim out forwards.
- Remove both outer bolts of battery tray.
1. Cwtinderheas 45 @ ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
Assemble engine support bracket 10-222 A with legs 10-222
AV14 and 10-222 A/15 as shown,
= Bolt leg 10-222 A/14 to battery tray with bolts M&x35
-arrows-. Specified torque: 25 Nm
Continuation for all vehicles
‘Take up weight of engine in its installation position
Release load on engine mounting by lifting engine slightly.
Unscrew securing bolts -arrows- and remove bracket -1-.
Unbolt assembly mounting -2- from longitudinal member.
= Remove engine support at cylinder block
(F) no
# When loosening the upper engine mounting bolts the engine
must be raised with the support bracket.
'¢ When loosening the lower engine moiihiing bolts the engine
must be lowered with the supportbracket.
— Remove vibration damper/balt pulley.
~ Remove centre and lowet toothed belt guards.
= Turn crankshaft to TDG No. 4 cylinder.
46 0p. or.15- Cynder noad. valve gear 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
(a) Note
Turn the crankshaft until the mark on the crankshaft toothed belt
pulley is on the top and the arrow on the rear toothed belt guard
‘aligns with the lug on the hub sender whee! -arrows-
— Lock hub using locking pin - 3359- . To do this, slide locking
pin through the fre elongated hole on lft into hole in cyinder
1a
(a) Note
Gradual introduction of oval crankshaft toothed belt pulleys.
When installing this toothed belt pulley, the crankshaft stop -
T10100- must be installed to determine the TOC postion.
Characteristics of crankshaft toothed belt pulley
A= round belt pulley, lock using crankshaft stop - T10050-, TDC
marking at 12 o'clock
B = oval belt pulley, lock using crankshaft stop - 110100- . TDC
marking at 1 o'clock
= Lock crankshaft toothed belt pulley with crankshaft stop -
T10050- or crankshaft stop - T10100- . To do this, push
crankshaft stop into teeth of belt pulley from face side.
(se
The marks on the crankshaft toothed belt pulley and the crank
shaft stop must align. When doing this, the pin of the crankshaft
stop must engage in the driling of sealing flange.
= Mark direction of rotation of toothed belt
1.3.2. Vehicles with hydraulic belt tensioning
system
‘Vehicles with’tretion dampened tensioning system = page 51
Identficatioa: with toothed belt tensioner -arrow-.
1. Cylnderheas 47 @ ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
= Insert a hexagon key into the hexagon hole onto stop and use
it to press the tensioning roller anti-clockwise in -direction of
arrow: until the toothed belt tensioner can be locked with the
locking plate - T10008-
w Note .
Ifthe hexagon key is not inserted deeply enough there is a gfeat
danger that key will slip out
= Loosen tensioning roller securing nut.
= Unscrew ard remove securing bolts -1- of toothed belt ten-
sioner and temove tensioning element.
Remove toothed belt.
1.3.3 Anstalling
Z\ weenie
When doing any répair work, especially in the engine compart-
‘ment, pay attention tothe following die tothe cramped cond.
fons:
» Route all the various lineS'(e.g, for fuel, hydraulics, acti
vated charcoal fiter system, coolant and refngeramt brake
fluid and vacuum) and electrical wiring in their original po-
sitions.
¢ Ensure that there is sufficient clearance to all moving or
‘hot components.
+ Camshaft locked with locking pin - 3359.
+ Crankshaft locked with crankshaft stop - T10050- or crank-
shaft stop - T10100-
+ Tensioning roller locked with locking pin - T10115- and se-
cured to right stop,
(F we
Always perform adjustment work on toothed belts only on cold
engines.
4B 0p. or.15- Cynder noad. valve gear 4-cylinder diesel engine
= Loosen securing bolts -1- of camshaft pulley untilthe camshaft
pulley can be moved within the elongated holes,
= Tum camshaft pulley clockwise -direction of arrow. in elonga-
ted holes onto stop.
= Now/carefully turn eccentric clockwise using pin wrench -
3387- until eccentric lug lies directly before limit stop -B-
— Fit toothed belt on camshaft bsit pulley, tensioning roller,
crankshaft belt pulley and finally on coolant pump belt pulley.
~ ‘Install toothed belt tensioning device.
