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Workshop Manual
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Sharan 1996 ➤
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4-cylinder injection engine (5-valve), mechanics
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Engine ID AJH AWC
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Edition 06.2019
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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
26 - Exhaust system
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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg K0056763820

Sharan 1996 ➤
4-cylinder injection engine (5-valve), mechanics - Edition 06.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 Additional information and assembly work for vehicles with air conditioner . . . . . . . . . . . . 13
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.1 Part I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Part II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 Removing and installing sealing flanges agen and flywheel A
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2.2 Removing and installing sealing oris flange - pulley end . . . . . . . . . . .an.te.e. . . . . . . . . . . . . . . . . 25
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2.3 Removing and installing au drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . r.ac. . . . . . . . . . . . . . . 27
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3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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3.1 Colour coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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4.1 Checking pistons, piston rings and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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4.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 t to the co
1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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1.1 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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1.3 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2 Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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2.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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2.2 Renewing camshaft oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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2.3 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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2.4 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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2.5 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

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2.6 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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1.1 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.2 Assembly overview - parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.3 Dismantling and assembling oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.4 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.5 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Contents i
Sharan 1996 ➤
1.1 Parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

1.2 Parts of cooling system - engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.3 Connection diagrams for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.4 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.5 Removing and installing radiator and fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.6 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.7 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.8 Checking coolant circulation pump V50 (AJH) or continued coolant circulation pump V51
(AWC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.1 Removing and installing fuel tank with attachments and fuel filter . . . . . . . . . . . . . . . . . . . . 113
1.2 Safety measures when working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.3 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.4 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.5 Removing and installing fuel gauge sender: engine code AWC . . . . . . . . . . . . . . . . . . . . 123
1.6 Crash fuel shut-off: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.7 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.1 Repairing accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.2 Adjusting accelerator cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3 Electronic power control (EPC): engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.1 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.2 Repairing parts of electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.3 Checking accelerator position agen sender . . . A. G. d. o.es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.1 Function . . t.ho.ris. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n. te.e.o . . . . . . . . . . . . . . . . . . . . . . . . . 140
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4.2 Repairing sparts
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4.3 Activated charcoal filter solenoid valve 1 N80 : engine code AWC . . . . . . . . . . . . . . . . . . 143
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4.4 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

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21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
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1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

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1.1 Removing and installing turbocharger with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . 148

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1.2 Removing and installing parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

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1.3 Schematic diagram of turbocharging system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

1.4 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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1.6 Removing and installing charge air cooler: engine code AWC . . . . . . . . . . . . . . . . . . . . . . 157
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2 Checking charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

2.1 Checking charge air system: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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2.2 Checking charge pressure system: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

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1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

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1.1 Front exhaust pipe and catalytic converter with attachments . . . . . . . . . . . . . . . . . . . . . . . . 171
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1.2 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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2 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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2.1 Secondary air system: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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2.2 Secondary air system: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
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3 Exhaust gas recirculation system: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.1 Repairing parts of exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.2 Checking exhaust gas recirculation potentiometer G212 . . . . . . . . . . . . . . . . . . . . . . . . . . 183
ii Contents
Sharan 1996 ➤
00 – Technical data
1 Technical data byV
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Engine number ⇒ page 1 ss
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Engine data ⇒ page 1
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1.1 Engine number
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The engine number (“code letters” and “serial number”) can be
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Additionally there is a sticker on the toothed belt guard with “en‐
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The engine code is also included on the vehicle data sticker.
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The engine number consists of up to nine characters (alphanu‐
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“engine code”, and the second part (6 characters), the “serial

number”. If more than 999,999 engines were produced with the
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1.2 Engine data
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Engine code AJH AWC
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Manufactured 11.97 ► 05.00 06.00 ►
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Displacement l 1.8 1.8
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Power kW at rpm 110/5500 110/5800
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Torque Nm at rpm 210/1850…4500 210/1800…4300
Bore ∅ mm 81.0 81.0
Stroke mm 86.4 86.4
Compression ratio 9.5 9.5
RON 95 unleaded1) 95 unleaded1)
System designation Motronic ME3.8.5 Motronic ME7.5
Exhaust emissions fulfil D3 standard EU4 standard
Self-diagnosis Yes OBD
Knock control 2 knock sensors 2 knock sensors
Lambda regulation 1 probe 2 probes
Catalytic converter Yes Yes
Exhaust gas recirculation No Yes
1) in exceptional circumstances at least 91 RON, but with reduced output
Engine code AJH AWC

Charging Yes Yes
Boost pressure regulation Yes Yes
Secondary air system Yes Yes
Electronic power control No Yes
Variable intake manifold No No
Camshaft timing adjustment No No
1. Technical data 1
Sharan 1996 ➤
10 – Removing and installing engine

1 Removing and installing engine
Special tools and workshop

equipment required
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♦ Lifting tackle - 2024 A-

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♦ Workshop hoist - VAS 6100- Cop py
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♦ Engine and gearbox support - VAS 6095- p by
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2 Rep. gr.10 - Removing and installing engine

Sharan 1996 ➤
♦ Engine support - T10012-
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♦ Drip tray - V.A.G 1306- or drip tray for workshop hoist - VAS
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♦ Torque wrench - V.A.G 1331- (5…50 Nm)

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

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♦ Pliers for spring-type clips - VAS 5024A-

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♦ Step ladder - VAS 5085-

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♦ Grease - G 000 100-

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1. Removing and installing engine 3

Sharan 1996 ➤
1.1 Notes on removing
Note
The engine is removed downwards together with the gearbox. To

do this, the lock carrier must be placed in the service position and
the radiator has to be removed.
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removed must be replaced in the same oposition
ris
e when engine nte
eo
is installed. auth
ra
ss c
– Remove engine cover panel.
ce
e
nl
pt
du
an
– First check whether a coded radio is fitted. If so, obtain anti-
itte
y li
theft coding.
erm
ab
ility
ot p
– With ignition switched off, disconnect battery earth strap.
wit
, is n
h re
– Remove battery.
hole
spec
es, in part or in w
– Remove trim panel/air duct -1-.
t to the co
– Unbolt battery trim panel -2- with coolant expansion tank and
lay aside; do not yet open cooling system.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– During remaining disassembly, disconnect connectors

f
en
ng
t.
yi
-arrows- behind battery.
Co
Cop py
t. rig
– Remove battery tray.
gh ht
pyri by
Vo
co lksw
by
– Pull off or disconnect all other electrical cables as necessary cted agen
Prote AG.
from engine and body and expose.
– Remove air filter ⇒ Rep. gr. 24 .
Vehicles with engine code AJH
– Remove intake hose ⇒ page 151 , Removing and installing
parts of the charge air cooling system: engine code AJH.
– Disconnect throttle cable at throttle valve control module cable

disc and support bracket -arrows- (do not remove locating clip
on support bracket).
Vehicles with engine code AWC
parts of the charge air cooling system: engine code AWC.
Continued for all vehicles

Sharan 1996 ➤
– Disconnect fuel supply and return pipe and cable from activa‐
ted charcoal filter system solenoid valve 1 -arrows- from fuel
rail.
WARNING
Fuel supply lines are under pressure! Wrap a cloth around the
connection before loosening hose connections. Then release
pressure by carefully pulling hose off connection.
– Unclip fuel hoses from bracket.

– Seal lines so that fuel system is not contaminated by dirt.
– Observe rules for cleanliness ⇒ page 120 .
– Pull off necessary vacuum and breather hoses from engine.
– Remove noise insulation tray.
– Remove pressure hose between secondary air pump motor
and combination valve ⇒ page 174 , Removing and installing
agen
AG. Volkswagen AG d
oes
parts of the secondary air system. olksw not
yV gu b ara
ed nte
oris e
th or
au
Note ss
ac
ce
e
nl
pt
du
Press buttons on hose couplings to do this.
an
itte
y li
erm
ab
ility
– Remove air pipes between turbocharger/charge air cooler and
ot p
wit
charge air cooler/throttle valve control module ⇒ page 151 ,
, is n
h re
Removing and installing parts of the charge air cooling system:
hole
spec
engine code AJH.
es, in part or in w
t to the co
rrectness of i
parts of the secondary air system.
l purpos
Note
nf
ercia
orm
m

atio
om
n in
or c
– Remove air pipes between turbocharger/charge air cooler,

thi
te
sd
a
turbocharger/air filter and charge air cooler/throttle valve con‐

iv
o
r
rp
cu
trol module ⇒ page 152 , Removing and installing parts of the

o
m
f
charge air cooling system: engine code AWC.

en
ng
t.
yi Co
op py
Vehicles with 5-speed manual gearbox 006 t. C rig
gh ht
pyri by
– Pull off pipe/hose from slave cylinder on gearbox ⇒ Rep. gr.
co Vo
by lksw
cted
30 .
agen
Prote AG.
– Remove operating cables from gearbox ⇒ Rep. gr. 34 .

– Remove drive shafts ⇒ Rep. gr. 40 .
Vehicles with 6-speed manual gearbox 02N
– Pull off pipe/hose from slave cylinder on gearbox and move to
one side ⇒ Rep. gr. 30 .
– Remove operating cables from gearbox ⇒ Rep. gr. 34 .
– Remove drive shafts ⇒ Rep. gr. 40 .

Sharan 1996 ➤
olkswagen AG
4-cylinder injection engine (5-valve),
swa
gmechanics
en AG. V - Edition
doe06.2019
s
k not
Vol gu
d by ara
Vehicles with 4-speed automatic ogearbox
ris
e 099 nte
th eo
u ra
– Remove selector lever cable
ss from gearbox:
a ⇒ Rep. gr. 37 . c
ce
e
nl
– Unbolt drive shafts from flanged shaft/gearbox and tie up ⇒
pt
du
an
Rep. gr. 40 .
itte
y li
erm
ab
Vehicles with 5-speed automatic gearbox 09B
ility
ot p
wit
, is n
– Remove selector lever cable from gearbox: ⇒ Rep. gr. 37 .
h re
hole
spec
– Unbolt drive shafts from flanged shaft/gearbox and tie up ⇒
es, in part or in w
Rep. gr. 40 .
t to the co
Vehicles with air conditioning system
– Observe additional information and installation work
rrectness of i
⇒ page 13 .
l purpos

– Remove poly V-belt ⇒ page 18 .
nform
ercia
– Unbolt power-assisted steering vane pump from compact

m
at
om
bracket and move to one side; hoses remain connected ⇒
ion
c
Rep. gr. 48 .
in t
or
his
ate
– Unbolt hydraulic line for power-assisted steering from right
do
priv
c
engine bracket.
um
for
en
ng
t.
yi
– Remove front exhaust pipe ⇒ page 171 , Front exhaust pipe
Co
op py
and catalytic converter and attachments. t. C rig
gh ht
pyri by
– Drain coolant ⇒ page 101 .
co Vo
by lksw
cted agen
Prote AG.
– Pull connectors off thermal switch and radiator fan.
– Pull radiator coolant hoses off engine using hose clip pliers -
V.A.G 1921- or spring-type clip pliers - VAS 5024A- .
– Remove front bumper ⇒ Rep. gr. 63 .
– Bring lock carrier into service position ⇒ Rep. gr. 50 .
– Removing radiator ⇒ page 104 .
– Insert engine bracket - T10012- in engine and gearbox jack -
V.A.G 1383 A- .
– Bolt engine bracket - T10012- to cylinder block with securing

bolt M10x25. Specified torque: 45 Nm
– Lift engine and gearbox slightly using engine and gearbox jack
- V.A.G 1383 A- .
– Remove pendulum support ⇒ Rep. gr. 40 .

Sharan 1996 ➤
– Unscrew right assembly mounting securing bolts -1-.

– Unscrew left assembly mounting securing bolts -A-.
Note
To remove securing bolts use a stepladder - VAS 5085- .
– Carefully lower assembly slightly.
lkswage es n
o ot g
byV ua
ed ran
– Unscrew securing bolts -A-or and remove bracket -B-.
is tee
th or
u
Vehicles with engine codess AWC
a ac
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Unscrew left assembly mounting securing bolts/nuts

-arrows-.
ss o
cial p
f inform
Note
mer
atio
m
To remove securing bolts use a stepladder - VAS 5085- .

o
n
c
i
or
n thi
te
sd
a

iv
o
pr
cum
r
fo
– Carefully lower engine with gearbox.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note
p by
co Vo
by lksw
cted agen
Prote AG.
Engine and gearbox must be guided carefully when lowering to
prevent damage to the bodywork, hoses and lines.
1.2 Securing engine to assembly stand

Procedure
– Unbolt gearbox.

Sharan 1996 ➤
Vehicles with automatic gearbox

– Secure torque converter against “falling out” after separating
engine from gearbox.
– Attach lifting tackle - VAS 2024A- as follows and lift off engine
and gearbox jack - V.A.G 1383/A- using workshop hoist.
Belt pulley end: 4th hole in hook rail at position 1
Flywheel end: 3rd hole in hook rail at position 8
WARNING
The hooks and locating pins must be secured with locking pins!
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Note auth or
ac
ss
ce
le
♦ The positions marked 1…4 on the bar must face towards the
un
pt
V-belt pulley end.
an
d
itte
y li
erm
ab
♦ The holes in the hook rails are counted up from the hook.
ility
ot p
wit
is n
h re
– Secure engine on engine and gearbox support - VAS 6095/1-
ole,
using universal mounting - VAS 6095- .
spec
t to the co
1.3 Notes on installing
Installation is carried out in the reverse order. When installing,
rrectne
note the following:
ss o
WARNING
cial p
f inform
mer
Observe the following points during all installation work, in par‐
atio
ticular in the engine compartment, due to the space limitations:
om
n
c
i
or
n
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
thi
te
sd
vated charcoal filter system, coolant, refrigerant, brake
iva
o
r
fluid and vacuum) and electrical wiring in their original po‐

p
cum
r
fo
sitions.
en
ng
t.
yi Co
op
♦ Ensure that there is sufficient clearance to all moving or
C py
t. rig
gh
hot components.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Check whether dowel sleeves for centring engine/gearbox

have been fitted in cylinder block, insert if necessary.

AG. Volkswagen AG d
agen oes
ksw not
by Vol
gu
ara
Sharan 1996 ➤
d
orise 4-cylinder injection engine (5-valve),
nte mechanics
eo
- Edition 06.2019
th
au ra
s c
– Hook intermediate plate onto sealing flange and slide onto s
ce
e
dowel sleeves -arrows-.
nl
pt
du
an
itte
y li
Vehicles with 5-speed manual gearbox 006
erm
ab
ility
– Clean input shaft splines and lightly grease with grease - G ot p
wit
, is n
000 100- .
h re
hole
– Check clutch and clutch operating mechanism and install ⇒
spec
es, in part or in w
Rep. gr. 30 .
t to the co
– Clean input shaft splines and lightly grease with G 000 100.
rrectness of i
– Check clutch and clutch operating mechanism and install ⇒
l purpos
Rep. gr. 30 .
nf
ercia
orm
– Screw in all bolts on assembly mountings by hand approx. 5…
m
atio
m
6 turns.
o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
Note
Before starting assembly mounting bolts, bracket -B- must be in‐

stalled and tightened; torque settings for bracket ⇒ page 12 .

– Align assembly mountings stress-free by rocking.
Note
Specified torques for engine and gearbox mountings

⇒ page 12 .

– Fit pipe/hose line to slave cylinder and secure with clamp ⇒
Rep. gr. 30 .
– Install actuator cables on gearbox; adjust if necessary ⇒ Rep.
gr. 34 .
– Fit pipe/hose line to slave cylinder and secure with clamp ⇒
Rep. gr. 30 .
– Install actuator cables on gearbox; adjust if necessary ⇒ Rep.
gr. 34 . swa
gen AG
. Volkswagen AG
does
k not
Vol gu
Vehicles with 4-speed automatic gearboxse099
db
y ara
nte
i
or eo
– Install gate lever cable on gearbox,auadjust
th if necessary: ⇒ Rep. ra
gr. 37 . ss c
ce
e
nl
pt
du

an
itte
y li
erm
– Install gate lever cable on gearbox, adjust if necessary ⇒ Rep.

ab
ility
gr. 37 .
ot p
wit
, is n

h re
hole
spec
– Install front exhaust pipe ⇒ page 171 ; front exhaust pipe and
es, in part or in w
catalytic converter with attachments.

t to the co
– Install drive shafts ⇒ Rep. gr. 40 .

rrectness of i
– Install pendulum support ⇒ Rep. gr. 40 .

l purpos
– Install power-assisted steering vane pump ⇒ Rep. gr. 48 .

– Bolt hydraulic line for power-assisted steering onto right en‐
nform
ercia
gine bracket; torque setting 20 Nm.

m
Vehicles with air conditioning system

at
om
ion
c
in t
– Install A/C compressor ⇒ Rep. gr. 87 .

or
his
ate

do
priv
cum
or
– Install poly V-belt ⇒ page 18 .

f
en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
– Install air pipes between turbocharger/charge air cooler, tur‐ cop Vo
by lksw
bocharger/air filter and charge air cooler/throttle valve control
cted agen
Prote AG.
module ⇒ page 151 , Removing and installing parts of charge
air cooling system: engine code AJH
– Install intake hose ⇒ page 151 , Removing and installing parts
of the charge air cooling system: engine code AJH.

Sharan 1996 ➤
– Install pressure hose between secondary air pump motor -

V101- and combination valve ⇒ page 174 , Removing and
installing parts of the secondary air system.
– Adjust throttle cable ⇒ page 131 , Repairing accelerator
mechanism.
– Install air pipes between turbocharger/charge air cooler, tur‐
bocharger/air filter and charge air cooler/throttle valve control
module ⇒ page 152 , Removing and installing parts of charge
air cooling system: engine code AWC
of charge air cooling system: engine code AWC.
– Install pressure hose between secondary air pump motor -
installing parts of the secondary air system. agen
AG. Volkswagen AG d
oes
olksw not
V gu
Continued for all vehicles ed by ara
n ris tee
ho
– Install air filter ⇒ Rep. gr. 24 . aut or
ac
ss
– Install battery and battery holder.
ce
e
nl
pt
du
an
– Electrical connections and routing ⇒ Current flow diagrams,
itte
y li
erm
Electrical fault finding and Fitting locations.
ab
ility
ot p
Filling with new coolant ⇒ page 101 .
wit
, is n
h re
– Install noise insulation tray ⇒ Rep. gr. 50 .
hole
spec
es, in part or in w
t to the co
– Carry out a road test and interrogate fault memory ⇒ Rep. gr.
01 ; Fault memory; Reading and erasing fault memory .
rrectness of i
– Adapt control unit for engine electronics to throttle valve con‐
l purpos
trol module ⇒ Rep. gr. 24 .

nf
ercia
o
– Carry out a road test and interrogate fault memory ⇒ Rep. gr.
rm
m
01 ; Fault memory; Reading and erasing fault memory .
atio
om
n in
c
– Adapt engine control unit to throttle valve control module and

or
thi
e
to exhaust gas recirculation valve ⇒ Rep. gr. 24 .

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
– On vehicles with automatic gearbox, gearbox control unit must
Co
op py
also be adapted: ⇒ Self-diagnosis for 5-speed automatic
t. C rig
gh ht
yri
gearbox 09B; Rep. gr. 01 . p by
o Vo
by c lksw
cted agen
Specified torques Prote AG.
Bolted connection Specified torque

Nuts and bolts M6 10 Nm
M7 15 Nm
M8 25 Nm
M10 40 Nm
M12 60 Nm
Deviations
Hydraulic line to engine bracket 20 Nm
Starter to gearbox and engine 45 Nm
Front exhaust pipe to turbocharger 25 Nm

Sharan 1996 ➤
Note
Specified torques for engine and gearbox mountings

⇒ page 12 .
1.4 Assembly mountings

Specified torques
(Bolts oiled)
Assembly mounting, right:
A = 55 Nm B = 60 Nm
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Assembly mounting, left on vehicles with manual gearbox:
h re
hole
spec
A = 55 Nm
es, in part or in w
t to the co
B = 110 Nm
C = 100 Nm
rrectness of i
D = 20 Nm
l purpos
nf
ercia
orm
m
atio
om
n in
or c
Left assembly mounting on vehicles with automatic gearbox:

thi
te
sd
iva
o
r
A = 55 Nm
rp
cu
o
m
f
en
ng
B = 110 Nm
t.
yi Co
Cop py
C = 60 Nm
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
Assembly mounting, left:

A = 60 Nm + 1/4 turn (90°) further 2)
B = 90 Nm + 1/4 turn (90°) further 2)
C = 50 Nm + 1/4 turn (90°) further 2)

D = 25 Nm
2) Renew securing bolts/nuts
Note
All threaded holes into which self-locking bolts are to be screwed

must be cleaned of residual locking fluid with a thread chaser.
1.5 Additional information and assembly

work for vehicles with air conditioner
swage es n
WARNING
byV
olk ot g
ua
d ran
ir se tee
o
Do anot
u open the air conditioner refrigerant circuit. or a
th
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
♦ The opening of the refrigerant circuit can only be carried out

h re
ole,
in workshops, which have trained personnel and the neces‐

spec
sary range of tools and workshop equipment.

t to the co
♦ To prevent damage to condenser, refrigerant lines or hoses,

ensure that lines and hoses are not stretched, kinked or bent.
rrectne
To facilitate removing and installing engine without opening re‐

frigerant circuit:
ss o
– Remove retaining clamp(s) for refrigerant lines.

cial p
f inform

mer
atio
m
– Remove alternator ⇒ Rep. gr. 27 .

o
n
c
i
or
n thi
– Remove air conditioner compressor ⇒ Rep. gr. 87 .

te
sd
iva
o
r
– Secure air conditioner compressor to body so that the refrig‐

p
cum
r
fo
erant lines or hoses are not under tension.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
AG. Volkswagen AG d
agen
13 – Crankshaft group
oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
1 Dismantling and assembling engine ss a c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
♦ Before carrying out repair work, secure engine on engine and gearbox support - VAS 6095/1- using universal
, is n
h re
mounting - VAS 6095- .
hole
spec
♦ If large quantities of swarf or metal particles (caused, for example, by partial seizure of the crankshaft or
es, in part or in w
t to the co
conrod bearings) are found in the engine oil when performing repairs, clean the oil passages thoroughly and
renew the oil cooler and oil filter in order to prevent subsequent damage.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
I ⇒ page 15
II ⇒ page 17
14 Rep. gr.13 - Crankshaft group

Sharan 1996 ➤
1.1 Part I
1 - Toothed belt guard upper

part
. Volkswagen AG
gen AG does
2 - Toothed belt Volkswa not
gu
y
❑ Mark directiondb of rota‐
ara
rise nte
tionutbefore
ho removing eo
ra
a c
❑ Check
ss for wear
ce
le
un
❑ Do not kink
pt
an
d
itte
y li
❑ Removing, installing
rm
ab
and tensioning
pe
ility
⇒ page 38 .
ot
wit
, is n
h re
3 - Idler roller
hole
spec
es, in part or in w
4 - 27 Nm
t to the co
5 - 65 Nm
❑ Use counterhold - 3036-
rrectness of i
to loosen and tighten.
l purpos
6 - Camshaft sprocket
❑ Note installation posi‐
nform
ercia
tion: the narrow web of

camshaft toothed belt
m
pulley faces outwards a

com
tio
and the TDC No. 1 cyl‐
n in
r
te o
inder marking is visible.

thi
s
iva
do
❑ Note position when in‐

r
rp
cum
stalling toothed belt

fo
en
g
⇒ page 38 , removing,
n
t.
yi Co
op
installing and tensioning
C py
t. rig
toothed belt.
gh ht
pyri by
Vo
co lksw
by
7 - Tensioning pulley Prote
cted AG.
agen
❑ Removing, installing
and tensioning toothed
belt ⇒ page 38
8 - Washer
9 - Toothed belt tensioner
❑ Removing, installing and tensioning toothed belt ⇒ page 38
10 - O-ring
❑ Renew
11 - Coolant pump
❑ Check for ease of movement.
❑ If damaged or leaking, renew complete.
❑ Removing and installing ⇒ page 107
12 - 15 Nm
13 - Crankshaft toothed belt pulley
14 - 90 Nm + 1/4 turn (90°) further
❑ Renew
❑ Use counterhold - 3415- to loosen and tighten.
❑ Threads and shoulder must be free of oil and grease.
❑ Turning further can be done in several stages.
1. Dismantling and assembling engine 15

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
15 - 20 Nm olksw not
y V gu
d b ara
se nte
16 - Toothed belt guard centre part tho ri
eo
au ra
17 - Toothed belt guard lower part ss c
ce
le
un
pt
18 - 10 Nm
an
d
itte
y li
❑ Install using locking fluid - D 000 600 A2-
erm
ab
ility
ot p
19 - Poly V-belt
wit
is n
h re
❑ Mark direction of rotation before removing
ole,
spec
❑ Check for wear
t to the co
❑ Do not kink
rrectne
20 - Pulley
❑ For power-assisted steering vane pump.
ss
21 - 25 Nm
o
cial p
f inform
22 - Belt pulley and vibration damper
mer
❑ Can only be fitted in one position
atio
om
n
❑ Note position when installing toothed belt ⇒ page 38 , removing, installing and tensioning toothed belt.
c
i
or
n thi
te
sd
23 - Tensioning device for poly V-belt
iva
o
pr
c
❑ Swing with open-jaw spanner to relieve poly V-belt tension ⇒ page 18 , Removing and installing poly
um
r
fo
en
ng
V-belt
t.
yi Co
Cop py
24 - 45 Nm
t. rig
gh ht
pyri by
Vo
o
25 - Right engine bracket
c by lksw
cted agen
Prote AG.
❑ Removing and installing ⇒ page 38 Removing, installing and tensioning toothed belt.