— Tum eccentric anti-clockwise using pin wrench - 3387- (lug of
eccentric moves in direction of limit stop -A-), until the locking
platé- T10008- is not under tension and can be pulled out.
— Release force of tensioning elementin clockwise direction (lug
of eccentric moves towards stop -B-) until dimension -a- has
been attained. Specification dimension -a-: 4+ 1 mm.
fa) Note
© Dimension -a- reduces when the tensioning roller securing nut
is fighlened. Therefore adjust generously using 2 4 mm dll
bit
¢ Measurement -2- may be reduced to 1 mm at operating tem-
perature.
Hold tensioning roller in this position and tighten tensioning
roller securing nut ae follows: 20 Nm and 45° (1/8 turn) further.
4.9 | engine) - Edition 04.2014
1. Cytnderheas 49 @ ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
= Tighten securing bolts -1- of camshaft pulley to 25 Nm.
— Remove locking pin - 3359- and crankshaft stop - T10050- or
crankshaft stop - T10100-
— Tum crankshaft two rotations in engine direction of rotation
and set again to TOC no. 1 cylinder.
(F ne»
4% Wihen doing this, the pin of the crankshah stop must engage
In the sealing flange from the rotational movement,
ifthe crankshaft is turned pas? TOC No. 1 cylinder and the
crankshaft stop could not engage in the sealing flange, turn
the crankshaft back. tum to be able to turn the crankshaft
‘in engine direction’6f rotation again to set it to TDC No. 1 cyl.
Inder. Corrections to the position by turning against engine
dlrection of rotation in order to insert the crankshaft stop are
not permissible.
= Once crarikshaft stop - 710050- or crankshaft stop - T10100-
has bem inserted, check whether:
Dimension -2- is attained and
the huticen be locked with locking pin - 3359-
It dimension -2- is not attained:
— Tensich the tensioning roller again. To do this, hold tensioning
roller with pin wrench - 3387. loosen securing nut and release
force offensioning device until dimension -a-is attained, Spec-
ification-dimension -a-: 4 + 1 mm.
— Tighten securing nut to 20 Nm and 45° (1/8 tum) further.
Ifthe hub canjot be locked:
— Pullcrankshaif stop pin out of drilling in sealing flange and turn
crankshaft untithub can bs locked with locking pin.
= Loosen securing bélts -1- of camshaft pulley.
50 0p. or.15- cinder noad. valve gear 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
- Tum crankshaft slightly against engine direction of rotation
unti the pin of the crankshaft stop is positioned just before the
hole in the sealing flange -arrow-.
= Now turn crankshatin engine rection af sotatit il aA
shaft stop pin engages in sealing flange whist tuning
— Tighten securing bolts of camshait belt pulley to 25 Nm.
— Remove locking pin - 3359¢and crankshaft stop - T10050- or
crankshaft stop - T10109> .
= Tum crankshaft two rotations in engine direction of rotation
until crankshaft is set to TDC No. 1 cylinder again
(8) note :
© When doing this? the pin of the crankshaft stop must engage
inthe Seating fangs rom the rotational movement
© Ifthe crankshaft js tumed past TOC No. 1 cylinder and the
crankshaft stop could not engage in the sealing flange, turn,
the crankshaft back 1/4 turn to be able to turn the crankshaft
in engine direction of rotation again to set ito TDC No. 1 cyt-
‘inder. Corrections to the position by turning agaist engine
direction of rotation in order to insert the crankshaft stop are
not permissible.
= Repeat check
1.3.4 Vehicles with-friction dampened ten-
sioning system
= Loosen tensioning roller securing rt
— Loosen securing bolts -1- of camshaft pulley'Until the camshaft;
pulley can be moved within the elongated holes,
= Turn pin wrench - 3387- anti-clockwise (opposite direction of
arrow) unt toothed belt tensioning roller can be locked with
locking pin - T10115-
— Nowtur pin wrench in direction of arrow onto stop and tighten
securing nut hand:-tight.
— Remove toothed belt frst from coolant pump and then from
remaining pulleys.