Sharan 1996 ➤
1.2 Part II
1 - Knock sensor 1 - G61-

❑ Checking (engine code
AJH) ⇒ Rep. gr. 01 ;
Fault memory; Interrog‐
ating and erasing fault
memory .
AWC) ⇒ Rep. gr. 01 ;
ating and erasing en‐
gine control unit fault
memory .
2 - 20 Nm
❑ The torque specification
influences the function
of knock sensor 1 - G61-
3 - Knock sensor 2 - G66-
AJH) ⇒ Rep. gr. 01 ;
ating and erasing fault
memory .
AWC) ⇒ Rep. gr. 01 ;
ating and erasing en‐
gine control unit fault AG. Volkswagen AG d
memory . lksw
agen oes
n o ot g
yV ua
4 - Oil dipstick rised b ran
tee
❑ The oil level tho must not be or
au ac
aboves the max. mark
s
ce
e
nl
❑ Markings ⇒ page 79 .
pt
du
an
itte
y li
5 - Dipstick guide
erm
ab
ility
ot p
❑ for oil dipstick

wit
, is n
❑ Secured with bracket to

h re
hole
intake manifold
spec
es, in part or in w
6 - O-ring
t to the co
❑ Renew
7 - Coolant pipe
rrectness of i
❑ Coolant hose schematic diagram: engine code AJH ⇒ page 99

l purpos
❑ Coolant hose schematic diagram: engine code AWC ⇒ page 100

8 - 20 Nm
nform
ercia
9 - Seal
m
at
om
io
❑ Renew
n
c
in t
or
his
e
10 - Oil filter bracket

at
do
riv
❑ Ensure clearance to adjacent components

p
cum
for
en
g
❑ Dismantling and assembling: engine code AJH ⇒ page 80

n
t.
yi Co
op
❑ Dismantling and assembling: engine code AWC ⇒ page 82
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
11 - 15 Nm + 1/4 turn (90°) further
agen
Prote AG.
❑ Renew

Sharan 1996 ➤
AG. Volkswagen AG d
12 - 10 Nm lksw
agen oes
not
Vo gu
by
13 - Engine speed sender -risG28-
ed ara
nte
o eo
❑ Checking (engineaucode
th
AJH) ⇒ Rep. gr. 01 ; Fault memory; Interrogating
and erasing fault memory .
ra
ss c
❑ Checking (engine code AWC) ⇒ Rep. gr. 01 ; Fault memory; Interrogating and erasing engine control
ce
le
un
unit fault memory .
pt
an
d
itte
y li
14 - Connection
rm
ab
pe
ility
15 - 15 Nm
ot
wit
, is n
h re
16 - Thermostat
hole
spec
es, in part or in w
t to the co
❑ Observe installation position ⇒ page 108 , Removing and installing thermostat
❑ Checking: heat thermostat in water.
rrectness of i
❑ Begins to open at approx. 87°C
❑ Ends at approx. 102°C
l purpos
❑ Opening lift min. 7 mm
nform
ercia
17 - 25 Nm
m
18 - Support
a
com
tion in
❑ Between intake manifold and cylinder block
r
te o
thi
s
19 - 45 Nm
iva
do
r
rp
cum
20 - Compact bracket
fo
en
ng
t.
yi
❑ For alternator, air conditioner compressor and power-assisted steering vane pump
Co
Cop py
t. rig
gh
21 - Bracket
ht
pyri by
Vo
o
by c lksw
❑ Only on vehicles with engine code AJH Prote
cted AG.
agen
❑ For air pipe between turbocharger/charge air cooler

22 - 40 Nm
23 - Cylinder block
❑ Removing and installing crankshaft ⇒ page 30 .
❑ Dismantling and assembling pistons and conrods ⇒ page 33 .
24 - Spacer sleeve
❑ Only on vehicles with manual gearbox
25 - 25 Nm
26 - Support
❑ Between turbocharger and cylinder block.
1.3 Removing and installing poly-V belt

Special tools and workshop equipment required

Sharan 1996 ➤
♦ Locking pin - T10060 A-
Removing poly V-belt
Note
Before removing the poly V-belt mark the direction of rotation.

When installing belt ensure it is correctly seated in pulleys.

– Mark poly V-belt direction of rotation.
– Swing tensioning element in direction of -arrow- using AF
16 mm open jaw spanner until tensioning element can be
locked.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Lock tensioning element with locking pin - T10060 A-

-arrow-.
– Remove noise insulation tray ⇒ Rep. gr. 50 .
– Remove poly V-belt.
Installing poly V-belt
– Install in reverse order of removal.
Note
♦ Ensure, before installing poly V-belt, that all ancillaries (alter‐

nator, air conditioner compressor vane pump) are secured
tightly.
♦ When fitting the poly V-belt observe belt direction of rotation
and that the belt is seated correctly in the belt pulleys.
♦ For vehicles with air conditioning, fit poly V-belt over air con‐
ditioning compressor last.
– Fit poly V-belt.

After completing repairs always:
– Start engine and check if belt runs properly.
Poly V-belt routing
Belt drive without air conditioner compressor
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c ce
e
nl
pt
du
an
itte
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Belt drive with air conditioner compressor

erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
Engines with an air conditioner compressor are fitted with a dou‐

t to the co
ble poly V-belt.

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
2 Removing and installing sealing flanges and flywheel or drive plate
Note
♦ Repairs to clutch (engine code AJH) ⇒ 5-speed
Volkswa
manual gearbox 006; Rep. gr. 30 ; Repairing clutch .
AG. gen AG
agen do
♦ Repairs to clutch (engine code
yV
olksAWC) ⇒ 6-speed manual
w es n
ogearbox
tg 02N; Rep. gr. 30 ; Repairing clutch .
b ua
ed ran
oris tee
th or
au ac
1 - 90 Nm + 1/4 turn s(90°) fur‐
s
ce
le
ther
un
pt
an
d
itte
❑ Renew
y li
rm
ab
pe
❑ Use counterhold - 3415-
ility
ot
to loosen and tighten.
wit
, is n
h re
❑ Threads and shoulder
hole
spec
must be free of oil and
es, in part or in w
grease.
t to the co
❑ Turning further can be
done in several stages.
rrectness of i
2 - Crankshaft toothed belt pul‐
ley
l purpos
3 - 15 Nm
nform
ercia
4 - Seal
m
a
❑ Renewing ⇒ page 22
com
tion in
r
5 - Sealing flange
te o
thi
s
iva
❑ Must seat on dowel

do
r
rp
sleeves.
um
fo
en
g
❑ Clean sealing surface

n
t.
yi Co
op
before fitting. C py
t. rig
gh ht
❑ Install with silicone seal‐ pyri by
Vo
o
by c
ant - D 176 404 A2- .
lksw
cted agen
Prote AG.
❑ Removing and installing
⇒ page 25
6 - Cylinder block
crankshaft
⇒ page 30 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 33 .
7 - 60 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew
8 - Flywheel/drive plate
❑ When removing and installing flywheel, lock with counterhold - 3067- .
❑ Removing and installing drive plate ⇒ page 27
9 - Adapter
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
2. Removing and installing sealing flanges and flywheel or drive plate 21

Sharan 1996 ➤
10 - Sealing flange with oil seal

❑ Renew only as complete unit
❑ Remove sump in order to remove and install ⇒ page 83 .
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Use support sleeve supplied when installing
❑ Only remove supporting sleeve after sealing flange has been slid onto crankshaft journal.
2.1 Renewing crankshaft oil seal - pulley end

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Fitting sleeves for seal - 2080 A-

♦ Seal puller - 3203-
♦ Fitting sleeve - 3265-
♦ Counter-hold tool - 3415-
For vehicles with PTFE seals:

Sharan 1996 ➤
♦ Assembly tool - T10053+3-

Removing
– Remove poly V-belt and tensioning element ⇒ page 18 .
– Remove toothed belt ⇒ page 38 .
– Remove crankshaft toothed belt pulley. by locking the toothed-

belt pulley using counterhold - 3415- .
– To guide seal extractor, screw centre bolt into crankshaft up

to the stop by hand.
– Screw inner part of oil seal extractor - 3203- two turns (approx.
3 mm) out of outer part and lock using knurled screw.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
– Lubricate threaded head of oil seal extractor - 3203- , place it

nl
pt
du
in position and while exerting firm pressure, screw it into oil

an
itte
y li
seal as far as possible.

erm
ab
ility
ot p
– Loosen knurled screw and turn inner part against crankshaft

wit
, is n
until the oil seal is pulled out.

h re
hole
spec
Installing
es, in part or in w
t to the co
Note
rrectness of i
Gradual introduction of PTFE seals (polytetrafluoroethylene).

Identifying features: no annular spring, sealing lip is wider. The
l purpos
sealing lip of this oil seal must not be oiled or greased. An older
design radial shaft seal (with garter spring) may be replaced by a
nf
ercia
PTFE seal, but not the other way around.

orm
m
atio
m
– Remove oil residue from crankshaft journal using clean cloth.

o
n in
or c
thi
e
Install seal with annular spring

t
sd
iva
o
r
rp
cu
– Lightly oil sealing lip of oil seal.

o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
23
by c lksw
cted
2. Removing and installing sealing flanges and flywheel or drive plate
agen
Prote AG.
Sharan 1996 ➤
– Position guide sleeve from fitting sleeves - 2080 A- onto crank‐

shaft journal.
– Slide oil seal over guide sleeve onto crankshaft journal.
– Press oil seal in with fitting sleeve - 3265- . To do this, use old
centring bolt -1- for crankshaft belt pulley:
– Press in seal 2…3 mm.
Installing PTFE seal
– Fit guide sleeve - T10053/1- onto crankshaft journal.

– Slide oil seal over guide sleeve onto crankshaft journal.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
– Press in oil seal with fitting sleeve from assembly tool -

an
d
itte
T10053- and bolt - T10053/2- (M16 x 1.5 x 60) onto stop.

y li
erm
ab
ility
Continuation for all seals

ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
24
Prote AG.
Rep. gr.13 - Crankshaft group
Sharan 1996 ➤
– Install crankshaft toothed belt pulley and lock with counterhold

- 3415- .
– Tighten new centre bolt to 90 Nm and turn 90° (1/4 turn) further
(turning further can be done in several stages).
Note
Thread and shoulder must be free of oil and grease.
– Install toothed belt and adjust valve timing ⇒ page 38 .

– Install poly V-belt and tensioning element ⇒ page 18 .
olkswagen AG
en AG. V
2.2 Removing
yV
oand
lksw installing sealing
ag does
nflange
ot g - pulley end
b ua
ed ran
oris tee
th or
Special tools and au workshop ac
ss
equipment required
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Fitting sleeves for seal - 2080 A-

Not illustrated

Sharan 1996 ➤
♦ Silicone sealant - D 176 404 A2-

♦ Hand drill with plastic brush attachment
♦ Safety glasses
♦ Scraper
Removing
– Remove toothed belt ⇒ page 38 .
– Remove crankshaft toothed belt pulley. by locking the toothed-
belt pulley using counterhold - 3415- .
. Volkswagen AG
a gen AG does
– Remove sump ⇒ page
Vol 83 .
ksw not
gu
y
db ara
– Unbolt sealingorisflange.
e nte
eo
h
ut ra
– Remove sealing
ss
a
flange; if necessary, loosen using light blows c
with a rubber headed hammer.
ce
e
nl
pt
du
an
– Remove sealant residue from cylinder block with a flat scraper.
itte
y li
erm
ab
– Cover seal with a clean cloth.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Remove residual sealant on sealing flange using a rotating

plastic brush (wear eye protection). t to the co
– Clean sealing surfaces. They must be free of oil and grease.
rrectness of i
Installing
l purpos
Note
nform
mercia
♦ Note the expiry date of the Silicone sealant - D 176 404 A2- .
at
om
ion
c
♦ The sealing flange must be installed within 5 minutes of ap‐

in t
or
his
e
plying the silicone sealant - D 176 404 A2- .

at
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Cut off tube nozzle at forward marking (approx. 3 mm nozzle

∅).
– Apply silicone sealant - D 176 404 A2- to clean sealing surface
of sealing flange, as shown. Sealant bead must be:
♦ 2…3 mm thick
♦ Run bead along inner side of bolt holes -arrows-.
Note
♦ Sealant bead should not be thicker, otherwise excess sealant

may enter sump and plug up strainer in oil pump suction pipe,
as well as drip onto crankshaft oil seal.
♦ Before applying sealant bead, cover sealing surface of oil seal
with a clean cloth.
– Fit sealing flange immediately and lightly tighten all bolts.
Note
To locate sealing flange with oil seal installed, use guide sleeve
from seal fitting sleeves - 2080 A- .
– Tighten sealing flange securing bolts diagonally and alternate‐

ly. Specified torque: 15 Nm
– Remove excess sealant.
– Install sump ⇒ page 83 .
Note lkswage es n
o ot g
byV ua
d ran
ir se
Leave the sealant to dry for approx. 30 minutes after th assembly.
o tee
or
Only then fill with engine oil. au ac
ss
ce
e
nl
pt
du
an
itte
– Install crankshaft toothed belt pulley and lock with counterhold

y li
erm
ab
- 3415- .
ility
ot p
wit
– Tighten new centre bolt to 90 Nm and turn 90° (1/4 turn) further
, is n
(turning further can be done in several stages). h re

hole
spec
es, in part or in w
t to the co
Note
Thread and shoulder must be free of oil and grease.

rrectness of i
l purpos

nf
ercia
orm
m
2.3 Removing and installing drive plate

atio
om
n in
or c

thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
♦ Clutch counterhold - VW 558-
♦ Hexagon bolt M8×45 and two M10 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.
Position of counterhold:
A - To loosen
B - To tighten
– Loosen drive plate bolts.
AG. Volkswagen AG d
Installing drive plate olksw
agen oes
not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Fit drive plate using ring with recesses -1-.
es, in part or in w
t to the co
– Fit new bolts -3- and tighten to 30 Nm.

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
– Check dimension -a- at three points and calculate average.

Specification: 19.5…21.1 mm
Note
Measure through hole in drive plate to milled surface of cylinder

block.
If specification is not attained:
– Remove drive plate again and fit shim -2-. Tighten bolts to 30
Nm again.
– Tighten bolts to 60 Nm and turn 90° (1/4 turn) further (turning
further can be done in several stages).
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
29
co Vo
by lksw
cted
2. Removing and installing sealing flanges and flywheel or drive plate
agen
Prote AG.
Sharan 1996 ➤
3 Removing and installing crankshaft
Note
♦ Before removing crankshaft, make provision for a suitable surface for storing crankshaft to ensure that
sender wheel ⇒ Item 8 (page 31) is not damaged or lies against any other item.
1 - Oil pump with sprocket

❑ With 12 bar pressure re‐
lief valve
❑ Before installing, check
that both dowel sleeves
for centring oil pump on
cylinder block are fitted.
⇒ page 77
2 - 15 Nm
3 - Sprocket
❑ For oil pump drive.
❑ Check for wear AG. Volkswagen AG d
agen oes
lksw not
4 - Bearing shells 1, 2, 4 and 5 by
Vo gu
ara
ed
❑ For bearing cap without tho ris nte
eo
oil groove. s au ra
c
s
❑ for cylinder block with oil
ce
e
nl
pt
groove
du
an
itte
y li
❑ Do not interchange
erm
ab
used bearing shells

ility
ot p
(mark)
wit
, is n
h re
Vehicles 06.00 ►
hole
spec
es, in part or in w
❑ Classification for order‐

t to the co
ing spare parts

⇒ page 31 .
rrectness of i
5 - 65 Nm + 1/4 turn (90°) fur‐

ther
l purpos
❑ Renew
❑ Threaded along com‐
nform
ercia
plete length.
m
at
❑ Only tighten to 65 Nm
om
ion
when measuring radial

c
in t
or
clearance of crankshaft
his
ate
do
riv
6 - Bearing cap
p
cum
for
en
g
❑ Bearing cap 1: belt pulley end.

n
t.
yi Co
op
❑ Bearing cap 3 with recesses for thrust washers
C py
t. rig
gh ht
yri
❑ Bearing shell retaining lugs in cylinder block and bearing caps must align.
p by
o Vo
by c lksw
cted agen
7 - Bearing shell 3
Prote AG.
❑ For bearing cap without oil groove.

❑ for cylinder block with oil groove
❑ Do not interchange used bearing shells (mark)
Vehicles 06.00 ►

Sharan 1996 ➤
❑ Classification for ordering spare parts ⇒ page 31 .
8 - Sender wheel
❑ Renew
❑ For engine speed sender - G28-
❑ Can be installed only in one position - bores are offset
9 - 10 Nm + 1/4 turn (90°) further
❑ Renew
10 - Thrust washer
❑ For bearing cap, bearing 3.
❑ Note fixing arrangement
11 - Crankshaft
❑ Axial clearance new: 0.07 to 0.23 mm, wear limit: 0.30 mm
❑ Measure radial clearance with Plastigage, new: 0.01…0.04 mm; wear limit: 0.15 mm
❑ Do not rotate crankshaft when checking radial clearance
❑ Crankshaft dimensions ⇒ page 31 .
Identification of crankshaft upper bearing agen

AG. Volkswagen AG d
oes
olksw not
Upper bearing shells of the proper thickness are allocated d by
V to the gu
ara
cylinder block in the factory. Coloured dots are used oris to identify
e nte
eo
the thickness of the bearing shells. aut
h
ra
ss c
ce
e
nl
pt
du
an
Note
itte
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erm
ab
ility
Arrow points in direction of travel.
ot p
wit
, is n
h re
hole
Letters on the lower sealing surface of the cylinder block indicate
spec
which bearing thickness is to be used at each position.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
3.1 Colour coding

m
atio
om
n in
or c
Letter on cylinder Bearing colour

thi
te
sd
a
block
iv
o
r
rp
cu
S = black
o
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f
en
ng
t.
yi
R = red
Co
Cop py
t. rig
G = yellow
gh ht
pyri by
Vo
o
by c lksw
cted
– Lower bearing shells with colour mark “yellow” are always
agen
Prote AG.
supplied as spare parts.
3.2 Crankshaft dimensions
Note
Dimensions are given in mm.
3. Removing and installing crankshaft 31

Sharan 1996 ➤
Honing dimension Main journal ∅ . VConrod

olkswagejournal
n AG d ∅
gen AG
swa oes
Engine code AJH Engine codebyAWC Volk not
gu
d ara
-0.022 horise
-0.017 -0.022
nte
eo
ut
Basic dimension 54.00 54.00
ss a 47.80 ra
c
-0.042 -0.037 -0.042
ce
e
nl
pt
du
an
-0.022 -0.017 -0.022
itte
y li
erm
ab
Stage I 53.75 53.75 47.55
ility
ot p
-0.042 -0.037 -0.042
wit
, is n
h re
-0.022 -0.017 -0.022
hole
spec
Stage II 53.50 53.50 47.30
es, in part or in w
t to the co
-0.042 -0.037 -0.042
-0.022 -0.017 -0.022
rrectness of i
Stage III 53.25 53.25 47.05
-0.042 -0.037 -0.042
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
4 Dismantling and assembling pistons and conrods
Note
Before carrying out repair work, secure engine on

gen engine
AG. Volksand
wagegearbox
n AG d
oes support - VAS 6095/1- using universal
swa
mounting - VAS 6095- . y Volk not
gu b ara
ed nte
oris e
th or
au ac
1 - Piston rings ss
ce
le
un
pt
❑ Offset gaps by 120°
an
d
itte
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❑ Use piston ring pliers to
erm
ab
remove and install.
ility
ot p
wit
❑ “TOP” faces towards
is n
h re
piston crown.
ole,
spec
❑ Checking ring gap
⇒ page 34 .
t to the co
❑ Checking ring-to-groove
clearance ⇒ page 34 .
rrectne
❑ 2 or 3 part oil scraper
ring, mixed installation
s
permissible
s o
cial p
f
2 - Piston
inform
mer
❑ Checking ⇒ page 35
atio
m
❑ Mark installation posi‐

o
n
c
i
tion and cylinder num‐
or
n thi
e
ber.
t
sd
iva
o
r
❑ Arrow on piston crown

p
cum
r
fo
points to belt pulley end.

en
ng
t.
yi Co
❑ Install using piston ring Cop py
ht. rig
clamp. opy
rig by
Vo
ht
c lksw
3 - Conrod
by
cted agen
Prote AG.
❑ Renew as set only.
❑ Installation position:
markings -A- face to‐
wards belt pulley end.
❑ Mark cylinder number
-B-
4 - Conrod bearing cap
❑ Installation position:
markings -A- face to‐
wards belt pulley end.
❑ Mark cylinder number -B-
5 - 30 Nm + 1/4 turn (90°) further
❑ Renew
❑ Oil threads and contact surface.
❑ To measure radial clearance, tighten to 30 Nm but not further.
6 - Pressure relief valve, 27 Nm
❑ Opening pressure: 1.3…1.6 bar
7 - Oil spray jet
❑ For piston cooling
8 - Bearing shell
❑ Observe installation position
4. Dismantling and assembling pistons and conrods 33

Sharan 1996 ➤
❑ Do not interchange used bearing shells.
❑ Ensure secure seating in retaining lugs
❑ Axial clearance new: 0.10 to 0.31 mm, wear limit: 0.40 mm
❑ Measure radial clearance using Plastigage; new: 0.01 … 0.05 mm; wear limit: 0.12 mm. Do not rotate
crankshaft when checking radial clearance.
9 - Cylinder block
❑ Checking cylinder bores ⇒ page 35 .
❑ Piston and cylinder dimensions ⇒ page 36 .
10 - Conrod bolt
❑ Renew
11 - Retaining ring
12 - Piston pin
❑ If difficult to remove, heat piston to 60°C.
❑ Remove and install using drift - VW 222 A- .
4.1 Checking pistons, piston rings and cyl‐

inder bores
Checking piston ring gap
. Volkswage
Special tools and workshopksequipment
wage
n AG required
n AG d
oes
n
ol ot g
yV
♦ Feeler gauge ised b ua
ran
r tee
ho
Test sequence s aut or
ac
s
– Insert ring at right angles from above and push down into cyl‐
ce
le
un
pt
inder approx. 15 mm from bottom end of cylinder.

an
d
itte
y li
erm
ab
Piston ring Ring gap

ility
ot p
New Wear limit

wit
is n
h re
ole,
Compression rings mm 0.20 … 0.40 0.80

spec
Oil scraper ring mm 0.25 … 0.50 1.00

t to the co
rrectne
Checking ring-to-groove clearance

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.

Sharan 1996 ➤
♦ Feeler gauge
Clean annular groove before check.
Piston ring Clearance
New Wear limit
Compression rings mm 0.02 … 0.07 0.12
Oil scraper ring mm 0.02 … 0.06 0.12
Checking piston
Special tools and workshop equipment requireden AG. Volkswagen AG

wag does
♦ External micrometer 75…100 mm olks not
byV gu
ara
ed nte
ris
Measure pistons approx. 10 mmufrom
tho bottom of skirt, at 90° to eo
ra
piston pin axis. ss
a c
ce
le
Difference between actual and nominal diameter max. 0.04 mm

un
pt
an
d
itte
y li
Checking cylinder bores
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
g

n
t.
yi Co
Cop py
♦ Cylinder gauge 50 to 100 mm
t. rig
gh ht
pyri by
Vo
o
– Take measurements at 3 positions in both lateral direction
c by lksw
cted agen
-A- and longitudinal direction -B-.
Prote AG.
Difference between actual and nominal diameter max. 0.10 mm
4. Dismantling and assembling pistons and conrods 35

Sharan 1996 ➤
Note
Cylinder bores must not be measured when the cylinder block is

secured to engine and gearbox support - VAS 6095/1- with uni‐
versal mounting - VAS 6095- , as measurements may be incor‐
rect.
4.2 Piston and cylinder dimensions

Honing dimension Piston ∅ Cylinder bore ∅
Basic dimension mm 80.9653)
81.010
Stage I mm 81.4653) 81.510
3) Dimension without graphite coating (thickness 0.02 mm). The graphite coating
wears away.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
36
AG.
Rep. gr.13 - Crankshaft group
Sharan 1996 ➤
15 – Cylinder head, valve gear

1 Cylinder head
Note
♦ When installing an exchange cylinder head with fitted cam‐

shaft, the contact surfaces between the bucket tappets and
the cam must be oiled before installing the cylinder head cov‐
er.
♦ The plastic protectors fitted to protect the open valves must be
removed only immediately before the cylinder head is fitted.
♦ If the cylinder head is renewed, all the coolant in the system
must also be renewed.
AG. Volkswagen AG d
agen oes
lksw n
Removing andd installing
by
Vo
intake manifold ⇒ Rep.ot gr.gu 24 .
ara
ise nte
r
Checkingutcompression
ho ⇒ page 55 . eo
ra
s a c
s ce
e
nl
pt
1 - Cap
du
an
itte
y li
❑ Renew seal if damaged.
erm
ab
ility
ot p
2 - Seal
wit
, is n
❑ Renew if damaged
h re
hole
spec
3 - Connection hose
es, in part or in w
t to the co
❑ To pipe line for crank‐

case breather
4 - Cylinder head cover
rrectness of i
5 - Cylinder head cover gasket

l purpos
❑ Before fitting, seal tran‐
nform
ercia
sitions between bearing

m
cap/cylinder head and

at
om
io
chain tensioner/cylinder
n
c
in t
r
head ⇒ page 61 , and

o
his
te
⇒ page 61
a
do
priv
cum
or
6 - Oil deflector
f
en
ng
t.
yi
❑ Observe installation po‐
Co
op py
sition: above inlet cam‐
. C rig
ht ht
rig
shaft. py by
co Vo
by lksw
cted agen
7 - Cylinder head Prote AG.
❑ Check for distortion

⇒ page 38 .
⇒ page 50
❑ Reworking sealing sur‐
face ⇒ page 60 .
❑ After renewing, renew
entire coolant.
8 - Intake manifold gasket
❑ Renew
sition
1. Cylinder head 37
Sharan 1996 ➤
9 - Cylinder head gasket

❑ Metal gasket.
❑ Renew
❑ After renewing, renew entire coolant.
❑ Note installation position: identification: part No. must be readable from inlet side
10 - Toothed belt
❑ Mark direction of rotation gbefore AG. Vremoving
olkswagen AG
a en does
ksw
❑ Check for wear by V ol not
gu
ara
ed
❑ Do not kink horis nte
eo
u t
❑ Removing, ss a installing and tensioning ⇒ page 38 . ra
c
ce
le
11 - Exhaust manifold gasket

un
pt
an
d
itte
❑ Renew
y li
erm
ab
ility
ot p
wit
is n
12 - Cylinder head bolt
h re
ole,
❑ Renew
spec
❑ Sequence for loosening and tightening ⇒ page 50 , Removing and installing cylinder head
t to the co
13 - 10 Nm
14 - Seal
rrectne
ss
15 - Adapter
o
cial p
❑ To remove, turn breather housing anti-clockwise f inform

mer
atio
om
n
c
Checking cylinder head for distortion

i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Straight edge
♦ Feeler gauge
Max. permissible distortion: 0.1 mm
1.1 Removing, installing and tensioning

toothed belt
Removing, installing and tensioning toothed belt, engine code
AJH ⇒ page 39
Removing, installing and tensioning toothed belt, engine code
AWC ⇒ page 44
38 Rep. gr.15 - Cylinder head, valve gear

Sharan 1996 ➤
1.1.1 Removing, installing and tensioning toothed belt, engine code AJH

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
♦ Support - 10 - 222 A- Prote AG.
♦ Tensioning bolt - T10092-

♦ Pin - T40011-
Not illustrated
♦ Adapter - 10 - 222 A /5-
♦ Locking fluid - D 000 600 A2-
Removing
– Note safety precautions before beginning work ⇒ page 119 .
– Observe rules for cleanliness ⇒ page 120 .
1. Cylinder head 39
Sharan 1996 ➤

– Remove air pipe between turbocharger and charge air cooler
⇒ page 151 , Removing and installing parts of charge air cool‐
ing: engine code AJH
– Remove toothed belt guard upper part.
– Mark direction of rotation of toothed belt.
– Set camshaft pulley to TDC no. 1 cylinder mark by turning
crankshaft. Marking on camshaft toothed belt pulley must align
with mark on cylinder head cover.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Remove vibration damper/belt pulley.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Position support bracket - 10 - 222 A- together with adapter -

f
en
ng
10 - 222 A /5- .
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
– Bolt adapter - 10 - 222 A /5- with body bolts -arrows-.