1. Cyindorheas 51 ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
1.3.5 Installing
ZV wane
When doing any repair work, especially in the engine compart-
‘ment, pay attention to the fellowing die tothe cramped condi-
tions:
Route all the various lines (e.g. for fuel, hydraulics, acti-
vated charcoa/ iter system, coolant and refrigerant. brake
{fluid and vacuum) and electrical wiring in their original po-
sitions.
¢ Ensure that there is sufficient clearance to all moving or
‘hot components.
[noe
# Adjustment ork on toothed belts must be performed only on
cold engines, as the indicator position on the tensioning ele-
‘ment varies depending on the engine temperature.
The terisioning roller must be locked with locking pin -T10115-
and secured fo right limit stop.
— Turm-camshatt pulley in elongated holes anti-clockwise -direc-
tion of arrow- onto stop,
~_ Fitfoothed belt to crankshaft toothed belt pulley, tensioning
roller and camshaft pulley.
= Then fit toothed belt on coolant pump toothed belt pulley.
(Fro
Ensure that tensioning roliec seats correctly in rear toothed belt
‘guard -arrow..
= Loosen tensioning roller securing nut.
= Release tension on tensioning roller by turning with pin wrench
in opposite direction of arrow and remove locking pin from,
tensioning roller.
52. R0p.9:18- Cyindar head, valve goar 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
- Now carefully turn tensioning roller in direction of arrow using
pin wrench - 3387- until indicators in middle of gap in the base
plate -arrowe,
= Hold tensioning roller in this position and tighten tensioning
roller securing nut as follows: 20 Nm and 45° (1/8 turn) further.
= Tighten securing bolts of camshaft belt pulley to 25 Nm.
— Remove locking pin - 3389- and crankshaft stop - 110050- or
crankshaft stop - 710100-
= Tum crankshaft two rotations in engine direction of rotation
and set again to TDC no. 1 cylinder.
(8) note
+ When doing itis, the pin ofthe crankshaft stoo must engage
in the sealing flange trom the rotational movement.
© Ifthe crankshaft is tured past TOC No. 1 cylinder and the
‘crankshaft stop could not engage in the sealing flange, tun
the crankshaft back 1/4 turn to be able to turn the crankshaft
‘in engine direction of rotation again to set ito TDC No. 1 cyt-
‘nder. Corrections to the position by turning against engine,
direction of rotation in order to igsert the crankshaft stop are
not permissible.
= Once crankshaft stop, 7 10050- or crankshaft stop - T10100-
has been inserted, check whether:
tensioning roller indicator is positioned centrally in the gap of
base plate and
¢ the hub can be locked with locking pin - 3359-
If the hub cannat be locked:
— Pull the pin 6f crankshaft stop - 110050- or crankshatt stop -
T10100- cuf of the driling in the sealing flange anc turn the
crankshaft Gntil the hub can be locked with the locking pin = :
3359.
— Loosen sectiring bolts -1- of camshatt pulley.
1. Cyinderheas 53 @ ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
= Tum crankshaft slightly against engine direction of rotation
until the pin of the crankshaft stop is positioned just before the
hole in the sealing flange -arrow..
= Now turn crankshaft in engine direction of rotation until crank-
shaft stop pin engages in sealing flange whilst turning,
= Tighten securing bolts of camshatt belt pulley to 25 Nm
Remove locking pin - 3359- and crankshaft stop - T10050- or
crankshaft stop - T10100-
— Tur crankshaft two rotations in engine direction of rotation
until crankshaft is set to TOG.No't cylinder again...
(Bow é >
+ Wihen dojfig this, the pin of the crankshaft stop must engage
In the sealing flange from the rotational movement.
if thazrankshaft is turned past TOC No. 1 cylinder and the
crankshaft stop could not engage in the sealing flange, turn
the crankshaft back 1/4 tum to be able to turn the crankshaft
‘in @ngine direction of rotation again to set it to TDC No. 1 cy
‘inder. Corrections to the position by turning against engine
dtrection of rotation in order to insert the crankshaft stop are
not permissible.
= Repeat check.
Continuation for all vehicles
Install lower toothed belt guard and pulley vibration damper.
= Install centre toothed belt guard.
— Fitengine support to cylinder block. Specified torque for -M&-
30 Nm; specified torque for -M10-: 45 Nm
— Bolt poly. V-belt tensioning device to ancillary bracket. Speci-
fied torque; 25 Nm.
= Install poly Vanelt = page 14
~ Install engine assembly mounting. Specified torque: 60 Now
—_ Install bracket for engine assembly mounting, Soebifiéd torque
for bolts: 60 Nm; specified torque for nuts; 55.'Nm_
- Remove support bracket - 10-2224.
—_ Install air fiter housing together with intake manifold.
Vehicles 08.00
Install air duct trim,
54 op. or.15- Cynder noad. valve gear 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
Install the plug connector between turbocharger and charge
air cooler by pulling the securing clamp -arrow-.
fa) Note Xe . a
When instaling ensure that lock luge engage securely
opage iat
Continuation for ll vehicle’
= Install noise insulation > Body Repairs; Rep. ar. 50: Exterior;
Body - front; Assembly overview - noise insulation (diesel en-
gine’
— Read fault memory > page 168,
14 Removing and installing cylinder head
Special tools and workshop
equipment required
© Drip tray - V.AG:1306- or
drip tray - VAS 6208-
© Torque wrench (5'%50Nm)
“VAG 1331-
@ Torque wrench (40...
200'Nm) - V.AG 13322,
¢ Hand vacuum pump -
V.AG 1390-
© Water drainage container -
V.AG 1390/1-
© Bracket -T10014-
Prerequisite
+ The engine must be no more than warm to touch.
1. Cylnderheas 5S @ ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
1.4.1 Removing
ZV waren
When doing any repair work, especially in the engine compart-
‘ment, pay attention to the fellowing die tothe cramped condi-
tions:
Route all the various lines (e.g. for fuel, hydraulics, acti-
vated charcoal fiter system, coolant and refigerant, brake
{fluid and vacuum) and electrical wiring in their original po-
sitions.
¢ Ensure that there is sufficient clearance to'all moving or
‘hot components.
With ignition switched off, disconnect earth strap from battery.
- Remove engine cover.
= Beforefemoving cylinder head extract fuelusing hand vacuum
pump: V.AG 1390. and fluid receptacle - VAG 1390/1- on
the tandem pump = page 138
— Retnove toothed belt > page 42
— Remove hub for camshaft pulley = page 67
- Remove front exhaust pipe from turbocharger = page 170
= Dyain coolent > page 100
— Pull off or disconnect all other electrical connections as nec-
‘essary from cylinder head and lay to side.
= Séperate all connecting, coolant and vacuum hoses from cyl-
inder head.
= Remove engine support -1- and in place screw retainer -
T10044- into cylinder block
— Tighten Securing bolt -2- of retainer - 110014- to 20 Nm.
56 Rep. 9:15- Cyindar head, valve goar 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
Se, |
- Secure the spindle -A- to retainer - 710014- and slightly it
engine unti the spindle -B- is relieved.
= Remove spindle -B.
— Remove cylinder head cover = page 40
= Loosen cylinder head bolts in the sequence given starting at
the outside and working inwards and then remove completely.
= Carefully remove cylinder head.
— Place clean cloths in cylinders so that no dirt or emery cloth
particles can get in between cylinder wall and piston.
— Also prevent dirt and emery cloth particles from getting into
coolant!
Now carefully clean sealing surfaces of cylinder head and cyl.
inder block. When doing this, ensure that surfaces are not
scored or scratched (if abrasive paper is usedgrade must not
be less than 100), ¢
1.4.2 Installing
A WARNING
When doing any repair work, especially in the engine compart-
ment, pay attention tothe following dive to the cramped cone
ns
¢ Route all the various lines (e.g. for fuel, hydrauiics, acti-
vated charcoal fiter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po-
sitions.
# Ensure that there Is suffcient clearance to all moving or
‘hot components
1. Cylnderheas 57 @ ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
fw Note
4 Alnays renew cylinder head bolts:
1 itrepairing, carefully remove any/?emaining gasket material
‘rom the éylinder block and eylinder head. Ensure that no long
scores or scratches are made on the surfaces. When using
abrasive paper do natuise a grade less than 700
+ Donetremove naw aylinder head gasket fom packaging unt
itis ready to be fi
+ Handle gasket very carefully. Damage to the silicone layer or
the indented area will lead fo leaks.
© Carefully refnove remains of emery and abrasives.