– Insert fastening hooks of support bracket - 10 - 222 A- into
lifting eye on right of cylinder head and raise engine slightly.
– Remove pendulum support ⇒ Rep. gr. 40 .
– Remove bolts and nuts from engine assembly mounting

-arrows- and completely remove assembly mounting.
– Raise engine as far as possible using support bracket.
– Remove engine bracket on cylinder block and lift out upwards.
– Remove centre and lower parts of toothed-belt guard. AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 41
Sharan 1996 ➤
– Screw tensioning bolt - T10092- into toothed belt tensioner.

– If necessary, align ram before tensioning using long nose pli‐
ers or thin wire. (Hole in ram and hole in housing must align.)
– Tension the tensioner pressure piston until the pressure piston
can be locked with locking pin - T40011- .
– Remove toothed belt.
– Turn crankshaft back slightly.
Installing
A - Toothed belt completely removed ⇒ page 42
B - Toothed belt only removed from camshaft pulley
⇒ page 43
Note
When camshaft is turned, crankshaft must not be at TDC. Danger

of damage to valves and piston crowns.
A - Toothed belt completely removed

If toothed belt was only removed from camshaft pulley
⇒ page 43 .
Condition
• The pistons cannot be positioned at TDC.
AG. Volkswagen AG d
Procedure lksw
agen oes
not
o
byV gu
ara
ed
is nte
– Align mark onthcamshaft
or toothed belt pulley with mark on cyl‐ eo
inder head scover.
au ra
c
s
ce
le
– Place toothed belt on crankshaft toothed belt pulley and cool‐

un
pt
ant pump (observe direction of rotation).

an
d
itte
y li
rm
ab
– Fit centre and lower toothed-belt guard. (Insert securing bolts

pe
ility
with locking fluid - D 000 600 A2- ). Specified torque: 10 Nm

ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Install vibration damper/belt pulley (can only be installed in one

position). Specified torque: 25 Nm
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
– Turn crankshaft to TDC No. 1 cylinder. ss c
ce
e
nl
pt
du
an
itte
y li
erm
– Install air pipe between turbocharger and charge air cooler
ab
ility
⇒ page 151 , Removing and installing parts of charge air cool‐
ot p
wit
ing: engine code AJH
, is n
h re
hole
– Fit toothed belt onto camshaft pulley and tension
spec
⇒ page 43 .
es, in part or in w
t to the co
rrectness of i
l purpos
– Align mark on camshaft toothed belt pulley with mark on cyl‐

inder head cover.
nform
ercia
– Turn crankshaft to TDC No. 1 cylinder.

m
at
om
io
– Fit toothed belt onto camshaft pulley and tension
n
c
in t
r
⇒ page 43 .
o
his
ate
do
riv
Tensioning toothed belt

p
cum
for
en
g
Conditions
n
t.
yi Co
op py
• The engine must be no more than warm to touch.
. C rig
ht ht
rig by
py Vo
• Engine positioned at TDC No. 1 cylinder.
co lksw
by
cted agen
Prote AG.
Procedure
– Tension toothed belt, to do this pull out locking pin - T40011-

and unscrew tensioning bolt - T10092- .
1. Cylinder head 43
Sharan 1996 ➤
– Turn crankshaft two full turns and check whether camshaft and
crankshaft marks align with their reference points.
Continuation - Installing toothed belt completely
– Fit upper toothed-belt guard.
– Fit engine bracket to cylinder block. Specified torque: 45 Nm
– Install engine mounting. Specified torques ⇒ page 12 .
– Install air filter ⇒ Rep. gr. 24 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
1.1.2 Removing, installing and tensioning
erm
ab
ility
toothed belt, engine code AWC
ot p
wit
, is n
h re
Tensioning toothed belts ⇒ page 50 .
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
equipment required
♦ Support - 10 - 222 A-
♦ Pin - T40011-
♦ Shackle - 10 - 222 A /12-
Not illustrated
♦ Adapter - 10 - 222 A /14- and adapter - 10 - 222 A /15-
♦ Locking fluid - D 000 600 A2-
♦ 2 bolts M8×35
Removing
– Observe rules for cleanliness ⇒ page 120 . . Volkswagen AG
gen AG does
swa
– First check whether a coded radio is fitted.y VIf so, obtain anti-
o lk not
gu
theft coding. risedb ara
nte
ho eo
– Remove engine cover. aut ra
ss c
ce
le
– Remove battery.
un
pt
an
d
itte
– Remove noise insulation ⇒ Rep. gr. 50 .
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove securing bolts -arrows- from bracket on sump for air
pipe of charge air cooler. rrectness of i
l purpos
– Unbolt drive shaft from right gearbox flange.

– Move right drive shaft up to right-hand side and secure in this
nform
ercia
position.
m

a
com
tion in
– Mark direction of rotation of toothed belt.

r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Cylinder head 45
Sharan 1996 ➤

– Remove vibration damper/belt pulley.

– Remove both outer bolts of battery tray.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c ce
le
un
pt
an
d
itte
– Position support bracket - 10 - 222 A- together with adapter -

y li
rm
ab
10 - 222 A /14- and adapter - 10 - 222 A /15- as shown.

pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Tighten adapter - 10 - 222 A /14- on battery bracket using

m
M8×35 bolts -arrows-. Specified torque: 25 Nm

com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
– Insert shackle - 10 - 222 A /12- into lifting eye on right of cyl‐

inder head.
– Insert fastening hooks of support bracket - 10 - 222 A- at
shackle - 10 - 222 A /12- and pre-tension engine slightly.
– Remove pendulum support by loosening bolts -1-, nuts -2- and

bolt -3-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
– Remove bolts and nuts from engine assembly mounting

y li
erm
ab
-arrows- and completely remove assembly mounting.

ility
ot p
wit
– Raise engine as far as possible using support bracket.

is n
h re
ole,
– Unscrew two upper bolts of engine bracket on cylinder head.

spec
– Lower engine as far as possible using support bracket.

t to the co
– Unscrew securing bolt for servo hose -arrow- on engine brack‐

et.
rrectne
– Remove centre and lower parts of toothed-belt guard.

s
– Unscrew lower bolt of engine bracket and remove bracket

s o
cial p
downwards.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Cylinder head 47
Sharan 1996 ➤
– Screw tensioning bolt - T10092- into toothed belt tensioner.

– If necessary, align ram before tensioning using long nose pli‐
ers or thin wire. (Hole in ram and hole AinG.housing
Volkswagemust
n
align.)
n AG do
ks wage es
– Tension the tensioner pressure Volpiston until the pressure piston
not
gu
by
can be locked with locking
ris
e pin - T40011- .
d ara
nt ee
tho or
– Remove toothed belt.
sa
u ac
s
ce
le

un
pt
an
d
itte
Installing
y li
erm
ab
ility
A - Toothed belt completely removed ⇒ page 48
ot p
wit
is n
h re
ole,
⇒ page 49
spec
t to the co
Note
rrectne
When camshaft is turned, crankshaft must not be at TDC. Danger
of damage to valves and piston crowns.
ss o
cial p
f
A - Toothed belt completely removed
inform
mer
If toothed belt was only removed from camshaft pulley
atio
⇒ page 49 .
om
n
c
i
or
n
Condition
thi
te
sd
va
• The pistons cannot be positioned at TDC.

i
o
pr
cum
r
fo
en
ng
Procedure
t.
yi Co
Cop py
t. rig
gh
ht
pyri by
Vo
inder head cover.
co lksw
by
cted agen
Prote AG.
– Place toothed belt on crankshaft toothed belt pulley and cool‐
ant pump (observe direction of rotation).

AG. Volkswagen AG d
agen oes
olksw not
d by
V gu
ar Sharan 1996 ➤
ris 4-cylinder injection engine (5-valve), amechanics
e nte
- Edition 06.2019
ho eo
aut ra
ss c
– Raise engine as far as possible via spindles -1- and -2- of
ce
e
nl
support bracket - 10 - 222 A- and screw in upper bolts of en‐
pt
du
an
itte
gine mounting. Then lower engine as far as possible and
y li
erm
ab
screw in lower bolt of engine mounting.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Install vibration damper/belt pulley (can only be installed in one

position). Specified torque: 25 Nm
nform
ercia
– Fit centre and lower toothed-belt guard. (Insert securing bolts

m
at
om
i
with locking fluid - D 000 600 A2- ). Specified torque: 10 Nm
on
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Install bracket for air pipe on oil sump. Specified torque: 20

Nm
– Fit toothed belt onto camshaft pulley and tension ⇒ page 43 .
1. Cylinder head 49
Sharan 1996 ➤

inder head cover.
– Fit toothed belt onto camshaft pulley and tension ⇒ page 43 .
Tensioning toothed belt
Conditions
• Engine positioned at TDC No. 1 cylinder.
Procedure
– Tension toothed belt, to do this pull out locking pin - T40011-

and unscrew tensioning bolt - T10092- .
– Turn crankshaft two full turns and check whether camshaft
olks
wage and es n
ot g
crankshaft marks align with their reference points.
db
y V ua
ran
e
ris tee
Continuation - Installing toothed belt completely
ut
ho or
a ac
ss
ce
e
nl
pt
du
an

itte
y li

erm
ab
ility
ot p
– Install battery.
wit
, is n
h re
– Fit engine bracket to cylinder block. Specified torque: 45 Nm

hole
spec
– Install engine mounting. Specified torques ⇒ page 12 .

es, in part or in w
t to the co

rrectness of i
l purpos
nf
ercia
orm
m
atio
m
1.2 Removing and installing cylinder head

o
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Prote AG.

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. Volkswagen AG
does Sharan 1996 ➤
swa
4-cylinder injection
y Volk engine (5-valve), mechanics
not
gua
- Edition 06.2019
db ran
rise tee
Special tools and workshop au
tho or
ac
equipment required ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Guide pin - 3070-

♦ Special wrench, long reach - T10070-
♦ Ball joint puller - T40010-
6208-
1. Cylinder head 51
Sharan 1996 ➤

Prerequisite
Procedure
– Observe rules for cleanliness ⇒ page 120 . agen
AG. Volkswagen AG d
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– First check whether a coded radio is fitted. d bIf so, obtain anti-
y ara
se nte
theft coding. thori
eo
au ra
– With the ignition switched off, disconnect
ss battery earth strap. c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
– Disconnect fuel supply and return pipe and cable from activa‐
h re
ole,
ted charcoal filter system solenoid valve 1 -arrows- from fuel
spec
rail.
t to the co
WARNING
rrectne
s
s o
cial p
f inform
mer
atio
om
n
– Seal lines so that fuel system is not contaminated by dirt.
c
i
or
n thi
te
sd
iva
o
pr
cum
r

fo
en
ng

t.
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Cop py
t. rig
gh ht
yri
– Disconnect throttle cable at throttle valve control module cable p by
co Vo
disc and support bracket -arrows- (do not remove locating clip
by lksw
cted agen
Prote
on support bracket).
AG.

parts of the secondary air system.
Note
– Pull vacuum hose off combination valve.


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d b ara
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thor eo Sharan 1996 ➤
u ra
ss a 4-cylinder injection engine
c (5-valve), mechanics - Edition 06.2019
ce
le
un
pt
– Pull off 6-pin connector (grey) from exhaust gas recirculation
an
d
itte
y li
valve - N18- -arrow-.
erm
ab
ility
ot p
– Remove pressure hose between secondary air pump motor -
wit
is n
h re
installing parts of the secondary air system.
ole,
spec
t to the co
Note
rrectne
ss
– Pull off vacuum hose on exhaust gas recirculation valve.
o
cial p
f in
form
mer
atio
– Remove intake manifold ⇒ Rep. gr. 24 .
om
n
c
i
or
n thi
te
sd
a
Note
iv
o
pr
cum
r
fo
en
ng
Block off intake ports in cylinder head with a clean rag.

t.
yi Co
Cop py
t. rig
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yri by
– Remove trim/air duct -1- and trim/battery -2-.
cop Vo
by lksw
cted agen
Prote AG.
– Remove crankcase breather pipe.
– Remove securing bolts from heat shield (exhaust gas side)

-arrows-.
– Remove three bolts -1- securing turbocharger/exhaust mani‐

fold.
– Now remove side coolant connection on cylinder head.
1. Cylinder head 53
AG. Volkswagen AG d
agen oes
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ara
Sharan 1996 ➤ rised
nte
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aut
h
mechanics - Edition 06.2019 ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Remove toothed belt from camshaft toothed belt pulley
wit
, is n
⇒ page 38 .
h re
hole
spec
es, in part or in w
t to the co
– Remove ignition coils with output stages ⇒ Rep. gr. 24 .
– Remove cylinder head cover.
rrectness of i
l purpos
nf
ercia
orm
m
atio
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n in
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sd
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f
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– Loosen cylinder head bolts using special wrench, long reach

t.
yi Co
op
- T10070- in sequence given and then remove completely. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted
Note
agen
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Use special wrench, long reach - T10070- for Polydrive cylinder

head bolts.
– Carefully remove cylinder head.
Note
Cover turbocharger with a clean cloth so that charge air system

is not contaminated by dirt.
Installing
Note
♦ There must be no oil or coolant in the cylinder head bolt pock‐

ets in the cylinder head.
♦ Do not remove new cylinder head gasket from its packing until
immediately before installing.
♦ Handle new gasket with extreme care. Damage will cause
leakage.
– 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. Ensure thereby that surfaces are not scored or
scratched (if abrasive paper is used, grade must not be less
than 100).
– Carefully remove metal particles, emery residue and cloths.

Sharan 1996 ➤

– To centralize screw guide pins - 3070- into holes for cylinder

head bolts 8 and 10.
– Fit new cylinder head gasket. Inscription (Part No.) must be
readable.
– Fit cylinder head, screw in 8 remaining cylinder head bolts and
tighten by hand.
– Remove guide pins through bolt holes with fitting tool from
guide pins - 3070- . To do this, turn removal tool anticlockwise,
until the pins are free.
– Now insert last two cylinder head bolts and tighten them hand-
tight also.
– Tighten cylinder head in sequence as follows:

– Pre-tighten all bolts to 40 Nm.
– Then tighten all bolts 1/4 turn (90°) further using a rigid wrench.
– Then tighten all bolts again 1/4 turn (90°) further.
Further assembly is basically a reverse of the dismantling se‐

quence.
AG. Volkswagen AG d
– Install cylinder head cover. lksw
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not
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– Install ignition coils and tighten
rised to 10 Nm.
b ara
nte
tho eo
– Install toothed belt and s auadjust valve timing ⇒ page 38 . ra
c
s
ce
le

un
pt
an
d
itte

y li
rm
ab
pe
ility
– Adjust throttle cable ⇒ page 131 , Repairing accelerator

ot
wit
mechanism.
, is n
h re
hole
– Interrogate fault memory and erase ⇒ Rep. gr. 01 .

spec
es, in part or in w

t to the co

rrectness of i
1.3 Checking compression

l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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rp
cum
fo
en
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t.
yi Co
Cop py
ht. rig
rig ht
by
55
copy Vo
by lksw
cted agen 1. Cylinder head
Prote AG.
Sharan 1996 ➤

equipment required
AG. Volkswagen AG d
agen oes
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d b ara
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tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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♦ Spark plug socket - 3122 B-

erm
ab
ility
ot p

wit
, is n
h re
♦ Compression tester - V.A.G 1763- with adapter - V.A.G

hole
spec
1763/6-
es, in part or in w
t to the co
Test conditions
• The engine oil temperature must be at least 30°C.
rrectness of i
• Battery voltage must be at least 11.5 V.

l purpos
• All electrical consumers, e.g. lights and rear window heating,

must be switched off.
nform
ercia
• If the vehicle is equipped with an air conditioner, it must be

switched off.
m
at
om
ion
c
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or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
Test sequence lkswage es n
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yV ua
– Remove fuse no. 14 out riof se fuse holder.
d b ran
tee
tho
or
Fuse holder on vehicless awith
u engine code AJH ac
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Fuse holder on vehicles with engine code AWC
ss o
Note
cial p
f inform
mer
Removing fuse no. 14 interrupts the voltage supply to the injec‐
atio
m
tors.
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
– Unscrew spark plugs using spark plug socket and extension -

fo
en
ng
3122 B- .
t.
yi Co
Cop py
.
– Have a second mechanic operate the starter. (On vehicles
t rig
gh ht
yri by
with engine code AJH, fully depress accelerator pedal in ad‐ cop Vo
by lksw
dition.) cted agen
Prote AG.
– Check compression using compression tester - V.A.G 1763-

and adapter - V.A.G 1763/6- .
Note
Using compression tester ⇒ operating instructions .
– Operate starter until tester shows no further pressure in‐

crease.
Compression pressures:
New: 10…13 bar, wear limit: 7.0 bar
Permissible difference between all cylinders: max. 3 bar
– Insert spark plugs using spark plug socket - 3122 B- and tight‐
en to 30 Nm.
– Install ignition coils and tighten to 10 Nm.
– Interrogate fault memory and erase ⇒ Rep. gr. 01 ; Reading
– Read and erase fault memory ⇒ Rep. gr. 01 ; Reading and
erasing engine control unit fault memory .
1. Cylinder head 57
Sharan 1996 ➤
2 Repairing valve gear

AG. Volkswagen AG d
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Note rised
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♦ Cylinder heads which have cracks between the valve seats or between a valve seat insert and the spark
ss c
ce
le
plug thread can be used further without reducing service life, provided the cracks do not exceed a maximum
un
pt
of 0.3 mm in width, or when no more than the first 4 turns of the spark plug thread are cracked.
an
d
itte
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rm
ab
♦ When new bucket tappets have been installed the engine must not be started for about 30 minutes. (Oth‐
pe
ility
erwise valves will contact pistons.) Then turn crankshaft two full revolutions.
ot
wit
, is n
h re
hole
spec
es, in part or in w
1 - 10 Nm
t to the co
2 - Inlet camshaft
❑ Checking axial clear‐
rrectness of i
ance ⇒ page 60 .
l purpos

⇒ page 69
❑ Check radial clearance
nform
ercia
with Plastigage; wear

m
limit: 0.1 mm
a
com
tion in
❑ Runout: max. 0.01 mm
r
te o
thi
3 - Drive chain
s
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rp
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❑ Before removing, mark
um
fo
en
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direction of rotation (in‐

n
t.
yi Co
stallation position) t. Cop py
⇒ page 69 , Removing
rig
gh ht
yri by
and installing cam‐ op Vo
by c lksw
shafts. cted agen
Prote AG.
4 - 10 Nm
5 - Chain tensioner
sleeves.
❑ Only rotate engine when
chain tensioner is instal‐
led.
❑ Secure with chain ten‐
sioner retainer - 3366-
before removing
and installing cam‐
shafts.
❑ Seal transitions be‐
tween chain tensioner/
cylinder head
⇒ page 61
6 - Bonded rubber seal
❑ Renewing ⇒ page 69 , Removing and installing camshafts
7 - Cylinder head
❑ Reworking valve seats ⇒ page 62 .
❑ Reworking sealing surface ⇒ page 60 .
❑ Sealing transitions ⇒ page 61 and ⇒ page 61
8 - Valves
❑ Do not rework; only lapping-in is permitted.

Sharan 1996 ➤
❑ Valve dimensions ⇒ page 61
❑ Exhaust valves with sodium filling: Observe disposal instructions ⇒ page 61 .
9 - Seal
10 - Shield
❑ For Hall sender n AG. Volkswagen AG do
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❑ When installing note fixing arrangement. yV
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11 - Washer ir se tee
tho
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❑ Conical ss
a ac
ce
e
nl
12 - 25 Nm
pt
du
an
itte
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13 - Hall sender - G40- housing
erm
ab
ility
❑ Check Hall sender - G40- ⇒ Rep. gr. 28 ; Checking Hall sender . ot p
wit
, is n
h re
14 - 10 Nm
hole
spec
15 - 65 Nm
es, in part or in w
t to the co
❑ Use counterhold - 3036- to loosen and tighten.
16 - Camshaft sprocket
rrectness of i
❑ Note installation position: the narrow web of camshaft toothed belt pulley faces outwards and the TDC
No. 1 cylinder marking is visible.
l purpos
❑ Note position when installing toothed belt ⇒ page 38 , removing, installing and tensioning toothed belt.
nform
ercia
17 - Seal
m
at
om
ion
18 - Valve guide
c
in t
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at
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priv
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19 - Valve stem seal
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for
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Cop py
. rig
20 - Valve springs
t
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pyri by
Vo
o
❑ Removing and installing:
c by lksw
cted agen
Prote AG.
Cylinder head removed: With valve spring tool - 3362- and press piece - 3362/1- .
Cylinder head installed: ⇒ page 74 , Renewing valve stem oil seals
21 - Valve spring plate

22 - Cotters
23 - Bucket tappet
❑ Do not interchange
❑ With hydraulic valve clearance compensation.
❑ Set down with contact surface facing downwards.
❑ Before installing, check camshaft axial clearance ⇒ page 60 .
❑ Oil contact surface
24 - Inlet camshaft bearing cap
❑ Observe installation position and installation sequence ⇒ page 69 , Removing and installing camshafts
25 - Double bearing cap
❑ Must seat on dowel sleeves.
❑ Lightly coat contact surface with sealing compound - AMV 174 004 01- , observe installation position and
installation sequence ⇒ page 69 , Removing and installing camshaft.
❑ Seal transition points between double bearing cap and cylinder head ⇒ page 61 .
2. Repairing valve gear 59

Sharan 1996 ➤
26 - Exhaust camshaft bearing cap

❑ Observe installation position and installation sequence ⇒ page 69 , Removing and installing camshafts
27 - Exhaust camshaft
❑ Checking axial clearance ⇒ page 60 .
❑ Check radial clearance with Plastigage; wear limit: 0.1 mm
❑ Runout: max. 0.01 olks
mm
wage es n
o
yV t gu
db ara
rise nte
tho eo
Reworking cylinder head sealing surface au ra
c
ss
ce
e
nl
The dimension for reworking is measured through the holes for
pt
du
an
the cylinder head bolts; a = minimum 139.2 mm
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Checking camshaft axial clearance nform

mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

♦ Universal dial gauge holder - VW 387-
♦ Dial gauge
Test sequence
Check with bucket tappets and chain removed and No. 2 and 4
bearing caps fitted.

Sharan 1996 ➤
Wear limit: max. 0.2 mm

Valve dimensions
Note
Do not rework valves. Only lapping-in is permitted.
Dimension Inlet valve Outlet valve

∅a mm 26.9 29.9
∅b mm 5.963 5.943
c mm 104.84…105.34 103.64…104.14
α ∠° 45 45
Note AG. Volkswagen AG d

agen oes
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Care must be taken whenisdisposing
ed
b of old sodium-cooled exhaust ara
nte
valves. They must be cuth or through in the centre of the stem with a eo
ut
hacksaw. When doing
ss a this, ensure that they do not come into ra
c
contact with water. After preparing the valves, throw a maximum
ce
e
nl
of ten into a bucket of water. Then step away immediately, since
pt
du
an
a chemical reaction will occur in which the sodium filling burns.
itte
y li
erm
After this treatment, the valves can be scrapped as normal scrap.
ab
ility
ot p
wit
, is n
h re
Sealing transition points between double bearing cap and cylinder
hole
spec
head
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd

iva
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cu
♦ Sealant - D 454 300 A2-

o
m
f
en
ng
t.
yi Co
– Carefully apply a thin coat of sealing compound - D 454 300 Cop py
. rig
A2- to both edges of sealing surfaces between double bearing
ht ht
rig by
py
cap and cylinder head -arrows- using a small screwdriver. co Vo
by lksw
cted agen
Prote
Seal transitions between chain tensioner/cylinder head
AG.

♦ Sealant - D 454 300 A2-

Sharan 1996 ➤
– Carefully apply a thin coat of sealing compound - D 454 300

A2- to both edges of sealing surfaces between chain tension‐
er/cylinder head -arrows- using a small screwdriver.
2.1 Reworking valve seats

♦ Depth gauge
♦ Valve seat refacing tool
Procedure
Note
♦ When repairing engines with leaking valves, it is not sufficient

to rework or renew valve seats and valves. Particularly on high
mileage engines, it is necessary also to check valve guides for
wear ⇒ page 74 .
♦ Valve seats are only to be reworked to the extent required to
yield a proper surface appearance. Before reworking the valve
seats, calculate the maximum permissible reworking dimen‐
sions. If the reworking dimension is exceeded, the hydraulic
valve clearance compensation can no longer be guaranteed
and the cylinder head must be renewed.
– Remove camshafts ⇒ page 69 .

The max. permissible reworking dimension is calculated as fol‐
lows:
– Insert valve and press firmly against seat. AG. Volkswagen AG d
agen oes
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byV gu
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d
Note orise nte
eo
h
aut ra
s c
If the valve is to be renewed as part of a repair, use a new valve s
ce
le
for the calculation.

un
pt
an
d
itte
y li
rm
ab
– Measure distance between end of valve stem and upper edge

pe
ility
of cylinder head.
ot
wit
, is n
h re
– Calculate maximum permissible reworking dimension from

hole
spec
measured distance and minimum dimension.

es, in part or in w
t to the co
Minimum dimension: outer inlet valve: 34.0 mm, centre inlet valve:
33.7 mm, exhaust valve: 34.4 mm.
Measured distance minus minimum dimension = max. permissi‐
rrectness of i
ble reworking dimension.

l purpos
Example:
nform
mercia
a
com
Measured distance -a- 31.4 mm

ion in
r
Minimum dimension 31.0 mm

te o
thi
s
iva
max. perm. rework dimension 4) 0.4 mm

do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
4) The max. permissible reworking dimension is shown as dimension “b” in the ht. rig
rig ht
illustrations for reworking valve seats. py by
co Vo
by lksw
cted agen
Prote AG.

wage es n
yV
olks Sharan
ot g 1996 ➤
b ua
4-cylinder injectionrisengine
ed (5-valve), mechanics - Edition 06.2019
ran
tee
tho
u or
a ac
2.1.1 Reworking inlet valve seat ss
ce
le
un
pt
an
d
Di‐ Inlet valve seat
itte
y li
rm
men‐
ab
pe
ility
sion
ot
wit
, is n
∅a mm 26.2
h re
hole
spec
b mm max. perm. rework dimension 5)
es, in part or in w
c mm 1.5 … 1.8
t to the co
Z Lower edge of cylinder head
α ° 45° valve seat angle
rrectness of i
β ° 30° upper correction angle
γ ° l purpos
60° lower correction angle
nform
ercia
5) Calculating max. permissible reworking dimension ⇒ page 62 .
m
a
com
tio
2.1.2 Reworking exhaust valve seat
n in
r
te o
thi
s
iva
Di‐ Inlet valve seat
do
r
rp
c
men‐
um
fo
sion
en
ng
t.
yi Co
op
∅a mm 29.0
C py
t. rig
gh ht
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b mm max. perm. rework dimension 6) cop Vo
by lksw
cted agen
c mm approx. 1.8 Prote AG.
Z Lower edge of cylinder head

α ° 45° valve seat angle
β ° 30° upper correction angle
γ ° 60° lower correction angle
6) Calculating max. permissible reworking dimension ⇒ page 62 .
2.2 Renewing camshaft oil seals

Removing and installing oil seal on camshaft toothed belt pulley
Remove oil seal on hall sender ⇒ page 66

Sharan 1996 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Seal puller - 2085-

♦ Assembly tool - T10071-
Removing

Sharan 1996 ➤

⇒ page 38 .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
– Remove camshaft sprocket. When undoing the camshaft pul‐
ility
ot p
ley bolt, hold with the counterhold - 3036- .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
– To guide oil seal extractor, screw securing bolt for camshaft

om
n in
pulley -arrow- into camshaft by hand to stop.

or c
thi
te
sd
iva
o
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rp
cu
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m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
– Lubricate threaded head of oil seal extractor, place it in posi‐

tion and while exerting firm pressure screw it into oil seal as
far as possible.
– Loosen knurled screw and turn inner part against camshaft
until oil seal is pulled out.
Installing
Note
Introduction of PTFE oil seals (identifying features: no circular

spring, wider sealing lip). The sealing lip of this oil seal must not
be oiled or greased.
– Remove oil residue from camshaft journal using a clean cloth.
– Fit assembly tool - T10071/1- onto camshaft journal.

– Slide oil seal over guide sleeve onto camshaft journal.
– Remove guide sleeve.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
– Press seal in to stop using assembly tool
oris - T10071/3- . Use
ed
nte
assembly tool - T10071/4- (bolt) to ado
ut this.
h eo
ra
ss c
– Install camshaft sprocket. When tightening camshaft toothed
ce
e
nl
pt
belt pulley bolt, hold with counterhold - 3036- .

du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Specified torque: 65 Nm
l purpos

quence.
nform
ercia

m
at
om
Remove oil seal from hall sender - G40-

ion
c
in t
or

his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Pull off 3-pin connector from Hall sender - G40- -arrow-.

parts of the charge air cooling system:
gen AG
. Volkswaengine
gen AG code AJH.
d oes wa
not olks
Vehicles with engined bcode
y V AWC gu
ara
ise nte
r
– Remove intakeut
ho hose ⇒ page 152 , Removing and installinge or
parts of the
ss charge air cooling system: engine code AWC.
a ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Remove Hall sender housing.
wit
, is n
h re
– Remove Hall sender washer and screen.
hole
spec
es, in part or in w
– To guide seal extractor, screw bolt - 2085/1- fully into camshaft
t to the co
by hand.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
– Lubricate threaded head of oil seal extractor, place it in posi‐

t.
yi Co
tion and while exerting firm pressure screw it into oil seal as Cop py
t. rig
far as possible. opyri
gh by
Vo
ht
by c
– Loosen knurled screw and turn inner part against camshaft
lksw
cted agen
Prote
until oil seal is pulled out.
AG.
Installing
Note
Introduction of PTFE oil seals (identifying features: no circular

spring, wider sealing lip). The sealing lip of this oil seal must not
be oiled or greased.
– Fit assembly tool - T10071/5- onto camshaft journal.

– Slide oil seal over guide sleeve onto camshaft journal.
– Remove guide sleeve.

Sharan 1996 ➤
– Press seal in to stop using assembly tool - T10071/3- . To do

this use bolt M8x60 -1-.
– Insert Hall sender screen into notch in inlet camshaft.
– Install washer (cone facing outwards) and tighten securing bolt
to 25 Nm.
– Install Hall sender housing and tighten to 10 Nm.
– Attach connector to hall sender - G40- -arrow-.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
2.3 Checking hydraulic bucket tappets

pe
ility
ot
wit
, is n

h re
hole
spec
♦ Feeler gauge
es, in part or in w
t to the co
♦ Wooden/plastic wedge
rrectness of i
Note
l purpos
♦ Renew defective bucket tappets complete (cannot be adjusted

or repaired).
nform
ercia
♦ Irregular valve noise during starting is normal.

m
a
com
tion in
Test sequence
r
te o
thi
– Start engine and run until radiator fan has switched on once.
s
iva
do
r
rp
cum
– Increase engine speed to about 2500 rpm for approx. 2 mi‐

fo
en
g
nutes.
n
t.
yi Co
Cop py
If hydraulic bucket tappets are still noisy, locate defective tappet
t. rig
gh ht
yri by
(s) as follows: op Vo
by c lksw
cted agen
Prote
– Remove pressure hose between combination valve and sec‐
AG.
ondary air pump motor - V101- and unclip pressure hose from
brackets.

Sharan 1996 ➤
Note

– Rotate crankshaft clockwise until cam of tappet to be checked
is pointing upwards.
– Determine play between cam and bucket tappet.
– If play exceeds 0.2 mm, renew bucket tappet. If play is less
than 0.2 mm or there is no play, continue with check as follows:
– Push bucket tappet down lightly with a wooden or plastic
wedge. If when bucket tappet is pushed down, a 0.2 mm feeler
gauge can be pushed between camshaft and bucket tappet,
bucket tappet must be renewed.
Note
When new bucket tappets have been installed the engine must
not be started for about 30 minutes. Hydraulic compensation el‐
ements must settle (otherwise valves will strike pistons).
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or
2.4 Removing and installing camshafts h eo
aut ra
ss c
ce
le
(With cylinder head installed)

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for

en
ng
t.
yi Co
op py
♦ Chain tensioner retainer - 3366- . C rig
ht ht
rig by
py
co Vo
by lksw
cted agen
Prote AG.
Not illustrated
♦ Sealant - AMV 174 004 01-
♦ Sealant - D 454 300 A2-
Removing

Sharan 1996 ➤

crankshaft. Marking on camshaft toothed belt pulley must align n AG. Volkswagen AG do
with mark on cylinder head cover. olks
wage es n
o V t gu
by ara
– Remove pressure hose between combination valve and ris sec‐
ed nte
ondary air pump motor on combination valve and unclip
tho pres‐ eo
au ra
sure hose from retainers. ss c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
⇒ page 38 .
t to the co
rrectness of i
l purpos
– Remove camshaft sprocket. When undoing the camshaft pul‐

ley bolt, hold with the counterhold - 3036- .
nf
ercia
orm
– Remove hall sender - G40- housing.
m
atio
om
n in
c
– Remove hall sender - G40- washer and trim.

or
thi
te
sd
iva
– Clean drive chain and camshaft sprocket in opposite area of
o
r
rp
cu
both arrows on bearing caps and mark installation position
o
m
f
en
ng
with a coloured mark.

t.
yi Co
Cop py
ht. rig
rig ht
py by
o Vo
Note by c lksw
cted agen
Prote AG.
♦ Do not mark chain with a centre punch mark, notch or any

similar means!
♦ The distance between both arrows or the coloured marks is
equal to 16 rollers on the drive chain.
– Secure chain tensioner with chain tensioner retainer - 3366- .
Note
If the retainer for chain tensioner is tightened excessively, this can

damage the hydraulic chain tensioner.

Sharan 1996 ➤
– First remove 3rd and 5th bearing caps from inlet and exhaust
camshafts.
– Remove double bearing cap.
– Remove both bearing caps at sprockets on inlet and exhaust
camshafts.
– Unscrew securing bolts of chain tensioner.
– Remove 2nd and 4th bearing caps from inlet and exhaust
camshaft alternately and diagonally.
– Remove inlet and exhaust camshaft chain tensioner and chain
. Volkswagen AG
tensioner retainer - 3366- . swagen AG does
olk not
yV gu
Installing edb ara
nte
ris
tho eo
au ra
c
ss
Note
ce
le
un
pt
an
d
itte
♦ When camshafts are installed, cams for No. 1 cylinder must
y li
rm
ab
point upwards.
pe
ility
ot
wit
♦ When installing the bearing caps, ensure that the cap mark‐
, is n
h re
ings can be read from the inlet side of the cylinder head.
hole
spec
es, in part or in w
– Fit drive chain onto both camshafts so that coloured markings
t to the co
match.
rrectness of i
Note
l purpos
♦ When using a new drive chain, the distance between the
nform
ercia
notches -A- and -B- on the camshafts must be 16 rollers on

the drive chain.
m
a
com
tion in
♦ The illustration shows the exact positions of the 1st and 16th
r
te o
thi
rollers on the sprockets where the chain must be fitted.

s
iva
do
r
♦ Notch -A- is offset slightly towards the inside in relation to chain

rp
cum
fo
roller -1-.
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
o Vo
– Renew rubber/metal gasket for chain tensioner and lightly coat by c lksw
cted agen
hatched area with sealing compound - D 454 300 A2- . Prote AG.
– Insert chain tensioner between drive chain.

– Oil running surfaces of camshafts.
– Place camshafts with drive chain and chain tensioner in cyl‐
inder head.
– Tighten chain tensioner to 10 Nm (note dowel sleeves).

Sharan 1996 ➤
– Tighten inlet and exhaust camshaft 2nd and 4th bearing caps
alternately and diagonally to 10 Nm (remember dowel
sleeves).
– Install both bearing caps at inlet and exhaust camshaft sprock‐

ets. Check camshafts are positioned correctly -arrows- and
tighten bearing cap to 10 Nm (remember dowel sleeves).
– Remove retainer for chain tensioner 3366.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Coat hatched area of double bearing cap lightly with sealant -

ility
ot p
AMV 174 004 01- , install and tighten to 10 Nm (note dowel

wit
, is n
sleeves).
h re
hole
spec
– Install remaining bearing caps and tighten to 10 Nm (remem‐

es, in part or in w
ber dowel sleeves).

t to the co
rrectness of i
l purpos
nform
mercia
at
om
– Install camshaft sprocket (the small web faces outwards

ion
c
-arrow- and TDC mark is visible) and tighten securing bolt to

in t
or
65 Nm (use counterhold - 3036- ).

his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
. Volkswagen AG
gen AG does
– Check position of camshafts to one another -arrows-Vagain.
olks
wa not
y gu
db ara
– Insert Hall sender screen ⇒ Item 10 (page 59) ointo
ris notch
e in nte
inlet camshaft. auth eo
ra
ss c
– Install washer (cone facing outwards) and tighten securing bolt
ce
e
nl
pt
to 25 Nm.
du
an
itte
y li
– Install Hall sender housing and tighten to 10 Nm.
erm
ab
ility
ot p
– Install cylinder head cover.
wit
, is n
h re
– Install ignition coils and tighten to 10 Nm. hole
spec
es, in part or in w
t to the co
quence.
rrectness of i
l purpos
Note
nf
ercia
When new bucket tappets have been installed the engine must
o
not be started for about 30 minutes. Hydraulic compensation el‐
rm
m
atio
ements must settle (otherwise valves will strike pistons).
om
n in
or c
thi
te
sd
a
2.5 Checking valve guides

iv
o
r
rp
cu
o
m
f
en
ng

t.
yi Co
Cop py
♦ Universal dial gauge holder - VW 387-
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Dial gauge
Test sequence
– Insert new valve into guide. The end of the valve stem must
be flush with the guide. On account of differing stem diame‐
ters, only use inlet valve in inlet guide and exhaust valve in
exhaust guide.
– Determine rock. Wear limit: 0.8 mm
If the amount of sideways play is exceeded:
– Renew cylinder head.
2.6 Renewing valve stem seals

(With cylinder head installed)

Sharan 1996 ➤

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
♦ Spark plug socket - 3122 B-

s
iva
do
r
rp
cum
♦ Hold down tool for valve springs - 3362- and press piece -
fo
en
g
3362/1-
n
t.
yi Co
Cop py
♦ Valve stem seal puller - 3364-
t. rig
gh ht
pyri by
Vo
o
♦ Pressure hose - VW 653/3-
c by lksw
cted agen
Prote AG.
♦ Valve stem seal fitting tool - 3365-
Removing
– Remove camshafts ⇒ page 69 .
– Remove bucket tappets and place them with the contact sur‐
face downwards. When doing this, ensure that tappets are not
interchanged.
– Unscrew spark plugs using spark plug socket and extension -
3122 B- .
– Set piston of respective cylinder to “bottom dead centre”.

Sharan 1996 ➤
– Screw pressure hose - VW 653/3- into spark plug thread.

– Insert thrust piece - 3362/1- into hold down tool for valve
springs - 3362- .
– Secure valve spring tool - 3362- to cylinder head with the tool
securing bolts.
– Bring valve spring tool - 3362- into the following position to
compress valve springs:
Outer inlet valves: lower position
Middle inlet valve: upper position
Exhaust valve: lower position
– Connect pressure hose - VW 653/3- to compressed air system
supplying at least 6 bar and remove valve springs.
– Pull off valve stem seals using valve stem seal puller - 3364- .
Installing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– To prevent damage to new valve stem seals, place plastic

rrectness of i
sleeve -A- on valve stem.

l purpos
– Lubricate sealing lip of valve stem oil seal -B-, place it in the
valve stem oil seal fitting tool - 3365- and push carefully onto
valve guide.
nform
ercia
– Insert spark plugs using spark plug socket - 3122 B- and tight‐
m
at
om
en to 30 Nm.
ion
c
in t
or
– Install camshafts ⇒ page 69 .

his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
17 – Lubrication agen
AG. Volkswagen AG d
oes
olksw not
y V gu
1 Removing and installing parts of lu‐ d b ara
rise nte
ho eo
brication system ut ra
s a c
s
ce
e
nl
Assembly overview - parts of lubrication system ⇒ page 77
pt
du
an
itte
y li
erm
ab
ility
ot p
Dismantling and assembling oil filter bracket ⇒ page 80 .
wit
, is n
h re
Checking oil pressure and oil pressure switch ⇒ page 86
hole
spec
es, in part or in w
t to the co
Dismantling and assembling oil filter bracket ⇒ page 82 .
Checking oil pressure and oil pressure switch ⇒ page 88
rrectness of i
l purpos
Note
nform
ercia
♦ If large quantities of swarf or metal particles (caused, for ex‐

ample, by partial seizure of the crankshaft or conrod bearings)
m
at
om
i
are found in the engine oil when performing repairs, clean the
on
c
oil passages thoroughly and renew the oil cooler and oil filter
in t
or
his
e
in order to prevent subsequent damage.

at
do
priv
c
♦ The oil level must not be above the max. mark - danger of
um
for
en
damage to catalytic converter! Markings ⇒ page 79 .
ng
t.
yi Co
Cop py
t. rig
gh
1.1 Engine oil:
ht
pyri by
Vo
co lksw
by
cted agen
Engine oil specifications:
Prote AG.
⇒ Maintenance ; Booklet 10.1 “Service tables”

Oil capacities:
With oil filter 4.5 l 7)
7) Current values: ⇒ Exhaust emissions test
1.2 Assembly overview - parts of lubrication system
1. Removing and installing parts of lubrication system 77

Sharan 1996 ➤
1 - 15 Nm
2 - Sealing flange
sleeves.
❑ Clean sealing surface
before fitting.
❑ Install with silicone seal‐
ant - D 176 404 A2- .
⇒ page 25
3 - Chain tensioner with ten‐
sioning rail, 15 Nm
❑ Check for wear
❑ When installing, preten‐
sion spring and fit.
4 - Sprocket
❑ For oil pump drive.
❑ Check for wear
5 - Cylinder block
crankshaft ⇒ page 30 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 33 .
6 - Oil dipstick
❑ The oil level must not be
above the max. mark
❑ Markings ⇒ page 79 . AG. Volkswagen AG d
agen oes
7 - Dipstick guide olksw not
byV gu
ara
d
❑ for oil dipstick orise nte
eo
h
ut
❑ Secured with bracket toss a ra
c
intake manifold
ce
le
un
pt
an
8 - Guide tube
d
itte
y li
erm
ab
9 - Oil spray jet

ility
ot p
❑ For piston cooling

wit
is n
h re
ole,
10 - Pressure relief valve, 27 Nm

spec
❑ Opening pressure: 1.3…1.6 bar

t to the co
11 - Suction line
❑ Clean strainer if soiled
rrectne
12 - O-ring
s
❑ Renew
s o
cial p
13 - Baffle plate
inform
mer
14 - Sump
atio
m
❑ Clean sealing surface before fitting.

o
n
c
i
or
n thi
❑ Install with silicone sealant - D 176 404 A2- .

te
sd
va

i
o
pr
cum
r
fo
en
ng
15 - 15 Nm
t.
yi Co
op
❑ Loosen and tighten with T-bar and socket, 10 mm - 3185-
C py
ht. rig
rig ht
❑ Unscrew with hexagon key extension, 5 mm - 3249- .
py by
co Vo
by lksw
cted agen
Prote AG.
78 Rep. gr.17 - Lubrication

Sharan 1996 ➤
16 - Oil level and oil temperature sender - G266-

❑ Only on vehicles with engine code AWC
❑ Black connector, 3-pin.
17 - Seal
❑ Renew
❑ Lubricate before assembling.
18 - 10 Nm
19 - 20 Nm
20 - Bracket
❑ Remove air pipe between charge air cooler and turbocharger ⇒ page 152 , Removing and installing
parts of charge air cooling: engine code AWC
21 - Oil drain plug, 30 Nm
❑ Renew plug with attached seal.
22 - Seal
❑ Renew
23 - Oil return line
❑ From turbocharger ⇒ Item 24 (page 150)
24 - Oil pump
❑ With 12 bar pressure relief valve
❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
25 - Sprocket
❑ For oil pump. agen
AG. Volkswagen AG d
oes
lksw not
❑ Check for wear
db
y Vo gu
a
e ran
ris tee
26 - 25 Nm utho or
a ac
ss
27 - Timing chain
ce
e
nl
pt

du
an
itte
y li
❑ Check for wear

erm
ab
ility
ot p
28 - Dowel sleeves
wit
, is n
h re
❑ Check for firm seating

hole
spec
es, in part or in w
t to the co
Markings on oil dipstick

1 - max. marking
rrectness of i
2 - min. marking
l purpos
a - Area above hatched field up to max. mark: Do not top up with

engine oil!
nf
ercia
or
b - Oil level within hatched field: Can be topped up with engine

m
m
atio
oil.
om
n in
or c
c - Area from min. mark up to hatched field: top up, max. 0.5 l of
thi
te
engine oil!
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
1.3 Dismantling and assembling oil filter
Cop py
t. rig
gh ht
bracket
pyri by
Vo
co lksw
by
cted agen
Prote
Dismantling and assembling oil filter bracket: engine code AJH
AG.
⇒ page 80

Sharan 1996 ➤
Dismantling and assembling oil filter bracket: engine code AWC

⇒ page 82
wage
1.3.1 Dismantling and assembling oil filter bracket: engine code AJH
byV
olks es n
ot g
ua
d ran
ir se tee
tho
u or
a ac
Note ss
ce
le
un
pt
♦ All hose connections are secured with either spring-type or clamp-type clips.
an
d
itte
y li
erm
ab
♦ Always renew crimp-type clips with spring-type clips.
ility
ot p
wit
is n
h re
ole,
spec
1 - O-ring
❑ Push on to shoulder of
t to the co
pipe.
rrectne
2 - Connecting pipe
s
3 - Manifold
s o
cial p
f
❑ With non-return valve
inform
mer
4 - Connection hose
atio
m
❑ To connection on intake
o
n
c
i
manifold
or
n thi
te
sd
va
5 - Pipe
i
o
pr
cum
r
fo
❑ For crankcase ventila‐

en
ng
t.
tion.
yi Co
Cop py
t. rig
6 - Retaining clip
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.
7 - 0.25 bar oil pressure switch
- F22- , 25 Nm
❑ Identification: blue
❑ If seal is leaking, nip
open and renew.
8 - 1.4 bar oil pressure switch -
F1- , 25 Nm
❑ Identification: black
open and renew.
9 - Oil supply line
❑ To turbocharger
⇒ Item 5 (page 149) .
10 - Banjo bolt, 30 Nm
11 - Seal
❑ Renew
12 - Oil temperature sender - G8-
❑ For oil temperature gauge
❑ Tighten to 10 Nm
❑ If seal is leaking, nip open and renew.
13 - 15 Nm + 1/4 turn (90°) further
❑ Renew

Sharan 1996 ➤
14 - Seal
❑ Renew
❑ Fit into lugs on oil cooler.
15 - Oil cooler
❑ Coat contact surface to oil filter bracket outside the seal with sealing paste - AMV 188 100 02-
❑ Observe notes ⇒ page 77
16 - 25 Nm AG. Volkswagen AG d
agen oes
lksw not
17 - Oil filter d by Vo gu
ara
se nte
❑ Observe thorchange
i intervals. eo
u ra
❑ Loosen ss a
with strap wrench. c
ce
le
❑ Tighten by hand.
un
pt
an
d
itte
❑ Observe fitting instructions on oil filter
y li
erm
ab
ility
ot p
wit
is n
❑ With pressure relief valve, approx. 4 bar
h re
ole,
spec
19 - Plug, 40 Nm
20 - Spring t to the co
❑ For pressure relief valve, approx. 4 bar
rrectne
21 - Piston
ss

o
cial p
f in
22 - Seal
form
mer
❑ Renew
atio
om
23 - Non-return valve, 8 Nm
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
1.3.2 Dismantling and assembling oil filter bracket: engine code AWC
Note
♦ All hose connections are secured with either spring-type or clamp-type clips.
1 - O-ring
❑ Push on to shoulder of agen
AG. Volkswagen AG d
oes
pipe. yV
olksw not
gu
b ara
❑ Renew if damaged ris ed
nte
tho eo
2 - Connecting pipe s au ra
c
s
ce
e
3 - Manifold
nl
pt
du
an
itte
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erm
ab
ility
4 - Connection hose
ot p
wit
, is n
❑ Connection on bottom
h re
of intake manifold
hole
spec
es, in part or in w
5 - Pipe
t to the co
tion.
rrectness of i
6 - Retaining clip
l purpos

7 - Plug, 15 Nm nf
ercia

orm
open and renew.

m
atio
om
n in
c
8 - Oil supply line

or
thi
e
❑ To turbocharger
t
sd
iva
⇒ Item 5 (page 149) .

o
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rp
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ng
t.
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Cop py
10 - Seal ht. rig
rig ht
py by
❑ Renew
co Vo
by lksw
cted agen
Prote AG.
11 - 1.4 bar oil pressure switch
- F1- , 25 Nm
❑ Identification: black
open and renew.
12 - 15 Nm + 1/4 turn (90°) further
❑ Renew
13 - Seal
❑ Renew
❑ Fit into lugs on oil cooler.
14 - Oil cooler
❑ Coat contact surface to oil filter bracket outside the seal with sealing paste - AMV 188 100 02-

Sharan 1996 ➤
15 - 25 Nm
16 - Oil filter
❑ Observe change intervals.
❑ Loosen with strap wrench.
❑ Tighten by hand.
❑ Observe fitting instructions on oil filter
❑ With pressure relief valve, approx. 4 bar
18 - Plug, 40 Nm
n AG . Volkswagen AG
19 - Spring wage does
Volks not
❑ For pressure relief valve, approx.ed4bybar gu
ara
is nte
or
20 - Piston au
th eo
ra
ss c
ce
e
nl
pt
du
21 - Seal
an
itte
y li
erm
❑ Renew
ab
ility
ot p
22 - Non-return valve
wit
, is n
h re
❑ Insert in oil filter bracket (no longer screwed together with oil filter bracket)
hole
spec
es, in part or in w
t to the co
1.4 Removing and installing sump
rrectness of i
l purpos
♦ T-bar and socket, 10 mm - 3185-
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Socket insert - 3249-

Sharan 1996 ➤
Not illustrated
♦ Silicone sealant - D 176 404 A2-
♦ Hand drill with plastic brush attachment
♦ Safety glasses
♦ Scraper
Removing
– Drain engine oil.
Note
Please observe disposal instructions!

– Unscrew oil return line of turbocharger from sump.
– Remove securing bolt from air pipe bracket on sump. AG. Volkswagen AG d
agen oes
ksw
Vehicles with engine code AWC by
Vol not
gu
d ara
ise nte
– Pull 3-pin connector off oil level and oil temperature
hor sender - eo
ut
G266- -1-. ss a ra
c
ce
e
– Remove turbocharger oil return line -2- from sump.

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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84
cted agen
Prote
Rep. gr.17 - Lubrication
AG.
Sharan 1996 ➤
– Remove securing bolts -arrows- from bracket on sump for air

pipe of charge air cooler.
– Install sump bolts using T-bar and socket, 10 mm - 3185- .
Unscrew with Allen key, long reach - 3249- .
– Remove sump. Loosen sump with light blows of a rubber-
headed hammer if necessary.
– Remove sealant residue from cylinder block with a flat scraper.
– Remove sealant residue on sump with a rotating brush, e.g. a

hand drill with a plastic brush (wear eye protection).
. Volkswage n AG n AG d
wage oe
– Clean sealing surfaces.yThey
Vol
ks must be free of oil and sgrease.
not
g b ua
ed ran
Installing horis tee
t or
au ac
ss
ce
e
nl
Note
pt
du
an
itte
y li
erm
ab
♦ Note the expiry date of the Silicone sealant - D 176 404 A2- .
ility
ot p
♦ Install sump within 5 minutes of applying silicone sealant - D
wit
, is n
h re
176 404 A2- .
hole
spec
es, in part or in w
t to the co
– Cut off tube nozzle at forward marking (approx. 3 mm nozzle
∅).
– Apply silicone sealant - D 176 404 A2- , as shown, to clean rrectness of i
sump sealing surface. Sealant bead must be:
l purpos
♦ 2…3 mm thick
nf
ercia
♦ Run bead along inner side of bolt holes -arrows-.

orm
m
atio
om
n in
Note
or c
thi
te
sd
iva
The sealant bead must not be thicker, otherwise excess sealing

o
r
rp
cu
compound will enter the oil sump and may block the oil suction
o
m
f
en
ng
line strainer.
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Apply silicone sealant - D 176 404 A2- as shown in figure to

clean sealing surface of oil sump. (The figure shows the posi‐
tion of the sealant bead on the cylinder block)
– Install sump immediately and tighten all sump bolts lightly.
Note
Let sealing compound dry for approx. 30 minutes after installing

oil sump. Only then fill with engine oil.
– Tighten oil sump bolts to 15 Nm.