~ Turn crankshaft to TDC marking before fitting cylinder head.
= Turn crankshaft against engine rection of retation unt all
stoas arg about fhe santa cstanss Below TOG
= Position cylinder head gasket.
~ Fiteylinderhead and hand tighten all cylinder head bolts (Qty.
= Tighten cylinder head in four stages in sequence shown as
follows:
= 4. Tighten initially with torque wrench: stage | = 40 Nm; stage
I= 60Nm
~ 2. Tum further with’tigid spanner: stage ill = "/q turn (90°),
stage IV = vg turn (90%)
@ Note
‘Ate repair work itis not necessary to retighten the cylinder howd
=. After tightening cylinder head, turn camshaft so thet cams for
No. 1 cylinder point equally upwards. Turn cranksheff, in en-
gine direction of rotation, to TDC marking before fitting toothed
belt > page 42
—_ Install cylinder head cover > page 40
= Install camshaft pulley and hub > page 67
58 Rep. or.15- Cynder noad. valve gear Observe applicable safety precautions during road test
4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
Secure spindle -B- to lifting eye and slightly lift engine until the
spindle -B- is relieved.
Remove spindle -A..
Remove retainer - T10014-.
Fit engine Support -1- so that the boss cast on the engine
bracket faces towards the locking lug of the rear toothed belt
‘guard -arrows-.
Tighten secuting bolt -2- hand tight
Fit engine support -1- to cylinder bicek? Specified torque,foP
MB-: 30 Nm; specified torque for -M10-: 45 Nm_
Tighten securing bolt -2-. Specified torque: 45 Nm.
Install toothed belt and adjust valve timing > page 42
Install poly V-belt = page 14
Carry out road test and read fault memories = page 168
15 Compression test
1.Cylnderheas 5 ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
Special tools and workshop
equipment required
#40 mm jointed spanner -
3220-
# Torque wrench (5... 50 Nm)
“VAG 1331-
# Adapter -V.AG 1381/12
+ Compression tester -
VAG 1763-
Test prerequisites
+ Engine cil temperature must be at least 30 °C.
‘+ The battery voltage must be at least 11.5 V.
All electrical consumers, e.g. lights and rear window heating,
‘must be switched off. g
If the vehicle is equipped with an air conditioner, it must be §
© switched off. s
‘Test procedure
~-,Note safety precautions before beginning work = page 156
‘Remove engine cover. $
Puli off central connector for unit injectors. .
Remi all glow plugs using 10 mm jointed wrench - 3220-"
60 0p. or.15- Cynder noad. valve gear 4-cylinder digsel engine (1.9 | engine) - Edition 04.2014
— Screwin adapter - V.A.G 1381/12- in place of the glow plugs.
— Check compression using compression tester - V.AG 1763-
(CF) ne
Using compression tester = Operating instructions.
— Operate starter until tester shows ii further pressure in-
crease.
Compression pressures:
New: 25 ..81 bar, wear limit: 19 bar
Maximuin permissible difference between all cylinders: 5 bar
Install glow plugs using 10 mm jointed wrench - 3220- , speci-
fied torque. 18 Nm.
—2 Read fault memory = page 168 . 4
(A) Note
“Disconnecting the central connector for unit injectors causes 3
{faults to be stored. Therefore, read fault memory and clear ifnec-
‘essary.
1. Cyindorheas 61 ‘Sharan 1996 >
4-cylinder diesel engine (1.9 | engine) - Edition 04.2014
2 Valve gear
(B) woe
Cylinder heads with cracks between the valve seats may be used
wathout reducing engine life, provided the cracks are small and
not more than 0.5 mm wide.
‘Assembly overview - valve gear = page 62.
Checking valve guides = page 65
Renewing valve stem seals > page 65
Removing and installing camshaft = page 67
Removing and installing camshaft seal = page 74
24 Assembly overview - valve gear
4-20 Nm + "74 turn (90°) fur-
ther
Renew.
Observe sequencers"
when loosening'and
tightening = page 67
2- Rocker arm shaft
OD Dosiot interchange.
3- Cylinder head bolt
GS Observe sequence
when loosening and
© tightening > page 55.
Q._ Before installing, insert
washers
(= Item4 (page 62) )
in cylinder head.
4: Washer
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