– Tighten bolts securing sump to gearbox to 40 Nm.
quence.
– Tighten bolts securing sump/oil return line to 10 Nm.
swage es n
– Tighten bolts securing sump/air pipe bracket to 20bNm. yV
olk ot g
ua
d ran
ir se tee
o
1.5 Checking oil pressure and oil pressure
th or
au ac
ss
switch
ce
e
nl
pt
du
an
itte
Checking oil pressure and oil pressure switch: engine code AJH
y li
erm
ab
⇒ page 86
ility
ot p
wit
Checking oil pressure and oil pressure switch: engine code AWC
, is n
h re
⇒ page 88
hole
spec
1.5.1 Checking oil pressure and oil pressure switch: engine code AJH
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
♦ Oil pressure tester - V.A.G 1342- p by
o Vo
by c lksw
cted agen
♦ Voltage tester - V.A.G 1527B- Prote AG.
♦ Auxiliary measuring set - V.A.G 1594 A- or auxiliary measuring

set - V.A.G 1594C-
Test conditions
• Engine oil level OK, checking ⇒ page 79 .
• Engine oil temperature at least 80°C (radiator fan must have
run at least once).
Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations

Sharan 1996 ➤
Checking oil pressure switch

– Remove 1.4 bar oil pressure switch - F1- -A- and screw into
tester.
– Screw oil pressure tester - V.A.G 1342- into oil filter bracket in
place of oil pressure switch - F1- .
– Connect brown wire of tester to earth (-).
– Connect voltage tester - V.A.G 1527B- to battery positive (+)
and 0.25 bar oil pressure switch - F22- using cables from aux‐
iliary measuring set - V.A.G 1594 A- or auxiliary measuring set
- V.A.G 1594C- -B-. The LED must light up.
– Start engine and slowly increase engine speed. At 0.15…0.35
bar, the LED must extinguish; otherwise renew 0.25 bar oil
pressure switch - F22- ⇒ Item 7 (page 80) .
– Connect voltage tester - V.A.G 1527B- to 1.4 bar oil pressure
switch - F1- -A-. At 1.2…1.6 bar the LED must light up; other‐
wise renew oil pressure switch ⇒ Item 8 (page 80) .
Checking oil pressure
– Check oil pressure at different engine speeds: 2000 rpm - at
least 2.0 bar; above 2000 rpm - maximum 7.0 bar.
If specifications are not met:
– Rectify mechanical damage, e.g. bearing damage.
– Renew oil filter bracket with pressure relief valve Volkswa
⇒ Item 18 (page 81) and oil pump ⇒ Itemsw24 age(page
n AG. 79) . gen AG do
es k not
Vol gu
At higher engine speeds, the oil pressure by
ed must remain at or below
ara
ris nte
7.0 bar. tho eo
au ra
c
If the specification is exceeded:
ss
ce
e
nl
pt
du
– Check the oil passages.

an
itte
y li
erm
ab
– If necessary, renew oil filter bracket with pressure relief valve

ility
ot p
⇒ Item 24 (page 79) .

wit
, is n
h re
hole
1.5.2 Checking oil pressure and oil pressure switch: engine code AWC
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
♦ Oil pressure tester - V.A.G 1342- gh ht
pyri by
Vo
co lksw
by
♦ Voltage tester - V.A.G 1527B- Prote
cted AG.
agen

set - V.A.G 1594C-
Test conditions
• Engine oil level OK, checking ⇒ page 79 .
run at least once).

Sharan 1996 ➤ n AG. Volkswagen AG do
wage
4-cylinder injection engineV(5-valve),
olks mechanics - Editiones n
ot06.2019
g y ua
db ran
rise tee
Checking oil pressure switch tho or
s au ac
– Remove oil pressure switch - F1- and screw into tester. s
ce
le
un
pt
– Screw tester into oil filter bracket in place of oil pressure switch
an
d
itte
y li
- F1- .
rm
ab
pe
ility
– Connect brown wire of tester to earth (-).
ot
wit
, is n
h re
– Connect voltage tester - V.A.G 1527B- to battery positive (+)
hole
spec
and oil pressure switch using cables from auxiliary measuring
es, in part or in w
set - V.A.G 1594 A- or auxiliary measuring set - V.A.G 1594C- .
t to the co
LED must not light up.
If the LED lights up:
rrectness of i
– Renew oil pressure switch - F1- ⇒ Item 11 (page 82) .
l purpos
If LED does not light up:

– Start engine and run at idling speed. At 1.2…1.6 bar, the LED
nform
ercia
must light up, otherwise renew oil pressure switch - F1-

m
⇒ Item 11 (page 82) .
a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum
fo
Functional check and repair of the optical and acoustic oil pres‐
en
ng
t.
yi
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Co
Cop py
Fitting locations
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
Checking oil pressure
agen
Prote AG.
– Check oil pressure at different engine speeds: 2000 rpm -

2.7…4.5 bar; above 2000 rpm - maximum 7.0 bar
– Rectify mechanical damage, e.g. bearing damage.
– Renew oil filter bracket with pressure relief valve
⇒ Item 17 (page 83) and oil pump ⇒ Item 24 (page 79) .
At higher engine speeds, the oil pressure must remain at or below
7.0 bar.
If the specification is exceeded:
– Check the oil passages.
– If necessary, renew oil filter bracket with pressure relief valve
⇒ Item 17 (page 83) .

Sharan 1996 ➤
19 – Cooling olkswage
es n
ot g
byV ua
d ran
ir se
1 Removing and installing parts of cool‐ o tee
th or
au ac
ing system ss
ce
le
un
pt
an
d
itte
y li
WARNING
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
sitions.
rrectness of i
l purpos
hot components.
nform
mercia
a
Note
com
tion in
r
te o
thi
♦ Cooling system is pressurised when engine is warm. If nec‐
s
iva
do
essary, release pressure before carrying out repairs.
r
rp
cum
fo
♦ Hose connections are secured with spring-type clips. In case
en
ng
t.
yi
of repair, only use spring-type clips.
Co
Cop py
t. rig
gh ht
♦ It is recommended that spring-type clips should be installed yri
p by
o Vo
using spring-type clip pliers - VAS 5024A- or hose clamp pliers
c by lksw
cted agen
- V.A.G 1921- .
Prote AG.
♦ When installing coolant hoses, route stress-free so that they

do not come into contact with other components (observe
markings on coolant connection and hose).

Test for leaks in cooling system using cooling system tester -
V.A.G 1274- and adapter for cooling system tester - V.A.G
1274/8- and adapter for cooling system tester - V.A.G 1274/9- .
Parts of cooling system - body side ⇒ page 92 .
Parts of cooling system - engine side ⇒ page 95 .
Coolant hose schematic diagram ⇒ page 99
Draining and filling with coolant ⇒ page 101 .
Coolant mixture ratios ⇒ page 101 , draining and filling with cool‐
ant.
Test for leaks in cooling system using cooling system tester -
V.A.G 1274- and adapter - V.A.G 1274/7- and adapter - V.A.G
1274/1A- .
Parts of cooling system - body side ⇒ page 93 .
Parts of cooling system - engine side ⇒ page 97 .
Coolant hose schematic diagram ⇒ page 100
Draining and filling with coolant ⇒ page 101 .
Coolant mixture ratios ⇒ page 101 , draining and filling with cool‐
ant.
1. Removing and installing parts of cooling system 91

Sharan 1996 ➤
1.1 Parts of cooling system, body side

Parts of cooling system, body side: engine code AJH
Parts of cooling system, body side: engine code AWC
⇒ page 93
1.1.1 Parts of cooling system, body side: engine code AJH
1 - Rubber grommet
2 - Upper coolant hose
❑ Ensure firm seating
❑ Connection diagram for
coolant hoses
⇒ page 99 wage
es n
lks ot g
Vo
3 - Radiator d by ua
ran
ir se tee
❑ Removing anduthinstalling
o
or
⇒ page 104ss a ac
ce
e

nl
pt
du
an
entire coolant.
itte
y li
erm
ab
4 - Radiator fan thermal switch
ility
ot p
- F18- , 35 Nm
wit
, is n
h re
❑ For electric fan.
hole
spec
❑ Switching tempera‐
es, in part or in w
tures:
t to the co
1st stage on: 92…97°C, off:
84…91°C
rrectness of i
2nd stage on: 99…105°C, off:

l purpos
91…98°C
5 - Connector
nf
ercia
or
❑ Black, 3-pin
m
m
atio
m
❑ For thermal switch for

o
n in
c
radiator fan.
or
thi
te
sd
iva
6 - 10 Nm
o
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rp
cu
o
m
f
7 - Reinforcement strut
en
ng
t.
yi Co
op
8 - Connector
C py
t. rig
gh ht
yri
❑ black
p by
co Vo
by lksw
cted
❑ For right radiator fan -
agen
Prote AG.
V35- .
9 - Retaining clip
10 - Right radiator fan - V35-
11 - Fan ring
12 - Rubber grommet
13 - Washer
14 - Rubber washer
15 - Bush
16 - Connector
❑ black
92 Rep. gr.19 - Cooling

Sharan 1996 ➤
❑ For left radiator fan - V7- .
17 - Left radiator fan - V7-
18 - Securing clip
❑ For lower coolant hose.
19 - Lower coolant hose
❑ Connection diagram for coolant hoses ⇒ page 99
20 - Cowling
21 - Rubber bush
1.1.2 Parts of cooling system, body side: engine code AWC

AG. Volkswagen AG d
agen oes
lksw not
1 - Rubber grommet byV
o gu
ara
ed
is nte
2 - Radiator ut
hor eo
a ra
❑ Removing and installing ss c
⇒ page 104
ce
e
nl
pt
du
an
itte
y li
entire coolant.
erm
ab
ility
ot p
3 - 10 Nm
wit
, is n
h re
4 - Radiator fan thermal switch
hole
spec
- F18- , 35 Nm
es, in part or in w
t to the co
❑ Switching tempera‐
tures:
1st stage on: 92…97°C, off:
rrectness of i
84…91°C
l purpos
2nd stage on: 99…105°C, off:

91…98°C
nform
ercia
5 - Connector
m
at
om
io
❑ Black, 3-pin
n
c
in t
or
❑ For thermal switch for

his
ate
radiator fan.
do
priv
cum
or
6 - Rubber bush
f
en
ng
t.
yi Co
op
7 - Bracket C py
ht. rig
rig ht
❑ for charge air cooler py by
co Vo
by lksw
cted agen
8 - Cowling Prote AG.
9 - 9 Nm
10 - Right radiator fan - V35-
❑ With fan ring.
❑ Vehicles with optional
equipment only.
⇒ page 104
11 - Bracket
❑ For lower coolant hose.
12 - Left radiator fan - V7-
❑ With fan ring.

Sharan 1996 ➤
13 - Connector
❑ Black, 2-pin
❑ For radiator fan.
14 - Charge air cooler
16 - Quick-release coupling
❑ With retaining clip.
17 - O-ring n AG. Volkswagen AG do
wage es n
❑ Renew if damaged yV
olks ot g
ua
d b ran
18 - Upper coolant hose ir se tee
tho
u or
❑ Ensure firm seating ss
a ac
ce
le

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
1.2 Parts of cooling system - engine side

Parts of cooling system, engine side: engine code AJH
⇒ page 95
Parts of cooling system, engine side: engine code AWC
⇒ page 97
1.2.1 Parts of cooling system, engine side: engine code AJH
1 - 15 Nm
2 - To turbocharger
coolant hoses
⇒ page 99
3 - Coolant circulation pump -
V50-
❑ Black 2-pin connector
4 - Thermostat
❑ Checking: heat thermo‐
stat in water.
❑ Begins to open at ap‐
prox. 87°C
5 - O-ring
❑ Renew AG. Volkswagen AG d
agen oes
6 - Connection olksw not
V gu
d by ara
e nte
7 - To heat exchanger horis
eo
ut ra
❑ Connection diagram for ss a c
coolant hoses
ce
e
nl
pt
⇒ page 99
du
an
itte
y li
erm
8 - To back of heat exchanger

ab
ility
ot p
❑ Vehicles with optional

wit
, is n
equipment only.
h re
hole
❑ Location: in rear left spec

wheel housing
es, in part or in w
t to the co
9 - Retaining clip
rrectness of i
10 - Radiator outlet coolant - G62-

l purpos
❑ Blue, 4-pin
❑ With coolant temperature display sender - G2-
nform
ercia
❑ For engine control unit

m
at
❑ Before removing, release pressure in cooling system if necessary.

om
ion
c
❑ Checking ⇒ Rep. gr. 01 ; Interrogating and erasing fault memory .

in t
or
his
ate
11 - Connector
do
priv
cum
or
12 - Thermal switch for air conditioning shut-off - F163- and Thermal switch for radiator fan third speed - F165-
f
en
ng
t.
yi Co
❑ Brown, 4-pin Cop py
t. rig
gh
ht
pyri by
Vo
o
by c lksw
❑ Vehicles with air conditioner ⇒ Rep. gr. 87 . Prote
cted AG.
agen
❑ On vehicles without air conditioning, filler plug

Sharan 1996 ➤
13 - 10 Nm
14 - Air conditioning system coolant temperature sender - G110-
❑ 2polig
❑ Vehicles with air conditioner ⇒ Rep. gr. 87 .
15 - Bracket
16 - To top of radiator
18 - Oil cooler
❑ Removing and installing ⇒ page 80 , Dismantling and assembling oil filter bracket: engine code AJH
19 - From back of heat exchanger
❑ Vehicles with optional equipment only.
❑ Location: in rear left wheel housing
20 - 20 Nm
21 - Coolant pipe
22 - Cap
❑ Check using cooling system tester - V.A.G 1274- and adapter for cooling system tester - V.A.G 1274/9-
❑ The pressure relief valve must open at a pressure of 1.4…1.6 bar
23 - Seal
❑ Observe installation position on cap
❑ Renew if damaged . Volkswagen AG
gen AG does
swa
24 - Expansion tank y Volk not
gu
db ara
❑ Test cooling system for leaks orisusing cooling system tester - V.A.G 1274-
e nteand adapter
eo
for cooling system
tester - V.A.G 1274/8- . auth
ra
ss c
❑ Observe markings ⇒ page 101 Draining and filling coolant
ce
le
un
pt
an
25 - From heat exchanger

d
itte
y li
rm
ab

pe
ility
ot
26 - Connecting piece, 30 Nm
wit
, is n
h re
❑ For coolant presupply line

hole
spec
es, in part or in w
27 - Coolant supply line

t to the co
❑ for turbocharger
rrectness of i
28 - Coolant pump
l purpos
❑ Check for ease of movement.

❑ If damaged or leaking, renew complete.
nform
ercia

m
29 - Toothed belt
com
tion in

r
te o
thi
s
iva
❑ Check for wear

do
r
rp
cum
❑ Do not kink
fo
en
ng
t.
yi
❑ Removing, installing and tensioning ⇒ page 38 .
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
96
agen
Prote AG.
Rep. gr.19 - Cooling
Sharan 1996 ➤
n AG. Volkswag4-cylinder
en AG injection engine (5-valve), mechanics - Edition 06.2019
lkswage does
not
Vo gu
by
1.2.2 Parts of cooling system, engine side: engine code AWC
ara
ed nte
oris eo
th
au ra
ss c
1 - Bracket
ce
le
un
pt
an
d
❑ For continued coolant

itte
y li
circulation pump
erm
ab
ility
ot p
2 - Continued coolant circula‐
wit
is n
tion pump - V51-
h re
ole,
spec
❑ Black 2-pin connector
t to the co
3 - 10 Nm
rrectne
4 - To heat exchanger
s
coolant hoses
s o
⇒ page 100
cial p
f inform
5 - Connector
mer
atio
❑ Black, 2-pin
om
n
c
i
❑ For coolant temperature
or
n thi
e
sender
t
sd
iva
o
pr
c
6 - Retaining clip
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
7 - Connector
gh ht
pyri by
Vo
o
❑ Black, 2-pin
c by lksw
cted agen
Prote AG.
❑ For low coolant indicator
sender.
8 - Cap
❑ Note installation posi‐
tion of oil seal in sealing
cap
❑ Renew seal if damaged
❑ Check using cooling
system tester - V.A.G
1274- with adapter -
V.A.G 1274/1A- and
adapter - V.A.G
1274/7- .
❑ The pressure relief valve must open at a pressure of 1.4…1.6 bar
9 - Expansion tank
❑ Test for leaks in cooling system using cooling system tester - V.A.G 1274- and adapter - V.A.G 1274/7- .
❑ Observe markings ⇒ page 101 Draining and filling coolant
10 - From heat exchanger
11 - O-ring
12 - 20 Nm
13 - Coolant pipe
❑ From bottom of radiator.

Sharan 1996 ➤
15 - Upper coolant hose

❑ To top of radiator
16 - Oil cooler
❑ Removing and installing ⇒ page 82 , Dismantling and assembling oil filter bracket: engine code AWC
17 - 15 Nm
18 - Connection
❑ For thermostat
19 - O-ring
❑ Renew
20 - Thermostat
❑ Observe installation position ⇒ page 108 , removing and installing thermostat.
❑ Checking: heat thermostat in water.
❑ Begins to open at approx. 87°C
❑ For coolant presupply line
23 - Coolant pump
❑ Check for ease of movement. AG. Volkswagen AG d
agen
❑ If damaged or leaking, renew complete. Volksw
oes
not
gu
by ara
❑ Removing and installing ⇒ page 107 rised
nte
ho eo
ut
24 - Toothed belt ss a ra
c
ce
e
nl
pt
du
an
❑ Check for wear

itte
y li
erm
ab
❑ Do not kink
ility
ot p
❑ Removing, installing and tensioning ⇒ page 38 .

wit
, is n
h re
25 - Coolant distribution housing

hole
spec
es, in part or in w
t to the co

26 - Radiator outlet coolant - G62-
rrectness of i
❑ Black, 2-pin
l purpos
❑ For engine control unit

nf
ercia
❑ Checking ⇒ Rep. gr. 01 ; Interrogating and erasing fault memory .

orm
m
atio
27 - Connection
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
1.3 Connection diagrams for coolant hoses

Coolant hose schematic diagram: engine code AJH
⇒ page 99
Coolant hose schematic diagram: engine code AWC
⇒ page 100
1.3.1 Coolant hose schematic diagram: engine code AJH
1 - Cylinder block/cylinder
head
2 - Turbocharger
3 - Coolant circulation pump -
V50-
4 - Connection
5 - Heat exchanger for heater
6 - Expansion tank
7 - Coolant pipe
8 - Gear oil cooler
❑ Only on vehicles with
automatic gearbox
AG. Volkswagen AG d
9 - Upper coolant hose agen oes
olksw not
byV gu
ara
d
10 - Radiator orise nte
h eo
ut ra
11 - Lower coolant hose ss a c
ce
le
12 - Oil cooler
un
pt
an
d
itte
y li
13 - Thermostat
rm
ab
pe
ility
14 - Coolant pump
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
1.3.2 Coolant hose schematic diagram: engine code AWC
1 - Turbocharger
2 - Connection
3 - Continued coolant circula‐
tion pump - V51-
4 - Heat exchanger for heater
5 - Expansion tank
6 - Coolant pipe
7 - Gear oil cooler
automatic gearbox
AG. Volkswagen AG d
agen oes
8 - Upper coolant hose Volksw not
gu
d by ara
e
9 - Radiator horis nte
eo
aut ra
10 - Lower coolant hose ss c
ce
le
un
11 - Oil cooler
pt
an
d
itte
y li
12 - Coolant pump/thermostat
rm
ab
pe
ility
13 - Cylinder head/cylinder
ot
wit
, is n
block
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
1.4 Draining and adding coolant

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
♦ Refractometer - T10007-
wit
is n
h re
ole,
spec
6208-
t to the co
♦ Pliers for spring-type clips - VAS 5024-

Not illustrated:
rrectne
♦ Cooling system charge unit - VAS 6096-

Draining
ss o
cial p
– Remove engine cover panel.

inform
mer
– Open cap on coolant expansion tank.

atio
om
n
c
i
or
WARNING
thi
te
sd
iva
o
pr
Hot steam may escape when expansion tank is opened. Place

um
r
fo
en
ng
rag over cap and open with caution.

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
4-cylinder injection engine
en AG. V (5-valve),
olkswagen AGmechanics - Edition 06.2019
ag does
ksw not
y Vol gu
Vehicles with engine ed code AJH
b ara
nte
oris eo
h
– Pull the bottom
au
t hose off the radiator. ra
c
ss
ce
e
nl
pt
du
an
itte
– Pull out retaining clip -arrow- for coolant hose and remove
y li
erm
ab
coolant hose from quick-release coupling of radiator.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
o
– To drain coolant from engine, also remove coolant hose from
rm
m
atio
oil cooler -arrow-.
om
n in
or c
thi
te
sd
a
Note
iv
o
r
rp
cu
o
m
f
en
ng
Please observe disposal instructions!

t.
yi Co
Cop py
t. rig
gh
Replenishing
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
For mixing only tap water must be used. Tap water does not
have the required quality to ensure the coolant's function.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
thor Sharan 1996 e➤
o
u
a engine (5-valve), mechanics - Edition 06.2019r ac
ss
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
♦ Only use coolant additive G 12 in accordance with
, is n
h re
TL VW 774 F. Identification: purple colour
hole
spec
♦ G 12 and coolant additives marked "In accordance with
es, in part or in w
t to the co
TL VW 774 F" prevent frost and corrosion damage, scaling
and also raise the boiling point of coolant. For these reasons,
the cooling system must be filled all-year-round with a frost
rrectness of i
and corrosion protection additive.
l purpos
♦ G 12 purple (in accordance with TL W 774 F) can be mixed
with existing coolant additives G 11 and G 12 red!
nform
ercia
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
m
at
ical climates. om
ion
c
in t
r
♦ Frost protection is required down to about -25°C (in countries

o
his
te
with arctic climates: down to about -35°C).

a
do
priv
cum
or
♦ Do not reduce the coolant concentration by adding water even

f
en
g
in warmer seasons and in warmer countries. The coolant ad‐

n
t.
yi Co
op
ditive concentration must be at least 40%. C py
t. rig
gh ht
yri by
♦ If for climatic reasons greater frost protection is required, the cop Vo
by lksw
amount of G 12 can be increased, but only up to 60% (frost cted agen
Prote AG.
protection to about -40°C). Otherwise frost protection and
cooling effectiveness are reduced again.
♦ The refractometer - T10007- is recommended for determining
the current anti-freeze density.
♦ If radiator, heat exchanger, cylinder head or cylinder head
gasket is renewed, do not reuse old coolant.
Recommended mixture ratios:
Vehicle equipment Frost protection to Anti-freeze quantity 1) G 12 2) Water 2) 3)

One -25°C 40% 2.8 l 4.2 l
Heat exchanger -35°C 50% 3.5 l 3.5 l
Two -25°C 40% 3.6 l 5.4 l
Heat exchanger -35°C 50% 4.5 l 4.5 l
Two heat exchangers -25°C 40% 3.8 l 5.8 l
And auxiliary coolant -35°C 50% 4.8 l 4.8 l
heater
1) The amount of anti-freeze must not exceed 60%; frost protec‐

tion and cooling effectiveness will decrease if amount of anti-
freeze is too high.
2) Coolant capacities for vehicles with manual gearbox. For vehi‐
cles with automatic gearbox, coolant capacity for G 12 and water
is increased by approx. 0.1 l in each case.
3) Only use clean tap water.
With cooling system charge unit - VAS 6096-
– Screw adapter - V.A.G 1274/7- or adapter for cooling system
tester - V.A.G 1274/8- onto expansion tank.
– Fill coolant circuit using cooling system charge unit - VAS
6096- ⇒ operating instructions for cooling system charge unit
- VAS 6096- .

Sharan 1996 ➤
Without cooling system charge unit - VAS 6096-

– Push lower coolant hose onto radiator and secure using
spring-type clip.
– Install lower coolant hose and secure with retaining clip
-arrow-.
– Push coolant hose onto union of oil cooler and secure with a
spring-type clip.
– Turn off heater controls.
– Press upper radiator hose down.
– Slowly fill coolant to max. marking on expansion tank. Filling

takes approx. 5 minutes. en AG. V
olkswagen AG
ag does
lksw not
– Start engine and run at increased engine
yV
o speed (approx. 2500 gu
db ara
rpm). Fill with coolant up to max.
or
isemark on expansion tank. nte
h eo
ut ra
With or without cooling system
ss charge unit - VAS 6096-
a c
ce
e
– Close expansion tank cap.

nl
pt
du
an
itte
y li
– Run engine until radiator fan cuts in.

erm
ab
ility
ot p
– Then run for about a further 10 minutes at increased speed

wit
, is n
(approx. 2500 rpm).

h re
hole
– Check coolant level and top-up if necessary. The coolant level

spec
es, in part or in w
must be at the max. marking when the engine is at normal

t to the co
operating temperature, and between the min. and max. mark‐

ings when the engine is cold.
rrectness of i
WARNING
l purpos
Hot steam may escape when expansion tank is opened. Place

rag over cap and open with caution.
nf
ercia
orm
m
atio
om
– Install noise insulation tray ⇒ Rep. gr. 50 .

n in
or c
thi
te
sd
iva
1.5 Removing and installing radiator and fan

o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
104
cted agen
Prote AG.
Rep. gr.19 - Cooling
Sharan 1996 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
♦ Drip tray - V.A.G 1306- or drip tray for workshop hoist - VAS atio
om
n
6208-
c
i
or
n thi
te

sd
iva
o
pr
cum
r

fo
en
ng
t.
yi Co
Removing Cop py
t. rig
gh ht
yri
– Drain coolant ⇒ page 101 . p by
co Vo
by lksw
cted agen
Vehicles with engine code AJH Prote AG.
– Pull upper coolant hose off radiator.

– Detach bottom coolant hose from the clips on the air ducting.
– Pull off air hoses from charge air cooler.
– Remove air pipe between charge air cooler and throttle valve
control module ⇒ page 151 , Removing and installing parts of
the charge air cooling system: engine code AJH
– Pull connectors off thermal switch, secondary air pump motor
- V101- and radiator fan.
– Remove thermal switch.
– Remove reinforcement strut.

Sharan 1996 ➤
– Unscrew fan ring securing bolts and remove fan ring with fan.
Vehicles with air conditioner:
⇒ page 106 .
– Remove lateral radiator securing bolts.
– Remove radiator with charge air cooler downwards.
– Remove charge air cooler from radiator.
– Pull out retaining clip for upper coolant hose and remove cool‐
ant hose from quick-release connector of radiator.
– Detach lower coolant hose from bracket on the air ducting.
– Remove bracket for lower coolant hose.
– Remove air pipe between charge air cooler and throttle valve
control module ⇒ page 152 , Removing and installing parts of
the charge air cooling system: engine code AWC
– Pull connectors off thermal switch and radiator fan.
Vehicles with air conditioner:
⇒ page 106 .
– Remove charge air cooler from radiator. AG. Volkswagen AG d
agen oes
olksw not
y V gu
Additional information and assembly swork d b for vehicles with air ara
i e nte
conditioner thor eo
au ra
ss c
ce
e
WARNING
nl
pt
du
an
itte
y li
Do not open the air conditioner refrigerant circuit.

erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
To prevent damage to condenser, refrigerant lines or hoses, en‐

sure that lines and hoses are not stretched, kinked or bent.
rrectness of i
– Remove retaining clamp(s) for refrigerant lines.

l purpos

nf
ercia
– Remove radiator grille with trim frame ⇒ Rep. gr. 66 .

rm
m
atio
m
– Remove left headlight ⇒ Rep. gr. 94 .

o
n in
or c

thi
te
sd
iva
– Unscrew fan ring securing bolts and remove fan ring with fan.
r
rp
cu
o
m
f
en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
– Remove condenser from radiator.
c by lksw
cted agen
Prote AG.
– Secure condenser to body so that the refrigerant lines/hoses
are not under tension.

Sharan 1996 ➤

– Remove charge air cooler from radiator.
Installing
note the following:
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Check headlight adjustment and correct if necessary ⇒ Main‐
tenance ; Booklet 10.1
– Install radiator grille with trim frame ⇒ Rep. gr. 66 .
1.6 Removing and installing coolant pump
Special tools and workshop AG. Volkswagen AG d

equipment required agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
6208-

Sharan 1996 ➤
en AG. V mechanics
olkswagen AG - Edition 06.2019
ag does
ksw not
y Vol gu
♦ Pliers for spring-type clips ed - VAS 5024-
b ara
nte
oris eo
h
Removing au
t ra
c
ss
ce
le
un
pt
an
d
Note
itte
y li
rm
ab
pe
ility
♦ Always renew seals and gaskets.
ot
wit
, is n
♦ The lower part of the toothed belt guard need not be removed.
h re
hole
spec
♦ The toothed belt stays on the crankshaft toothed-belt pulley.
es, in part or in w
t to the co
♦ Cover toothed belt with a cloth to protect it from coolant before
removing coolant pump.
rrectness of i
l purpos

– Remove poly V-belt tensioning element.
nform
mercia
– Remove upper and centre part of toothed belt guard
a
com
ti
⇒ page 14 and ⇒ page 38 , Removing, installing and tensioning
on in
toothed belt ⇒ page 14 .
r
te o
thi
s
iva
do
– Remove toothed belt from coolant pump belt sprocket
r
rp
cum
⇒ page 38 , Removing, installing and tensioning toothed belt.
fo
en
ng
t.
yi
– Unscrew coolant pump securing bolts -1- and remove coolant
Co
Cop py
pump -2-.
t. rig
gh ht
pyri by
Vo
o
Installing
c by lksw
cted agen
Prote AG.
note the following:
– Moisten new O-ring with coolant.
– Insert coolant pump into cylinder block and tighten securing
bolts. Specified torque: 15 Nm
Note
The coolant pump plug faces downwards.

– Install poly V-belt ⇒ page 18 .
1.7 Removing and installing thermostat

Sharan 1996 ➤

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
6208-
nf
ercia
or

m
m
atio
m
Removing
o
n in
or c
thi
te
sd
iva
o
r
Note
rp
cu
o
m
f
en
ng
t.
yi Co
Always renew seals and gaskets. t. Cop py
rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
4-cylinder injection engine
AG. V(5-valve),
olkswagen Amechanics - Edition 06.2019
n G do
wage es n
Volks ot g
– Pull coolant hose ed off
by connection -3-. ua
ran
oris te
– Unscrew securing
auth bolts -4- of connection -3-, and removee or a
connection
ss -3- together with thermostat -1-. c
ce
e
nl
pt
Installing
du
an
itte
y li
erm
ab
ility
note the following:
ot p
wit
, is n
– Moisten new O-ring -2- with coolant.
h re
hole
spec
– Fit connection -3- with thermostat -1- into engine block.
es, in part or in w
t to the co
– Tighten securing bolts -4-. Specified torque: 15 Nm
rrectness of i
1.8 Checking coolant circulation pump -
l purpos
V50- (AJH) or continued coolant circu‐
nform
ercia
lation pump - V51- (AWC)

m
at
om
ion
c
in t
or
♦ Voltage tester - V.A.G 1527B-
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Adapter set - V.A.G 1594C-
♦ Current flow diagram

Sharan 1996 ➤
Prerequisites for testing
• Fuse 18 must be OK (vehicles with engine code AJH).

. Volkswagen AG
gen AG does
• Fuse 16 must be OK (vehicles with engine code AWC).
Vol
ksw
a
not
by gu
ara
Test sequence ed nte
oris eo
th
au ra
Vehicles with engine code AJH ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew securing nuts -arrows- of heat shield for coolant cir‐
culation pump - V50- from bulkhead.
rrectness of i
– Pull heat shield forwards slightly.
l purpos
– Pull 2-pin connector off continued coolant circulation pump -

V50- .
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
– Pull 2-pin connector off continued coolant circulation pump -
Co
op py
V51- -arrow-.
. C rig
ht ht
rig by
py
Checking function
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Join contacts of coolant circulation pump - V50- and continued

coolant circulation pump - V51- to battery using adapter cables
from auxiliary measuring set - V.A.G 1594C- . Pump must run.
If pump does not run:
– Renew pump.
If pump runs: ⇒ page 112
Checking activation
– Switch ignition on and off again.
– Connect voltage tester - V.A.G 1527B- using auxiliary leads

from auxiliary measuring set - V.A.G 1594C- to connector de‐
tached from coolant circulation pump - V50- or continued
coolant circulation pump - V51- . LED must light up.
Note
This check must be performed within 3 minutes of switching igni‐

tion off.
AG. Volkswagen AG d
agen
If LED does not light up: olksw
oes
not
byV gu
ar
d
– Locate and eliminate orisopen circuit referring to current flow di‐ ante
e
eo
agram: ⇒ Currentauflow
th diagrams, Electrical fault finding and ra
Fitting locations.ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
20 – Fuel supply system

1 Removing and installing parts of fuel
supply system
Note
♦ Hose connections are secured with either spring-type or

clamp-type clips.
♦ Fuel hoses on engine must be secured with spring-type clips
only. The use of crimp-type or screw-type clips is not permis‐
sible.
♦ It is recommended that spring-type clips should be installed
- V.A.G 1921- .
Removing and installing fuel tank with attachments and fuel filter:
engine code AJH ⇒ page 113 .
engine code AWC ⇒ page 116 .
Note safety precautions ⇒ page 119en. AG. Volkswagen AG
ag does
lksw not
Observe rules for cleanliness
by ⇒ page 120 .
Vo gu
ara
d
ise nte
Observe crash fuel shut-off:
ut
ho
r
engine code AWC ⇒ page 123 . eo
ra
sa c
Repairing accelerator
s mechanism: engine code AJH
ce
e
⇒ page 131 .
nl
pt
du
an
itte
y li
Adjusting accelerator cable: engine code AJH ⇒ page 131 .

erm
ab
ility
ot p
Electronic power control (EPC): engine code AWC ⇒ page 134 .

wit
, is n
h re
Activated charcoal filter system ⇒ page 140 .

hole
spec
1.1 Removing and installing fuel tank with

es, in part or in w
t to the co
attachments and fuel filter

rrectness of i
engine code AJH ⇒ page 113

l purpos
engine code AWC ⇒ page 116
nf
ercia
1.1.1 Removing and installing fuel tank with attachments and fuel filter: engine
rm
m
atio
code AJH
om
n in
or c
thi
te
sd
iva
Note
r
rp
cu
o
m
f
en
ng
t.
yi
Ensure, on completion of all work on the fuel delivery unit and fuel gauge that the fuel supply and fuel return
Co
op py
hoses do not touch the fuel tank (transfer of pumping noises).
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Removing and installing parts of fuel supply system 113

Sharan 1996 ➤
1 - Cap
2 - Seal
❑ If damaged only renew
together with cap.
3 - Clamp ring
4 - Rubber cup
5 - Gravity valve
❑ To remove valve unclip
upwards out of filler
neck
❑ Check valve for
through-flow. Valve ver‐
tical: open; valve tilted
45°: closed
6 - O-ring
7 - Bleeder valve agen
AG. Volkswagen AG d
oes
lksw not
❑ Cannot be removed, d by
Vo
re‐ gu
ara
new only otogether
ris
e with nte
filler neck
aut
h eo
ra
⇒ Item s 17 (page 115)
s c
ce
le

un
pt
an
d
itte
y li
8 - Pressure retention valve

erm
ab
ility
❑ For fuel tank breather.

ot p
wit
is n
❑ Checking ⇒ page 116 ,

h re
ole,
⇒ page 116 .
spec
9 - Return line
t to the co
❑ blue
rrectne
❑ Clipped onto fuel tank

❑ From fuel return pipe on
ss
fuel rail ⇒ Rep. gr. 24

o
cial p
f in
10 - Union nut, 75 Nm
form
mer
❑ Remove and install using union nut tool - 3217- .

atio
om
n
c
11 - Connector
i
or
n thi
te
❑ Black, 4-pin
sd
iva
o
pr
❑ For fuel gauge sender - G- and fuel pressurisation pump - G6- .

um
r
fo
en
ng
t.
yi
12 - Flange
Co
Cop py
t. rig
❑ Note installation position on fuel tank ⇒ page 115 opyri
gh by
Vo
ht
❑ Letters “V” (Vorlauf) and “R” (Rücklauf) stamped on underside for supply hose and return hose respec‐
by c lksw
cted agen
tively Prote AG.
13 - Supply hose
14 - Seal
❑ Renew
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange ⇒ Item 12 (page 114) .
15 - Return hose
114 Rep. gr.20 - Fuel supply system

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
lksw not
16 - 6 Nm byV
o gu
ara
ed
is nte
17 - Filler neck ut
hor eo
a ra
❑ With expansion tank and breather valve ss c
ce
e
nl
pt
18 - Breather line
du
an
itte
y li
erm
ab
ility
❑ To junction piece between activated charcoal filter and activated charcoal filter solenoid valve 1
ot p
wit
⇒ page 141 , Repairing parts of activated charcoal filter system: engine code AJH
, is n
h re
hole
19 - Sealing collar
spec
es, in part or in w
t to the co
20 - Clamp ring
rrectness of i
❑ Check for ease of movement
l purpos
22 - Breather line
nf
ercia
orm
m
23 - 25 Nm
atio
om
n in
c
24 - Fuel
or
thi
e
❑ When removing, support using engine and gearbox jack - V.A.G 1383 A-
t
sd
iva
o
r
rp
cu
25 - Securing strap
o
m
f
en
ng
t.
yi
❑ Note different lengths.
Co
Cop py
.
ht rig
rig ht
py by
co Vo
26 - 20 Nm
by lksw
cted agen
Prote AG.
27 - Bracket
❑ For fuel filter.
28 - Supply line
❑ black
❑ To fuel supply pipe on fuel rail ⇒ Rep. gr. 24
29 - Fuel filter
❑ Installation position: arrow indicates direction of flow.
30 - Fuel gauge sender - G-
31 - Fuel delivery unit
❑ Checking fuel pump ⇒ page 123 .
32 - Filter strainer
Installation position of fuel delivery unit flange

Marking on flange must align with marking on fuel tank -arrows-.
Note
After installing fuel delivery unit flange, check that supply, return
and breather lines are still clipped onto fuel tank.

Sharan 1996 ➤
Checking breather valve

Valve in rest position: closed
Valve pushed in direction of arrow: open
Checking pressure retention valve

From gravity valve, pressure retention valve is open in both di‐
rections of flow -arrow 1-.
From junction piece between activated charcoal filter/activated
charcoal filter solenoid valve 1, it is only open in one direction of
flow -arrow 2-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
1.1.2 Removing and installing fuel tank with attachments and fuel filter: engine aut
ho eo
ra
c
s
code AWC s
ce
e
nl
pt
du
an
itte
y li
erm
Note ab
ility
ot p
wit
, is n
♦ Ensure, on completion of all work on the fuel delivery unit and fuel gauge that the fuel supply and fuel return
h re
hole
hoses do not touch the fuel tank (transfer of pumping noises).

spec
es, in part or in w
♦ Fuel pump relay - J17- ⇒ page 119

t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
1 - Cap
2 - Fastener
3 - Seal
4 - Clamp ring
5 - Rubber cup
6 - Gravity valve
❑ To remove valve unclip
upwards out of filler
neck
❑ Check valve for
through-flow. Valve ver‐
tical: open; valve tilted
45°: closed
7 - O-ring n AG. Volkswagen AG do
lkswage es n
o ot g
❑ Renew if damaged d byV ua
ran
ir se tee
8 - Bleeder valve autho
or
ac
❑ Cannot be removed, re‐ ss
ce
e
new only together with

nl
pt
du
an
filler neck
itte
y li
⇒ Item 14 (page 117)
erm
ab
ility
ot p
wit
, is n
h re
9 - Pressure retention valve
hole
spec
❑ For fuel tank breather.
es, in part or in w
t to the co
10 - Return line
rrectness of i
❑ blue
l purpos

❑ From fuel return pipe on
nf
ercia
o
fuel rail ⇒ Rep. gr. 24
rm
m
atio
m
11 - Supply line
o
n in
or c
❑ black
thi
te
sd
iva

o
r
rp
cu
o

f
en
ng
t.
yi Co
❑ To fuel rail t. Cop py
rig
gh ht
yri
12 - Connector p by
co Vo
by lksw
❑ Black, 4-pin
cted agen
Prote AG.
❑ For fuel gauge sender - G- and fuel pressurisation pump - G6- .
13 - 6 Nm
14 - Filler neck
❑ With expansion tank and breather valve
15 - Breather line
❑ To junction piece between activated charcoal filter and activated charcoal filter solenoid valve 1
⇒ page 141 , Repairing parts of activated charcoal filter system: engine code AWC
16 - Sealing collar

Sharan 1996 ➤
17 - Clamp ring
18 - Breather line
AG. Volkswagen AG d
❑ Check for ease of movement
ksw
agen oes
n ol ot g
yV ua
20 - 25 Nm edb ran
ris tee
tho
21 - Fuel au
or
ac
ss
❑ When removing, support using engine and gearbox jack - V.A.G 1383 A-
ce
le
un
pt
an
d
22 - Securing strap
itte
y li
rm
ab
❑ Note different lengths.
pe
ility
ot
wit
, is n
h re
23 - 20 Nm
hole
spec
es, in part or in w
24 - Bracket
t to the co
❑ For fuel filter.
25 - Supply line
rrectness of i
❑ black
l purpos

❑ To fuel supply pipe on fuel rail ⇒ Rep. gr. 24
nform
ercia
26 - Fuel filter
m
a
com
❑ Installation position: arrow indicates direction of flow.

ion in
r
te o
27 - Union nut, 75 Nm
thi
s
iva
do
❑ Remove and install using union nut tool - 3217- .

r
rp
cum
fo
en
g
28 - Fuel delivery unit

n
t.
yi Co
op
❑ Note installation position on fuel tank ⇒ page 118
C py
ht. rig
rig ht
❑ Removing and installing ⇒ page 120 py by
co Vo
by lksw
cted
❑ Removing and installing fuel gauge sender ⇒ page 123
agen
Prote AG.
❑ Checking fuel pump ⇒ page 123 .

29 - Seal
❑ Renew
❑ When installing, fit dry in fuel tank opening.
❑ Only moisten with fuel when installing flange of fuel delivery unit
Installation position of fuel delivery unit flange

Marking on sender must align with the marking on fuel tank
-arrows-.
Return line -1- (blue or with blue marking) to connection marked
-R-.
Black supply line -2- to connection marked -V-.
Note
After installing fuel delivery unit flange, check that supply, return
and breather lines are still clipped onto fuel tank.

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
Checking breather valve olksw not
byV gu
ara
ed
Valve in rest position: closed horis nte
eo
aut ra
Valve pushed in direction of arrow: sopen
s c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Checking pressure retention valve
rrectness of i
From gravity valve, pressure retention valve is open in both di‐
l purpos
rections of flow -arrow 1-.

From junction piece between activated charcoal filter/activated
nform
ercia
charcoal filter solenoid valve 1, it is only open in one direction of

flow -arrow 2-.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
Fuel pump relay - J17- - relay position 21 -
rig ht
py by
co Vo
by lksw
Relay is located on lower multifunctional unit relay holder.
cted agen
Prote AG.
Note
♦ If tools are necessary to pull relays or control units out of the

relay plate, first disconnect battery earth strap
♦ Before disconnecting battery earth strap obtain code for radios
with anti-theft coding.
1.2 Safety measures when working on fuel

supply
WARNING

sitions.
hot components.
When removing and installing fuel gauge sender or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
following:

Sharan 1996 ➤
AG. Volkswagen AG d
WARNING
agen oes
olksw not
byV gu
ara
d
Fuel supply lines oriare
se
under pressure! Wrap a cloth around nthe
tee
connection before
aut
h
loosening hose connections. Then releaseor ac
pressure bysscarefully pulling hose off connection.
ce
le
un
pt
an
d
itte
y li
♦ Before beginning work, place an extraction hose close to
rm
ab
pe
ility
sender opening in fuel tank to extract escaping fuel fumes and
ot
switch on exhaust extraction system. If no exhaust gas ex‐
wit
, is n
h re
traction system is available, a radial fan with a displacement
hole
greater than 15 m3/h can be used providing that motor is not
spec
es, in part or in w
in air flow.
t to the co
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
rrectness of i
♦ For safety reasons, fuse No. 14 must be removed from the
l purpos
fuse holder before opening the fuel system. Otherwise the fuel
pump can be activated by the driver door contact switch.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
1.3 Rules for cleanliness
AG.
When working on the fuel supply/injection system, carefully follow

the “5 rules” below:
♦ Thoroughly clean all unions and adjacent areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ If system is open: do not use compressed air if possible. Try
not to move the vehicle.
1.4 Removing and installing fuel delivery

unit

Sharan 1996 ➤
♦ Key for union nut - 3217-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
♦ Torque wrench - V.A.G 1332- (40…200
ss a Nm) c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nf
ercia
orm
m
atio
om
theft coding.
n in
or c
thi
e
– With the ignition switched off, disconnect battery earth strap.

t
sd
iva
o
r
rp
cu
– Remove cover from fuel delivery unit.
o
m
f
en
ng
t.
yi
– Pull 4-pin connector and supply and return lines off flange.
Co
Cop py
t. rig
gh ht
pyri by
Vo
WARNING
co lksw
by
cted agen
Prote AG.
Note

– Unscrew union nut with union nut tool - 3217- .
– Pull flange and seal out of opening in fuel tank.
– Release and remove delivery unit from bayonet connection by
turning to the left.

Sharan 1996 ➤

– Pull fuel delivery unit and seal out of opening in fuel tank.
Note
If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.
Installing
– Installation of fuel delivery unit is carried out in reverse order.
Note
♦ When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.
♦ Insert seal for flange or fuel delivery unit dry into opening of
fuel tank.
♦ Moisten seal with fuel only when installing flange or fuel de‐
livery unit.
♦ Ensure fuel hoses are seated correctly.
♦ After installing fuel delivery unit, check that supply, return and
breather lines are still clipped onto fuel tank.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
♦ Note installation position of fuel delivery unit flange: mark on

rrectne
flange must align with mark -arrows- on fuel tank.

♦ On correct installation of fuel delivery unit, fuel gauge float
s
points in direction of travel A.

s o
cial p
f in

form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
♦ Note installation position of fuel delivery unit flange: mark on

flange must align with mark -arrows- on fuel tank.
1.5 Removing and installing fuel gauge

sender: engine code AWC
Removing
– Remove fuel delivery unit ⇒ page 120 .
– Release connector lugs on lines -3- and -4- and pull off.
– Lift retaining tabs -1- and -2- using a screwdriver and pull fuel
gauge sender off downwards -arrows-.
Installing
– Insert fuel gauge sender into guides on fuel delivery unit and
press upwards until it engages.
– Install fuel delivery unit ⇒ page 120 . n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
1.6 Crash fuel shut-off: engine code AWC

un
pt
an
d
itte
y li
Function
erm
ab
ility
ot p
Vehicles with an airbag are fitted with a crash fuel shut-off. It re‐
wit
is n
duces the danger of a fire in a crash as the fuel pump is switched

h re
ole,
off via the fuel pump relay. The system also improves the starting
spec
characteristics of the engine. When door is opened, the fuel pump

t to the co
is activated for 2 seconds to build up pressure in the fuel system.

When opening fuel system:
rrectne
Note safety precautions ⇒ page 119 .

– Check activation of fuel pump relay - J17- using testing system
ss
- V.A.G 1466A- and current flow diagram for reference ⇒ Cur‐

o
cial p
rent flow diagrams, Electrical fault finding and Fitting locations.

inform
mer
1.7 Checking fuel pump

atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
♦ Key for union nut - 3217-

t to the co
♦ K-Jetronic pressure tester - V.A.G 1318-

♦ Adapter set - V.A.G 1318/10-12-
rrectne
♦ Adapter - V.A.G 1318/11-

ss o
♦ Hose adapter - V.A.G 1318/16-

cial p
f inform

mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

. Volkswagen AG Sharan 1996 ➤
gen AG
4-cylinder
Volkinjection
swa engine (5-valve),
does
nmechanics
ot
- Edition 06.2019
by gu
ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Injection rate comparison meter - V.A.G 1348-

♦ Tester - V.A.G 1466A-
set - V.A.G 1594C-
♦ Multimeter - V.A.G 1715-
Not illustrated
♦ Measuring container
Test conditions
• Fuse 14 must be OK.

Sharan 1996 ➤
Fuse holder on vehicles with engine code AJH.
Fuse holder on vehicles with engine code AWC.

switched off.
AG. Volkswagen AG d
agen oes
lksw not
Note d by Vo gu
ara
rise nte
ho eo
Observe functional description
s aut
of crash fuel shutoff on vehicles ra
c
with engine code AWC s⇒ page 123 . ce
le
un
pt
an
d
itte
Checking function and voltage supply

y li
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec
Before carrying out further work, battery earth strap may have to
t to the co
be disconnected. First check whether a coded radio is fitted. Ob‐

tain anti-theft coding first if necessary.
rrectne
– Remove cover from fuel delivery unit.

– Briefly operate starter. Fuel pump must be heard to run.
ss o
cial p
– Switch off ignition.

f inform
mer
If the fuel pump does not start:

atio
m

o
n
c
i
or
n thi
te
sd
a
– Separate 6-pin connector -arrow- on left behind battery.

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
– Connect remote control for V.A.G 1348 - V.A.G 1348/3A- us‐

ing adapter lead - V.A.G 1348/3-2- and auxiliary leads from
auxiliary measuring set - V.A.G 1594 A- or auxiliary measuring
set - V.A.G 1594C- to contact 2 of connector and battery pos‐
itive (+).
AG. Volkswagen AG d
agen oes
olksw not
V
– Pull off 2-pin connector from no. 1 ecylinder
d by injector -arrow-. gu
ara
nte
ris
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Connect remote control for V.A.G 1348 - V.A.G 1348/3A- us‐
ing adapter lead - V.A.G 1348/3-2- and auxiliary leads from
l purpos

set - V.A.G 1594C- to contact 1 of connector and battery pos‐
itive (+).
nf
ercia
orm
m
atio
om
n in
– Operate remote control for V.A.G 1348 - V.A.G 1348/3A- .
or c
thi
te
If fuel pump runs:

sd
iva
o
r
rp
cu
– Check activation of fuel pump relay - J17- using testing system

o
m
f
en
ng
- V.A.G 1466A- and current flow diagram for reference ⇒ Cur‐

t.
yi Co
op
rent flow diagrams, Electrical fault finding and Fitting locations. C py
ht. rig
rig ht
by
If fuel pump does not run: copy Vo
by lksw
cted agen
Prote
– Pull 4-pin connector off fuel delivery unit flange.
AG.
– Connect voltage tester - V.A.G 1527B- to outer contacts of

connector using auxiliary leads from auxiliary measuring set -
V.A.G 1594 A- or auxiliary measuring set - V.A.G 1594C- .
– Operate remote control. LED must light up.
If LED does not light up:
– Locate and eliminate open circuit referring to current flow di‐
agram: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
If LED lights up (voltage supply OK):
– Unscrew union nut with union nut tool - 3217- .
– Check that electrical wires between flange and fuel pump are
connected.
If no open circuit can be found:
– Fuel pump defective. Renew fuel delivery unit ⇒ page 120 ,
removing and installing fuel delivery unit.

Sharan 1996 ➤
1.7.1 Checking delivery rate

Test conditions
• Voltage supply OK.
• Remote control for V.A.G 1348 - V.A.G 1348/3A- is connected.
Test sequence
– Remove filler cap from fuel tank filler neck.
– Pull off supply line -arrow- at fuel supply pipe of fuel rail and
catch escaping fuel with a cloth.
WARNING
G. Volkswage
Fuel system is under pressure! lksw
aBefore
gen A openingnthe system,
AG do
es n
place a cloth around the connection.
by Vo Then release pressure by
ot g
ua
carefully loosening the
o
ir sconnection.
ed ran
te
th eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Connect K-Jetronic pressure tester - V.A.G 1318- with adapter
ot
wit
, is n
set - V.A.G 1318/10-12- to fuel supply line.

h re
hole
– Connect hose adapter - V.A.G 1318/16- to adapter - V.A.G spec

es, in part or in w
1318/11- of K-Jetronic pressure tester - V.A.G 1318- and hold t to the co

it in a measuring container.
– Open the pressure tester shut-off tap. The lever then points in
rrectness of i
direction of flow -A-.

l purpos
– Operate remote control for V.A.G 1348 - V.A.G 1348/3A- .

Then slowly close shut-off tap until a pressure of 3 bar is dis‐
played on pressure gauge. From this point on do not move
nform
ercia
position of shut-off tap.

m
– Empty measuring container.

com
tion in
r
– The quantity delivered by the fuel pump depends on the bat‐

te o
thi
tery voltage. Therefore, connect multimeter to vehicle battery

s
iva
do
r
using adapter cables from auxiliary measuring set - V.A.G

rp
cum
fo
1594 A- or auxiliary measuring set - V.A.G 1594C- .

en
ng
t.
yi Co
op
– Operate remote control for V.A.G 1348 - V.A.G 1348/3A- for C py
t. rig
30 seconds and measure battery voltage in the process.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
– Compare quantity of fuel delivered with specification.
AG.
-*- Minimum delivery volume cm3/30 sec.

-**- Voltage at fuel pump with engine stationary and pump running
(approx. 2 volts less than battery voltage).
Reading example:
During the test a voltage of 12.2 volts is measured at the battery.
As the voltage at the pump is approx. 2 volts less than the battery
voltage, this will equate to a minimum delivery rate of 550 cm3/30
s.
If the minimum delivery rate is not attained:
– Check the fuel pipes for possible restrictions (kinks) or block‐
ages.

Sharan 1996 ➤
– Pull supply hose -1- off inlet to fuel filter.

– Connect K-Jetronic pressure tester - V.A.G 1318- with adapter
set - V.A.G 1318/10-12- to hose.
– Repeat delivery rate check.
If the minimum delivery rate is now attained:
– Replace fuel filter. agen
AG. Volkswagen AG d
oes
olksw not
V gu
If the minimum delivery d brate is again not attained:
y ara
rise nte
o e
– Remove fuel adelivery
ut
h
unit and check for dirt in filter strainer. or a
ss c
Only if still no fault has been detected:
ce
le
un
pt
an
d

itte
y li
rm
ab
pe
ility
ot
If delivery rate has been attained, but a fuel supply system fault
wit
, is n
is still suspected (e.g. intermittent failure of fuel supply system):
h re
hole
spec
– Check current draw of fuel pump as follows:
es, in part or in w
t to the co
– Reconnect all disconnected fuel lines.
– Connect multimeter - V.A.G 1715- using current clamp to wire
rrectness of i
of 4-pin connector contact 1 -arrow- of wiring harness.
l purpos
– Start engine and run at idling speed.

– Measure current draw of fuel pump. Specification: max. 8 am‐
nform
ercia
peres
m
a
com
tion in
r
te o
Note
thi
s
iva
do
r
rp
If the fuel system malfunction is intermittent, you can perform the

um
fo
en
check during a road test, but a 2nd person is necessary.

ng
t.
yi Co
Cop py
t. rig
gh
If the current draw is exceeded:
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.7.2 Checking non-return valve for fuel pump

Test conditions
• Remote control for V.A.G 1348 - V.A.G 1348/3A- is still con‐
nected.
• K-Jetronic pressure tester - V.A.G 1318- is still connected.
Note
At the same time, this test checks for leaks in the fuel supply line
connections from the fuel delivery unit to the point at which the K-
Jetronic pressure tester - V.A.G 1318- is connected.

Sharan 1996 ➤
Test sequence
– Close shut-off valve of K-Jetronic pressure tester - V.A.G
1318- (lever perpendicular to direction of flow -position B-).
– Operate remote control for V.A.G 1348 - V.A.G 1348/3A- at
short intervals, until a pressure of approx. 3 bar has built up.
– If pressure builds up too high, relieve excess pressure by
carefully opening shut-off tap.
WARNING
Danger of spray when opening shut-off tap. Hold econtainer

over free connection of pressure tester. olks
wag es n
o
yV t gu
db ara
rise nte
ho eo
– ut
Watch pressure drop on pressures agauge. Pressure must re‐ ra
c
main above 2.5 bar for 10 minutes.
s
ce
e
nl
pt
du
If the pressure drops further:
an
itte
y li
erm
ab
– Check line connections for leaks.
ility
ot p
wit
If no fault in lines is detected:
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
2 Accelerator pedal
2.1 Repairing accelerator mechanism

Engine code AJH
1 - Accelerator cable agen

AG. Volkswagen AG d
oes
lksw not
❑ Adjusting ⇒ page 131 d by Vo gu
ara
❑ Do not reuse damaged rise nte
tho eo
accelerator cable, re‐ s au ra
c
new. s
ce
e
nl
pt
du
2 - Cable cam
an
itte
y li
erm
❑ On throttle valve control
ab
ility
module.
ot p
wit
, is n
3 - Retainer
h re
hole
spec
❑ Adjusting accelerator
es, in part or in w
cable ⇒ page 131 .
t to the co
4 - Support bracket
❑ For accelerator cable.
rrectness of i
5 - Kickdown switch - F8-
l purpos
❑ Vehicles with 4-speed

automatic gearbox 099
nform
ercia
❑ On bulkhead.
m
at
❑ Checking ⇒ page 131 ,
om
io
Adjusting throttle cable
n
c
in t
or
on vehicles with auto‐
his
ate
matic gearbox.
do
priv
cum
or
6 - Connector
f
en
ng
t.
yi Co
❑ Black, 2-pin t. Cop py
rig
gh ht
7 - Vibration damper yri
p by
co Vo
by lksw
cted
8 - Spacer sleeve
agen
Prote AG.
9 - Accelerator
10 - Accelerator pedal stop
11 - Stop bolt
12 - Rubber ring
13 - Accelerator pedal shaft
2.2 Adjusting accelerator cable

Procedure
2. Accelerator pedal 131

Sharan 1996 ➤
– Adjust accelerator cable by moving retainer -arrow- at support

bracket, so that full throttle position is attained at cable cam of
throttle valve control module.
Vehicles with 4-speed automatic gearbox 099

♦ Hand multimeter - V.A.G 1526C-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
♦ Spacer 13 mm
um
r
fo
en
ng
t.
yi
Procedure
Co
Cop py
t. rig
– Clamp spacer -1-, a = 13 mm, between accelerator pedal -2-
gh ht
pyri by
and stop -3- and hold accelerator pedal in this position.
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Fully open throttle valve by pulling accelerator cable sleeve

and secure in this position with retainer -arrow-.
– Release accelerator pedal.
– Pull off 2-pin connector from kick-down switch - F8- in engine
compartment (on bulkhead).
– Connect hand multimeter - V.A.G 1526C- to kick-down switch

- F8- using auxiliary cables from adapter set - V.A.G 1594C- . agen
AG. Volkswagen AG d
oes
olksw not
V
– Check resistance at switch. Specification: ∞∼Ω ed by gu
ara
nte
ris
o eo
– Slowly move accelerator in direction of full throttle. auth
ra
ss c
Shortly after the kick-down pressure point the resistance must
ce
le
un
pt
drop to 0 Ω. At this point the accelerator must be just off the stop.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Accelerator pedal 133

Sharan 1996 ➤
3 Electronic power control (EPC): en‐

gine code AWC
3.1 Function of EPC system

With the EPC system, the throttle valve is not operated by a cable
from the accelerator There is no mechanical connection between
the accelerator and the throttle valve.
The position of the accelerator is transmitted to the engine control
unit by two accelerator position senders (variable resistors to‐
gether in one housing) connected to the accelerator.
The position of the accelerator (driver's requirement) is a main
input value for the engine control unit.
Actuation of the throttle valve is via an electric motor (throttle valve
positioner) in the throttle valve module. This occurs over the com‐
plete engine speed and load range.
The throttle valve is operated by the throttle valve positioner which
is controlled by the engine control unit.
When the engine is not running and the ignition is switched on,
the engine control unit moves the throttle valve exactly as pre‐
scribed by the accelerator position sender. That is, when the
accelerator is depressed halfway, the throttle valve positioner
opens the throttle valve by the same amount. The throttle is then
approximately half open.
When the engine is running (under load), the engine control unit
can open or close the throttle valve independently
n AG. Volkswagenof
AGthe accel‐
erator position sender. wage does
olks no
V t gu
by a
This means that the throttle
ris valve can already be completely open ntee
ed ra
even though the accelerator
au
tho
is depressed half way. This has the or
ac
advantage of preventing
ss throttling losses at the throttle valve.
ce
le
un
After evaluating the torque requirements of various components

pt
an
d
itte
(e.g. air conditioning, automatic gearbox, ABS/ESP and so on),

y li
rm
ab
the engine control unit calculates the optimal throttle valve open‐
pe
ility
ing angle for the particular situation.

ot
wit
, is n
h re
This also results in significantly improved consumption and ex‐

hole
haust emission values under certain load conditions.

spec
es, in part or in w
It would be incorrect to believe that “EPC” comprises one or two

t to the co
components only. EPC is a system containing all components

which have an influence on, or control and monitor, the position
of the throttle valve, such as the accelerator position sensor, the
rrectness of i
throttle valve control unit, the EPC warning lamp, the engine con‐
l purpos
trol unit…).
nform
ercia
Observe rules for cleanliness ⇒ page 120 .

m
a
com
ti
3.2 Repairing parts of electronic power control (EPC)

on in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
Volkswagen AG
1 - Mounting bracket
swa
gen AG
.
does
olk not
yV gu
2 - Connectoredb ara
nte
ris
❑ auBlack,
tho 6-pin eo
ra
ss c
3 - 10 Nm
ce
e
nl
pt
du
an
4 - Acceleration pedal position
itte
y li
sender - G79-
erm
ab
ility
ot p
❑ Not adjustable.
wit
, is n
❑ The accelerator position
h re
hole
sender passes the posi‐
spec
tion of the accelerator
es, in part or in w
t to the co
on to the engine control
unit.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Electronic power control (EPC): engine code AWC 135

Sharan 1996 ➤
3.3 Checking accelerator position sender

AG. Volkswagen AG d
equipment required ksw
agen oes
n ol ot g
yV ua
edb ran
ris tee
ho
aut or
ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Hand multimeter - V.A.G 1526 A- or hand multimeter - V.A.G

1526C-
set - V.A.G 1594C-
♦ Adapter cable, 121-pin - V.A.G 1598/31-
Not illustrated:
♦ Fault reader - V.A.G 1551- , vehicle system tester - V.A.G
1552- or vehicle diagnosis, testing and information system -
VAS 5052-
Function
Both accelerator position sender - G79- and accelerator position
sender 2 - G185- are located on the accelerator pedal and pass
on the driver's requirements to the engine control unit independ‐
ently of one another. Both senders are installed together in a
housing.

Sharan 1996 ➤
Test conditions
• Fuses must be OK.
switched off.
Test sequence
– Connect fault reader - V.A.G 1551- or vehicle system tester -
V.A.G 1552- or vehicle diagnosis and service information
system - VAS 5052- and select “address word” 01 for engine
electronics control unit. The ignition must be switched on for
this purpose ⇒ Rep. gr. 01 .
Indicated on display:
Rapid data transfer HELP
Select function XX
– Press keys 0 and 8 for function “Read measured value block”

and confirm entry with Q key.
Reading measured value block
Enter display group number XXX
wage es n
– Press buttons 0 , 6 and 2 for “Display groupy Vnumber
olks 62” and ot g
ua
b
confirm entry with Q button. rised ran
tee
tho or
Indicated on display: (1…4 = display zones)
ss
au ac
ce
le
un
pt
Read measured value block 62 -
an
d
itte
1 2 3 4
y li
erm
ab
– Check specification from accelerator position sender - G79- at
ility
ot p
idling speed stop in display zone 3. Specification: 6…96%.
wit
is n
h re
ole,
– Check specification from accelerator position sender 2 - G185-

spec
at idling stop in display zone 4. Specification: 3…48%.
t to the co
Note
rrectne
The engine control unit calculates the angle sender voltage value
as a percent of 5 Volts and displays this percentage. (5 volt supply
ss
voltage equals 100%).

o
cial p
f inform
mer
– Slowly depress accelerator down to full throttle position and

atio
observe the percentage display in display zones 3 and 4:

om
n
c
i
or
The percent figures in display zone 3 must rise evenly. The tol‐
thi
e
erance range of 6…96% is not covered completely.

t
sd
iva
o
pr
cum
The percent figures in display zone 4 must rise evenly. The tol‐
r
fo
en
ng
erance range of 3…48% is not covered completely.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Note
co Vo
by lksw
cted agen
Prote AG.
The figure displayed in display zone 3 must always be approxi‐

mately double that displayed in display zone 4.
– Press → button.

Sharan 1996 ➤
– Press buttons 0 and 6 for function “End output” and confirm

entry with Q button.
If the display does not indicate as described:
– Check accelerator position sender voltage supply and wiring
connections ⇒ page 138 .
Checking voltage supply and wiring to control unit
Checking voltage supply:
– Pull 6-pin connector off accelerator position sender.
– Switch ignition on.
– Connect multimeter for measuring voltage to the following
connector contacts using auxiliary cables from auxiliary meas‐
uring set - V.A.G 1594C- .
Contact 1 + earth
Contact 1 + 5
Contact 2 + earth
Contact 2 + 3
Specification: at least 4.5 V

– Switch off ignition and check wiring to control unit.
Checking wiring to control unit:
theft coding.
– Remove battery.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
– Connect adapter cable, 121-pin - V.A.G 1598/31- to control
ce
le
un
unit wiring harness. The engine control unit remains discon‐

pt
an
d
nected.
itte
y li
rm
ab
pe
– Check cables between test box and 6-pin connector for open
ility
ot
circuit using current flow diagram.

wit
, is n
h re
Contact 1 and test box socket 72

hole
spec
es, in part or in w

t to the co

rrectness of i

l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
Cable resistance: max. 1.5 Ω.

– Also check wiring for short to one another, short to vehicle
earth and short to battery positive. Specification: ∞ Ω.
If no fault is determined and power supply is OK:
– Renew accelerator position sender ⇒ Item 4 (page 135) .
If power supply is not OK and no fault is determined in wiring:
– Renew engine control unit:
– On vehicles with automatic gearbox, gearbox control unit must
also be adapted in addition ⇒ Rep. gr. 01 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
4 Activated charcoal filter system
4.1 Function
Fuel vapour forms above the level of fuel in the tank at a rate
relevant to the air pressure and ambient temperature.
The activated charcoal filter system prevents these HC emissions
escaping to the atmosphere.
In limited quantities, fuel vapours pass through a gravity valve
(which closes at an angle of 45°) located at the highest point in
the tank and through a pressure retention valve into the activated
charcoal filter.
The activated charcoal stores these vapours like a sponge.
When the vehicle is being driven and the Lambda control is active
(engine warm), the activated charcoal filter solenoid valve 1 -
N80- , also known as regeneration valve, is activated (pulsed) by
the engine control unit depending upon load and engine speed.
The opening period depends on the input signals.
During the purging procedure (regeneration of activated char‐
coal), the intake manifold vacuum draws fresh air through the
ventilation hose of the activated charcoal filter. The fuel vapours
stored in the activated charcoal and fresh air are fed to combus‐
tion in metered quantities.
The pressure retention valve prevents fuel vapours from being
drawn out of the fuel tank when activated charcoal filter system
solenoid valve 1 - N80- is open and intake manifold vacuum is
present. It thus ensures that the purging of the activated charcoal
filter has priority.
The activated charcoal filter solenoid valve 1 - N80- is closed
when it is not supplied with current (e.g. open circuit). The acti‐
vated charcoal filter will not be purged.
lkswage es n
o ot g
yV
Note ir se
d b ua
ran
o tee
th or
u
♦ Hose connections
ss are secured with either spring-type or
a ac
clamp-type clips.
ce
le
un
pt
an
d

itte
y li
erm
ab

ility
ot p

wit
is n
- V.A.G 1921- .
h re
ole,
spec

t to the co
Observe rules for cleanliness ⇒ page 120 .

Repairing parts of activated charcoal filter system: engine code
rrectne
AJH ⇒ page 141 .

s
Repairing parts of activated charcoal filter system: engine code

s o
AWC ⇒ page 141 .

cial p
f inform
Checking activated charcoal filter solenoid valve 1: engine code

mer
AWC ⇒ page 143 .

atio
om
n
c
Checking fuel tank breather: engine code AJH ⇒ page 145

or
n thi
te
sd
a
Checking fuel tank breather: engine code AWC ⇒ page 146

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
140
co Vo
by lksw
Rep. gr.20 - Fuel supply system cted agen
Prote AG.
Sharan 1996 ➤
4.2 Repairing parts of activated charcoal fil‐

ter system
Engine code AJH
1 - Connection
2 - Bracket
❑ For activated charcoal
filter
3 - Junction
4 - Breather line
❑ From pressure retention
valve on fuel valve
and installing fuel tank
with attachments and n AG. Volkswagen AG do
lkswage es n
fuel filter: engine code byV
o ot g
ua
AJH ir se
d ran
tee
tho
u or
5 - Activated charcoal filter ss
a ac
❑ Location: in front right
ce
le
un
pt
wheel housing
an
d
itte
y li
❑ Remove right wheel
rm
ab
pe
ility
housing to remove.
ot
wit
, is n
6 - 10 Nm
h re
hole
spec
7 - From air hose
es, in part or in w
t to the co
❑ Schematic diagram of
turbocharger system:
engine code AJH
rrectness of i
⇒ page 154
l purpos
8 - Throttle valve control mod‐

ule
nform
ercia
9 - Air filter lower part

m
10 - Activated charcoal filter

a
com
solenoid valve 1 - N80- tion in

r
te o
❑ When engine is warm,

thi
s
iva
valve will be activated

do
r
rp
(pulsed) by engine con‐

um
fo
trol unit
en
ng
t.
yi Co
op
❑ Checking activation: ⇒ Rep. gr. 01 ; Final control diagnosis . C py
t. rig
gh ht
yri by
11 - Connector cop Vo
by lksw
cted agen
❑ 2polig Prote AG.
❑ For activated charcoal filter system solenoid valve 1 - N80-

12 - Breather line
❑ To atmosphere.
❑ Secured to body
13 - O-ring
Engine code AWC
4. Activated charcoal filter system 141

Sharan 1996 ➤
1 - Connector
2 - Bracket
filter
3 - Junction
4 - Breather line
valve on fuel valve
and installing fuel tank
with attachments and
fuel filter: engine code
AWC agen
AG. Volkswagen AG d
oes
olksw not
V
5 - Activated charcoal filter d by gu
ara
rise nte
❑ Location: in front right utho eo
ra
wheel housing ss a c
ce
le
❑ Remove right wheel

un
pt
housing to remove.
an
d
itte
y li
rm
ab
6 - 10 Nm
pe
ility
ot
wit
7 - Junction
, is n
h re
hole
8 - Breather line
spec
es, in part or in w
❑ Black with white marks.
t to the co
❑ To upper connecting
rrectness of i
pipe on fuel rail ⇒ Rep.
gr. 24
l purpos
nform
ercia
filter system.
m
a
com
t
❑ Grey connection points
ion in
to junction piece
r
te o
thi
s
iva
do
r
rp
10 - Breather line
um
fo
en
g
❑ Schematic diagram of turbocharger system: engine code AWC ⇒ page 155

n
t.
yi Co
Cop py
11 - Air filter lower part
t. rig
gh ht
pyri by
Vo
o
12 - Activated charcoal filter solenoid valve 1 - N80-
c by lksw
cted agen
Prote AG.
❑ When engine is warm, valve will be activated (pulsed) by engine control unit
❑ Checking activation: ⇒ Rep. gr. 01 ; Final control diagnosis .
13 - Connector
❑ Green, 2-pin
❑ For activated charcoal filter system solenoid valve 1 - N80-
14 - Breather line
❑ To atmosphere.
❑ Secured to body
15 - O-ring

Sharan 1996 ➤
4.3 Activated charcoal filter solenoid valve 1

- N80- : engine code AWC
When unenergised, activated charcoal filter solenoid valve 1 -
N80- is closed.
Check activation ⇒ Rep. gr. 01 ; Final control diagnosis .
AG. Volkswagen AG d
♦ Fault reader - V.A.G 1551-
lksw
agen oes
not
o
yV gu
edb ara
ris nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Diagnostic cable - V.A.G 1551/3C-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Note Prote AG.
Instead of fault reader - V.A.G 1551- , vehicle system tester -

V.A.G 1552- can also be used, though a print-out is not possible.

Sharan 1996 ➤
Test conditions
• Coolant temperature must be at least 80°C, ⇒ display group
04, display zone 3
Functional check
– Connect fault reader - V.A.G 1551- ( Vehicle system tester -
V.A.G 1552- ) ⇒ Motronic injection and ignition system; Rep.
gr. 01 ; Connecting fault reader . Start engine and select “Ad‐
dress word” 01 of engine control unit.
Rapid data transfer HELP
Select function XX

Reading measured value block
– Press buttons 0 , 7 and 0 for “Display group number 70” and

confirm entry with Q button. G. Volkswage nA n AG d
wage oes
Indicated on display: (1…4 = display zones) Volks not
gu
by ara
ed nte
Read measured value block 70 -> oris eo
th
1 2 3 4 au ra
c
ss
ce
le
– Press button 4 for “basic setting” function (thereby initiating

un
pt
an
d
“tank breather valve diagnosis”)

itte
y li
rm
ab
pe
ility
ot
wit
Note
, is n
h re
hole
spec
No engine loading may be created during this diagnosis, other‐
es, in part or in w
wise the test will be terminated and can only be reinitiated by a t to the co
bust of the throttle.
Indicated on display: (1…4 = display zones)

rrectness of i
l purpos
System in basic setting 70 ->

1 2 3 4
nform
ercia
When the diagnosis of the engine control unit has been initiated
the display in display zone 4 will jump from “Test OFF” to “Test
m
ON”.
com
tion in
r
– Leave engine running at idle until the specification “TBV OK”

te o
thi
is displayed in display zone 4.

s
iva
do
r
rp
cum
fo
en
ng
t.
yi
Note
Co
Cop py
ht. rig
rig ht
TBV is the abbreviation for tank breather valve ( activated char‐
py by
co Vo
by lksw
coal filter system solenoid valve 1 - N80- ). cted agen
Prote AG.
If specification “TBV OK” is attained:


Sharan 1996 ➤
If display zone 4 shows “TBV n.OK”:

– Initiate final control diagnosis and actuate active charcoal filter
system solenoid valve 1 - N80- , ⇒ Rep. gr. 01 ; Performing
final control diagnosis .
4.4 Checking fuel tank breather

Checking fuel tank breather: engine code AJH ⇒ page 145
Checking fuel tank breather: engine code AWC ⇒ page 146
4.4.1 Checking fuel tank breather: engine

code AJH
♦ Vacuum tester - V.A.G 1368-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
♦ Hand operated vacuum pump - V.A.G 1390- ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
Test sequence
– Pull off breather line -5- of activated charcoal filter -1- from
throttle valve control module -3-.
– Connect hand vacuum pump - V.A.G 1390- to line -5-.
– Pull breather line -4- from fuel tank off activated charcoal filter
and connect to “connection A” of vacuum tester - V.A.G 1368- .
– Connect vacuum tester - V.A.G 1368- “connection B” to
. Volkswagen AG
breather line -2- to activated
sw agen AGcharcoal filter.does
k not
y Vol gu
– Set vacuum tester
se
d b to position “B”. ara
nte
ri
ho eo
– Initiate final
ut control diagnosis and select activated charcoal ra
sa c
filter system solenoid valve 1 - N80- , ⇒ Rep. gr. 01 ; Per‐
s
ce
e
forming final control diagnosis .

nl
pt
du
an
itte
y li
– Operate hand vacuum pump - V.A.G 1390- several times.
erm
ab
There must be no development of vacuum.
ility
ot p
wit
If vacuum builds up:
, is n
h re
hole
– Check breather connection -6- on activated charcoal filter -1-
spec
for soiling and clean if necessary.
es, in part or in w
t to the co
If vacuum does not build up:
rrectness of i
– Connect hand vacuum pump - V.A.G 1390- to vacuum tester
- V.A.G 1368- “connection B”.
l purpos
– Set vacuum tester to -A/B- position.

nf
ercia

or
Vacuum must build up.

m
m
atio
om

n in
or c
thi
e
– Check pressure retention valve ⇒ page 116 .

t
sd
iva
o
r
rp
cu
– Check line -1- from fuel tank for leaks.

o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
4.4.2 Checking fuel tank breather: engine
c by lksw
cted agen
Prote AG.
code AWC
♦ Vacuum tester - V.A.G 1368-

Sharan 1996 ➤
♦ Hand operated vacuum pump - V.A.G 1390- agen

AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Test sequence
rrectness of i
– Pull off breather line -3- from activated charcoal filter system
solenoid valve 1 - N80- -1-.
l purpos
– Connect vacuum tester - V.A.G 1368- “connection A” to acti‐

vated charcoal filter system solenoid valve 1 - N80- -1-.
nf
ercia
orm
– Connect hand vacuum pump - V.A.G 1390- to vacuum tester
m
atio
m
- V.A.G 1368- “connection B”.

o
n in
or c
– Set vacuum tester - V.A.G 1368- to -A/B- position.
thi
te
sd
iva
o
r
– Initiate final control diagnosis and select activated charcoal

rp
cu
o
m
filter system solenoid valve 1 - N80- , ⇒ Rep. gr. 01 ; Per‐
f
en
ng
t.
forming final control diagnosis .
yi Co
Cop py
t. rig
gh ht
pyri by
There must be no development of vacuum.
co Vo
by lksw
cted agen
Prote AG.
If vacuum builds up:
– Check breather hose -4- on activated charcoal canister for
soiling and clean if necessary.
– Seal breather hose -arrow- from activated charcoal canister.

– Initiate final control diagnosis again and select activated char‐
coal filter system solenoid valve 1 - N80- , ⇒ Rep. gr. 01 ;
Final control diagnosis .
Vacuum must build up.
– Check pressure retention valve ⇒ page 119 .
– Check breather hose -2- from fuel tank pressure retention

valve for leaks.

Sharan 1996 ➤
21 – Turbocharging/supercharging
1 Charge air system with turbocharger
Note
♦ All hose connections are secured by clips.

- V.A.G 1921- .
♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts. agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
Observe rules for cleanliness ⇒ page 156 . rised
nte
ho eo
ut
Note safety precautions ⇒ page 156 . ss a ra
c
ce
le
Removing and installing turbocharger with attachments

un
pt
an
⇒ page 148 .
d
itte
y li
rm
ab
Removing and installing parts of charge air cooling: engine code
pe
ility
AJH ⇒ page 151 .
ot
wit
, is n
h re
Removing and installing parts of charge air cooling: engine code
hole
spec
AWC ⇒ page 152 .
es, in part or in w
t to the co
Schematic diagram of turbocharger system: engine code AJH
⇒ page 154 .
Schematic diagram of turbocharger system: engine code AWC
rrectness of i
⇒ page 155 .
l purpos
Checking charge pressure system: engine code AJH

⇒ page 159 .
nform
ercia
Checking charge pressure system: engine code AWC

m
⇒ page 162 .
a
com
tion in
1.1 Removing and installing turbocharger

r
te o
thi
s
iva
with attachments
do
r
rp
cum
fo
en
ng
t.
yi Co
Caution ht. Cop py
rig
rig ht
py by
If a mechanical fault is found on the turbocharger, e.g. a de‐
co Vo
by lksw
cted
stroyed compressor impeller, just renewing the turbocharger is
agen
Prote AG.
not enough. To prevent this from causing further damage, per‐
form the following repairs:
♦ Check air filter housing, air filter element and intake hoses
for soiling.
♦ Check complete charged air routing and charge air cooler
for foreign objects.
If foreign objects are found in the charge air system, the charg‐
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.
148 Rep. gr.21 - Turbocharging/supercharging

Sharan 1996 ➤
1 - Exhaust manifold
2 - Seal
❑ Renew
sition
3 - Seal
❑ Renew
5 - From oil filter bracket
❑ Vehicles with engine
code AJH:
❑ Vehicles with engine
code AWC:
6 - Oil supply line
❑ Tighten to 25 Nm
7 - To coolant circulation pump
- V50- (AJH) or continued cool‐
ant circulation pump - V51-
(AWC)
❑ Coolant hose schematic
diagram: engine code
AJH ⇒ page 99
❑ Coolant hose schematic
diagram: engine code en AG. Volkswagen AG
AWC ⇒ page 100 olks
wag does
no
V t gu
by ara
8 - Coolant distribution
ris
ed housing nte
ho eo
❑ Tightensa
ut
to 30 Nm ra
c
s
ce
e
nl
pt
du
an
itte
10 - Washer
y li
erm
ab
ility
11 - 25 Nm
ot p
wit
, is n
12 - Vacuum hose
h re
hole
spec
❑ To charge pressure control solenoid valve - N75- .

es, in part or in w
❑ Schematic diagram of turbocharger system: engine code AJH ⇒ page 154

t to the co

rrectness of i
14 - From cylinder block.

l purpos

nform
mercia

at
om
ion
c
16 - 10 Nm
in t
or
his
ate
17 - Vacuum hose
do
priv
cum
❑ To charge pressure control solenoid valve - N75- .

for
en
ng
t.
yi
Co
Cop py
.
t rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.
19 - Spacer sleeve
❑ Only on vehicles with manual gearbox
1. Charge air system with turbocharger 149

Sharan 1996 ➤
20 - Support
❑ Between turbocharger and cylinder block.
21 - From air filter
❑ Schematic diagram of turbocharger system: engine codeenAJH
AG. V⇒
olkpage
swagen154
AG do
wag e
❑ Schematic diagram of turbocharger system: engine
yV
olkscode AWC ⇒ page 155 s not gu
b ara
ed
22 - To charge air cooler ris nte
utho e or
❑ Schematic diagram of turbocharger system:
ss
a engine code AJH ⇒ page 154 ac
ce
le
un
pt
an
d
itte
23 - Plug, 15 Nm
y li
rm
ab
pe
ility
24 - Oil return line
ot
wit
, is n
❑ To sump ⇒ Item 23 (page 79)
h re
hole
spec
25 - Seal
es, in part or in w
❑ Renew
t to the co
26 - Turbocharger
❑ The charge pressure control valve and vacuum unit for charge pressure control valve are integral parts
rrectness of i
of turbocharger and cannot be replaced individually.
l purpos
❑ Checking charge pressure system: engine code AJH ⇒ page 159

❑ Checking charge pressure system: engine code AWC ⇒ page 162
nform
ercia
❑ Before connecting oil supply line, fill turbocharger with engine oil via union.
m
a
❑ After installing turbocharger, run engine for about 1 minute at idling and do not rev up immediately, this
com
tion in
ensures that the turbocharger is fully primed with oil.
r
te o
thi
27 - Front exhaust pipe
s
iva
do
r
rp
cum
28 - 35 Nm
fo
en
ng
t.
yi
❑ Renew
Co
Cop py
t. rig
❑ Coat threads and bolt head contact surface with high-temperature paste - G 052 112 A3- . opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen
olksw
oes
Sharan
not 1996 ➤
yV gu
4-cylinder injection ed engine
b (5-valve), mechanics - Editionara06.2019
nte
ris
ho eo
ut ra
1.2 Removing and installing parts of charge s a c
s
ce
e
air cooling
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
1.2.1 Removing and installing parts of charge air cooling: engine code AJH
wit
, is n
h re
hole
spec
es, in part or in w
1 - Intake hose
t to the co
❑ From air filter
2 - Pressure regulating valve
rrectness of i
tion. l purpos
3 - From crankcase breather
nform
ercia
4 - From charge pressure con‐

m
trol solenoid valve - N75-
at
om
ion
c
in t
or
his
ate
engine code AJH
do
priv
c
⇒ page 154
um
for
en
ng
t.
yi
5 - Air intake pipe
Co
Cop py
t.
❑ Attached to cylinder
rig
gh ht
yri by
head cover op Vo
by c lksw
cted agen
Prote
6 - From activated charcoal fil‐
AG.
ter system solenoid valve 1 -

N80-
engine code AJH
⇒ page 154
7 - Air intake hose
❑ To turbocharger
engine code AJH
⇒ page 154
8 - Air intake hose
engine code AJH
⇒ page 154
9 - To throttle valve control module
10 - Air intake pipe
11 - Bracket
❑ For air intake pipe
12 - 25 Nm
13 - Bracket
❑ for charge air cooler
14 - 10 Nm
16 - Vacuum line
❑ Connection on intake manifold

Sharan 1996 ➤
17 - Overrun shut-off valve

lkswage es n
o ot g
byV ua
1.2.2 Removing and installing parts of charge air cooling: engine code AWC
d ran
ir se tee
tho
u or
a ac
ss
ce
le
1 - Intake hose
un
pt
an
d
itte
❑ From air filter
y li
rm
ab
pe
2 - 10 Nm
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
tion.
t to the co
4 - Connection hose
❑ From crankcase breath‐
rrectness of i
er pipe
l purpos
5 - Vacuum hose
❑ From charge pressure
nform
ercia
control solenoid valve -

N75-
m
a
com
t
ion in
r
te o
thi
engine code AWC
s
iva
do
⇒ page 155 .
r
rp
cum
fo
6 - Air intake pipe
en
ng
t.
yi Co
op
❑ Attached to cylinder C py
t. rig
head cover
gh ht
pyri by
Vo
co lksw
by
7 - Breather line cted agen
Prote AG.
❑ With connecting piece
❑ From non-return valve
for activated charcoal fil‐
ter system
engine code AWC
⇒ page 155
8 - Air intake hose
❑ Observe assembly
markings
❑ To turbocharger
9 - Air intake hose
❑ To throttle valve module - J338- .
10 - Breather hose
❑ From exhaust gas recirculation valve - N18-
12 - O-ring
13 - Charge air pressure sender - G31-

Sharan 1996 ➤
14 - 6 Nm
15 - Air intake hose
16 - Bracket
❑ for charge air cooler
❑ Observe assembly markings
19 - Bracket
❑ For air pipe ⇒ Item 21 (page 153)
20 - 20 Nm
❑ Adjust longitudinally in bracket ( ⇒ Item 19 (page 153) ) so that air pipe is not installed under tension
22 - Breather hose
❑ To connection on intake manifold
❑ From turbocharger
❑ Schematic Vdiagram wage of turbocharger system:
ot engine code AWC ⇒ page 155
es n
olks gu
y
db ara
25 - 25 Nmorise nte
h eo
ut ra
26 - Bracket
ss
a c
ce
e

nl
pt
du
an
❑ Attached to cylinder block

itte
y li
erm
ab
27 - 25 Nm
ility
ot p
wit
❑ Renew
, is n
h re
hole
28 - Bracket
spec
es, in part or in w

t to the co
❑ Secured to sump
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
1.3 Schematic diagram of turbocharginglksw

agen
AG. Volkswagen AG d
oes
not
system Vo gu
d by ara
se n ri tee
ho
aut or
ac
ss
1.3.1 Schematic diagram of turbocharger system: engine code AJH
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
2 - Activated charcoal filter sol‐
h re
enoid valve 1 - N80-
hole
spec
es, in part or in w
t to the co
trol unit
rrectness of i
❑ Checking activation: ⇒
Rep. gr. 01 ; Final con‐
l purpos
trol diagnosis .
3 - Breather line
nform
ercia

m
a
valve on fuel tank
com
tio
n in
r
te o
thi
s
iva
do
for crankcase breather
r
rp
cum
fo
en
g
n
t.
yi Co
op py
❑ For activated charcoal t. C rig
gh ht
filter system. yri
p by
o Vo
by c lksw
❑ Grey connection points cted agen
Prote AG.
to junction piece
7 - Turbocharger
❑ The charge pressure
control valve and vac‐
uum unit for charge
pressure control valve
are integral parts of tur‐
bocharger and cannot
be replaced individually.
8 - Pressure canister
❑ For charge pressure
control valve
❑ Integral part of turbocharger and cannot be replaced.
9 - Charge pressure control solenoid valve - N75-
10 - Cylinder head
11 - Throttle valve module - J338-
13 - Crankcase ventilation
14 - Fuel pressure regulator
15 - Intake manifold
16 - Air mass meter - G70-
17 - Air filter housing

Sharan 1996 ➤
1.3.2 Schematic diagram of turbocharger system: engine code AWC

2 - Activated charcoal filter sol‐
enoid valve 1 - N80-
trol unit
❑ Checking activation: ⇒
Rep. gr. 01 ; Final con‐
trol diagnosis .
3 - Breather line
valve on fuel tank agen
AG. Volkswagen AG d
oes
⇒ Item 9 (page 117) . olksw not
V gu
d by ara
e
4 - Pressure regulating valve horis nte
eo
ut ra
❑ For crankcase ventila‐ ss a c
tion.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
filter system.
ot
wit
, is n
❑ Grey connection points
h re
hole
to junction piece
spec
es, in part or in w
t to the co
7 - Turbocharger
❑ The charge pressure
rrectness of i
control valve and vac‐
l purpos
uum unit for charge

pressure control valve
are integral parts of tur‐
nform
ercia
bocharger and cannot

be replaced individually.
m
a
com
tion in
8 - Charge pressure control

r
te o
solenoid valve - N75-

thi
s
iva
do
❑ Vacuum hoses on solenoid valve ⇒ page 156

r
rp
cum
fo
en
ng
t.
yi Co
❑ Checking ⇒ page 164 Cop py
t. rig
gh
ht
pyri by
Vo
o
by c lksw
cted
9 - Pressure canister
agen
Prote AG.
❑ For charge pressure control valve

❑ Integral part of turbocharger and cannot be replaced.
10 - Exhaust gas recirculation valve - N18- with exhaust gas recirculation potentiometer - G212-
❑ Checking exhaust gas recirculation potentiometer - G212- ⇒ page 183 .
❑ Checking exhaust gas recirculation valve - N18- ⇒ Rep. gr. 01 ; Final control diagnosis .
11 - Cylinder head
12 - Throttle valve module - J338-
13 - Charge air pressure sender - G31-

Sharan 1996 ➤

15 - Manifold
16 - Crankcase ventilation
17 - Fuel pressure regulator
18 - Intake manifold
19 - Air mass meter - G70-
20 - Air filter housing
n AG - N75- . Volkswagen AG
Vacuum hoses on charge pressure control solenoid
ksw
agevalve does
not
ol
yV gu
1- From vacuum unit for charge pressuresed b control ara
nte
ri
⇒ Item 12 (page 149) ut
ho eo
a ra
ss 152) c
2- To intake hose ⇒ Item 5 (page
ce
e
nl
pt
du
3- From union on turbocharger ⇒ Item 17 (page 149)
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.4 Rules for cleanliness
rrectness of i
When working on the turbocharger, pay careful attention to the
l purpos
following “5 rules” for cleanliness:

♦ Thoroughly clean all unions and adjacent areas before dis‐
nf
ercia
connecting.
orm
m
♦ Place removed parts on a clean surface and cover them over.

atio
m
Use lint-free cloths only.

o
n in
or c
thi
e
♦ Carefully cover opened components or seal them if repairs

t
sd
iva
cannot be carried out immediately.

o
r
rp
cu
o
m
f
en
♦ Install clean components only. Do not remove replacement

ng
t.
yi Co
parts from packing until immediately before installing. Do not t. Cop py
use parts that have not been stored in their packing (e.g. in
rig
gh ht
yri by
tool boxes etc.). cop Vo
by lksw
cted agen
Prote
♦ If system is open: do not use compressed air if possible. Try
AG.
not to move the vehicle.
1.5 Safety precautions
WARNING

sitions.
hot components.
Note the following if testers and measuring instruments have to

be used during a road test:

Sharan 1996 ➤
♦ Test and measuring instruments must always be secured to

rear seat and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
1.6 Removing land kswageinstalling charge

n AG. Volkswagen AG do air cool‐
es n
er: engine y V code AWC
o ot g
d b ua
se ran
i tee
or
Special tools and
au workshop equipment required
th or
ac
ss
♦ Torque wrench - V.A.G 1331-
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Hand drill
♦ Drill bit, 14 mm in diameter
♦ Safety glasses
Removing
– Remove front bumper ⇒ Rep. gr. 63 .
– Remove bracket for lower coolant hose.

Sharan 1996 ➤
– Unscrew hydraulic line for power steering -1- on lock carrier

-arrows-.
– Drill holes in lock carrier at positions indicated by -arrows- (use

∅ 14 mm drill bit).
– Unscrew securing bolts of charge air cooler
agen
and
AG. Voremove
lkswagen AG
does
charge air cooler. Vo lksw not
g y ua
db ran
Installing rise tee
tho or
au ac
– Tighten securing bolts cooler and hydraulic line ofsscharge air
of power steering. Specified torque: 10 Nm
ce
e
nl
pt
du
an
itte
y li
erm
ab
quence.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
2 Checking charge air system

Checking charge air system: engine code AJH ⇒ page 159
Checking charge pressure system: engine code AWC
⇒ page 162
2.1 Checking charge air system: engine

code AJH
2.1.1 Checking charge pressure control

♦ Turbocharger tester - V.A.G 1397A-
lkswage es n
o ot g
Test conditions d byV ua
ran
ir se te
• There should be uth no faults stored in the fault memory ⇒ Rep.e o
o
ra
gr. 01 ; Reading
ss
a
and erasing fault memory . c
ce
le
• Engine oil temperature at least 60°C.

un
pt
an
d
itte
y li
• No leaks on intake and exhaust systems

erm
ab
ility
ot p
Test sequence
wit
is n
h re
– The charge pressure is measured under full load, whilst driving

ole,
spec
or on a rolling road. Test duration per measurement max.

10 seconds.
t to the co
Observe applicable safety precautions during road test

⇒ page 156 .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Checking charge air system 159

Sharan 1996 ➤
– Pull off vacuum hose between intake manifold and overrun

shut-off valve at intake manifold and connect using T-piece of
turbocharger tester - V.A.G 1397A- .
– Select measuring range l.
AG. Volkswagen AG d
agen
Note Volksw
oes
not
by gu
d ara
ise nte
♦ Handling turbocharger tester - V.A.G 1397A-
thor
⇒ Operating in‐ eo
structions . ss au ra
c
ce
e
♦ The lines must be properly connected and absolutely free of
nl
pt
du
an
leaks.
itte
y li
erm
ab
♦ If charge pressure is measured while the vehicle is in motion,
ility
ot p
a second person is required to operate the turbocharger tester
wit
, is n
for reasons of safety.
h re
hole
spec
♦ Ensure that the charge pressure line is not trapped between
es, in part or in w
the bonnet and body.
t to the co
– Measure charge pressure at full throttle: accelerate in 3rd gear
or in 2nd driving stage from approx. 2000 rpm to full throttle.
rrectness of i
– At 3000 rpm, press the memory button “M” on turbocharger
l purpos
tester. Specification: (absolute pressure): 1.3 … 1.4 bar

If the charge pressure is exceeded:
nf
ercia
orm
m
– Check charge pressure control solenoid valve - N75- . (Hose
atio
m
from turbocharger via valve to pressure unit not blocked when

o
n in
c
connector is pulled off).

or
thi
te
sd
iva
– Check that vacuum unit for charge pressure control valve is
o
r
rp
cu
securely mounted on turbocharger.
o
m
f
en
ng
t.
yi
– Check shaft bearing of charge pressure valve in turbocharger
Co
Cop py
for ease of movement. If corroded (seized), renew turbocharg‐
t. rig
gh ht
yri
er. p by
co Vo
by lksw
cted agen
If charge pressure is not reached: Prote AG.
– Check charge pressure control solenoid valve - N75-

⇒ page 160 .
2.1.2 Check charge pressure control solenoid

valve - N75-
♦ Fault reader - V.A.G 1551- or vehicle system tester - V.A.G
1552- with diagnosis cable - V.A.G 1551/3C-
♦ Hand multimeter - V.A.G 1526C- or multimeter - V.A.G 1715-
• Final control diagnosis has been performed ⇒ Rep. gr. 01 ;
final control diagnosis .
• Ignition off
Test sequence

Sharan 1996 ➤
– Pull connector -1- off charge pressure control solenoid valve

- N75- -2-.
– Check resistance of charge pressure control solenoid valve
between contacts. Specification: 25.0…35.0 Ω∼ (at room tem‐
perature)
If specification is not obtained
– Renew charge pressure regulation solenoid valve - N75- .
AG. Volkswagen AG d
agen oes
lksw not
2.1.3 Checking vacuum unit for charge pres‐
o
byV gu
ara
ed
is nte
sure control valve
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
• Engine oil temperature at least 60°C

itte
y li
rm
ab
Test sequence
pe
ility
ot
wit
, is n
– Pull connector -1- off charge pressure control solenoid valve
h re
- N75- -2-.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
– Start engine and bring up to maximum engine speed by ac‐

thi
s
iva
celerating spontaneously. The charge pressure control valve

do
r
rp
operating rod -2- must move.

um
fo
en
ng
t.
If the operating rod does not move:
yi Co
Cop py
ht. rig
– Check charge pressure control valve lever -1- for ease of rig ht
py by
movement. If corroded (seized), renew turbocharger.
co Vo
by lksw
cted agen
Prote AG.
If the operating rod does not move, even though the lever is free
to move:
– Pressure unit defective; renew turbocharger ⇒ page 148 , Re‐
moving and installing turbocharger with attachments.
2.1.4 Checking overrun shut-off valve


Sharan 1996 ➤
♦ Hand operated vacuum pump - V.A.G 1390-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
Prerequisites for testing ss
ce
e
nl
pt
du
• Reduced performance or load change jolts
an
itte
y li
erm
ab
Test sequence
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
The overrun shut-off valve is located in front of the turbocharger.
t to the co
It opens as a result of vacuum pressure in the overrun phase and
at idling speed.
rrectness of i
– Connect hand vacuum pump - V.A.G 1390- to vacuum con‐
l purpos
nection on overrun shut-off valve.

– Operate hand vacuum pump - V.A.G 1390- . Overrun shutoff
nform
ercia
valve must open in direction of -arrow-.

m
at
– Operate hand vacuum pump - V.A.G 1390- breather valve.
om
ion
Overrun shutoff valve must close.
c
in t
or
his
te
If overrun shut-off valve does not open or close, renew valve.

a
do
priv
cum
for
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri by
The overrun shut-off valve connections are secured with screw- cop Vo
by lksw
type clips. cted agen
Prote AG.
2.2 Checking charge pressure system: en‐

gine code AWC
2.2.1 Checking charge pressure control

♦ Fault reader - V.A.G 1551-
Note

Test conditions
• There should be no faults stored in the fault memory ⇒ Rep.
gr. 01 ; Reading and erasing fault memory .

Sharan 1996 ➤

run at least once).
Test sequence
– Connect fault reader - V.A.G 1551- ( vehicle system tester -
V.A.G 1552- ). Start engine and select “Address word” 01 of
engine control unit. Connect fault reader and select engine
control unit ⇒ Rep. gr. 01 .
Indicated on display: Rapid data transfer HELP
Select function XX

Indicated on display: Reading measured value block
– Press buttons 1 , 1 and 4 for “Display group number 114” and

confirm entry with Q button. wage
e ks s no
Vol t gu
Indicated on display: (1…4 = display zones) ed by ara block 114 ->
Read measured value
nte
ris 1 2 3 4
utho eo
ra
a c
– During road test or on rolling road (at be‐ ss
max. acceleration
ce
e
tween 1800…2300 rpm), check pulse duty of charge pressure

nl
pt
du
an
control solenoid valve - N75- in display zone 4. Specification:
itte
y li
5.0…95.0%
erm
ab
ility
ot p
Observe applicable safety precautions during road test
wit
, is n
⇒ page 156 .
h re
hole
spec
If reading matches specification:
es, in part or in w
t to the co
– Change to display group 115 as follows: on fault reader - V.A.G
1551- , press key 3; on vehicle system tester - V.A.G 1552- ,
press key ↑
rrectness of i
Indicated on display: (1…4 = display zones) Read measured value block 115 ->
l purpos
1 2 3 4
– Check actual charge pressure in display zone 4 at max. ac‐
nf
ercia
celeration:
orm
m
atio
On rolling road
om
n in
or c
In 3rd gear or in 2nd driving stage

thi
te
sd
iva
While vehicle is in motion

o
r
rp
cu
o
m
f
en
ng
Vehicles with manual gearbox

t.
yi Co
op py
– Accelerate vehicle in 2nd gear at max. acceleration.
t. C rig
gh ht
pyri by
Vo
o
Vehicles with automatic gearbox
c by lksw
cted agen
Prote AG.
– Manually engage 4th driving stage and accelerate vehicle
from low speed at maximum acceleration (without kickdown,
gearbox no longer changes down).
– Press print key between 1800…2300 rpm and read off actual
charge pressure value in display zone 4. Specification:
1350 … 1750 mbar.
– Compare actual charge pressure value with charge pressure
specification in display zone 3. Difference: max. 100 mbar

Sharan 1996 ➤
Note
Repeat test is full charge pressure has not yet built up or the dif‐
ference between the specification and the actual value is too
great.
If the charge pressure is exceeded:
– Check charge air pressure sender - G31- ⇒ page 165 .
– Check charge pressure control solenoid valve - N75- . (Vac‐
uum hose from turbocharger via solenoid valve to vacuum unit
not blocked when connector is pulled off).
Vacuum hoses on solenoid valve ⇒ page 156
– Check that vacuum unit for charge pressure control valve is
securely mounted on turbocharger.
– Check vacuum unit of charge pressure valve ⇒ page 168 .
If charge pressure is not reached:
– Check charge air pressure sender - G31- ⇒ page 165 .
– Check charge pressure regulation solenoid valve - N75-
⇒ page 164 .
AG. Volkswagen AG d
agen o
– Check vacuum unitVoof
lkscharge
w pressure valve ⇒
espage
not
g
168 .
y ua
db ran
Only if still no fault
or has been detected:
ise tee
th or
au
– Turbocharger
ss defective; renew turbocharger ⇒ page 148 , Re‐
ac
ce
e
nl
pt
du
an

itte
y li
erm

ab
ility
ot p
2.2.2 Check charge pressure control solenoid

wit
, is n
h re
valve - N75-
hole
spec
es, in part or in w

t to the co

rrectness of i
♦ Hand multimeter - V.A.G 1526C- or multimeter - V.A.G 1715-

l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
oris Sharan n1996
tee ➤
th or
s au engine (5-valve), mechanics - Edition 06.2019 ac
s
ce
le
un
pt
Test conditions
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
• Ignition switched off
es, in part or in w
t to the co
Test sequence
rrectness of i
l purpos
nform
mercia
– Unbolt heat shield from bulkhead -arrows-.
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Pull off 2-pin connector from charge pressure control solenoid

– Pull charge pressure control solenoid valve - N75- from brack‐
et (hoses remain connected).
– Check resistance of charge pressure control solenoid valve -

N75- between contacts. Specification: 25.0…35.0 Ω∼ (at room
temperature)
If specification is not obtained
– Renew charge pressure regulation solenoid valve - N75- .
If reading matches specification:
– Check specifications in measured value blocks for charge
pressure control: Display groups 110…119.
2.2.3 Checking charge air pressure sender - G31-

Sharan 1996 ➤

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Hand multimeter - V.A.G 1526 A- or hand multimeter - V.A.G

1526C-
set - V.A.G 1594C-
♦ Adapter cable, 121-pin - V.A.G 1598/31-
Not illustrated
Test conditions
• A charge pressure sender fault has been detected by self-di‐
agnosis ⇒ Rep. gr. 01 ; Reading and erasing fault memory .
• Ignition switched off

Sharan 1996 ➤
Checking voltage supply and wiring to control unit

– Pull off 4-pin connector from charge pressure sender - G31-
-arrow-.
– To measure voltage, connect multimeter with auxiliary leads AG. Volkswagen AG d

from auxiliary measuring set - V.A.G 1594 A- or auxiliary lkswagen oes
not
measuring set - V.A.G 1594C- to contacts 1 (earth) +d3by(pos‐
Vo gu
ara
itive) of charge pressure sender - G31- connector.orise nte
h eo
ut ra
– Switch ignition on. Specification: at least 4.5 Vss a c
ce
e
nl
pt
du
an
itte
y li
If no voltage is present:
erm
ab
ility
ot p
wit
, is n
theft coding.
h re
hole
spec
– Remove battery.
es, in part or in w
t to the co
nected.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
Contact 4 and test box socket 101 n AG. Volkswagen AG do
lkswage es n
Cable resistance: max. 1.5 Ω. d byV
o ot g
ua
ran
ir se tee
– Also check wiring for short to one another,
utho short to vehicle or
earth and short to battery positive.
ss Specification: ∞ Ω.
a ac
ce
le
If no wiring faults are detected and voltage is present between

un
pt
an
d
contacts 1 + 3:
itte
y li
rm
ab
– Check function ⇒ page 168 .
pe
ility
ot
wit
, is n
If no wiring faults are detected and no voltage is present between
h re
contacts 1 + 3:
hole
spec
es, in part or in w
– Renew engine control unit ⇒ Rep. gr. 24 .
t to the co
Checking function
– Connect adapter cable, 121-pin - V.A.G 1598/31- to engine
rrectness of i
control unit wiring harness and engine control unit.
l purpos
– Connect battery.
nform
ercia
– Reconnect 4-pin connector from charge pressure sender -

G31- -arrow-.
m
a
com
tion in
– To measure voltage, connect multimeter with adapter cables
r
te o
from auxiliary measuring set - V.A.G 1594 A- or auxiliary
thi
s
iva
measuring set - V.A.G 1594C- to sockets 101 (positive) + 108
do
r
rp
c
(earth).
um
fo
en
ng
t.
yi
– Start engine and measure voltage. Specification: 1.80…2.00
Co
op py
V t. C rig
gh ht
pyri by
– Bring engine up to speed by accelerating spontaneously.
co Vo
by lksw
cted
Specification: 2.00…3.00 V
agen
Prote AG.

– Renew charge air pressure sender - G31-
⇒ Item 13 (page 152) .
2.2.4 Checking vacuum unit for charge pres‐

sure control valve
Test conditions
• Engine oil temperature at least 60°C

Sharan 1996 ➤
Test sequence
– Unbolt heat shield from bulkhead -arrows-.
– Pull off 2-pin connector from charge pressure control solenoid

. Volkswagen AG
valve - N75- -arrow-. swa
gen AG does
k not
Vol gu
– Remove noise insulation
se
d btray ⇒ Rep. gr. 50 .
y ara
nte
ri
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Start engine and bring up to maximum engine speed by ac‐
celerating spontaneously. The charge pressure control valve
operating rod -1- must move.
rrectness of i
If the operating rod does not move:
l purpos
– Turbocharger defective; renew turbocharger ⇒ page 148 , Re‐

nform
ercia

m
at

om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi
2.2.5 Checking overrun shut-off valve
Co
Cop py
t. rig
gh ht
yri by
Special tools and workshop equipment required op Vo
by c lksw
cted agen
Prote
AG.

• Reduced performance or load change jolts

Sharan 1996 ➤
Test sequence
AG. Volkswagen AG d
agen oes
ksw
Note byV
ol not
gu
ara
e d
ris nte
o eo
The overrun shut-off valve is locatedaut in front of the turbocharger.
h
ra
It opens as a result of vacuum pressure
ss in the overrun phase and c
ce
le
at idling speed.
un
pt
an
d
itte
y li
rm
– Connect hand vacuum pump - V.A.G 1390- to vacuum con‐
ab
pe
ility
nection on overrun shut-off valve.
ot
wit
, is n
– Operate hand vacuum pump - V.A.G 1390- . Overrun shutoff
h re
hole
valve must open in direction of -arrow-.
spec
es, in part or in w
– Operate hand vacuum pump - V.A.G 1390- breather valve.
t to the co
Overrun shutoff valve must close.
If overrun shut-off valve does not open or close, renew valve.
rrectness of i
l purpos
Note
nform
ercia
The overrun shut-off valve connections are secured with screw-

type clips.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
ksw
gu Sharan 1996 ➤
ol not
V
d by ara
4-cylinder orisinjection engine (5-valve), mechanics - Edition
e nte 06.2019
h eo
aut ra
ss c
26 – Exhaust system
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
1 Removing and installing parts of ex‐
ot
wit
, is n
haust system
h re
hole
spec
es, in part or in w
t to the co
Note
♦ After working on the exhaust system, ensure that the system
rrectness of i
is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen clamps and align silencer and
l purpos
exhaust pipe so that sufficient clearance is maintained to the

bodywork and the mountings are evenly loaded.
nform
ercia
♦ Renew self-locking nuts.

m
a
com
tion in
1.1 Front exhaust pipe and catalytic converter with attachments
r
te o
thi
s
iva
do
r
rp
cum
fo
Note
en
ng
t.
yi Co
Cop py
t. rig
Parts marked with * are checked via self-diagnosis: opyri
gh by
Vo
ht
by c lksw
cted agen
Prote AG.
1 - Seal
❑ Renew
2 - 25 Nm
❑ Renew
3 - Front exhaust pipe
4 - Catalytic converter
5 - To front silencer
6 - Markings
❑ For insertion depth of
catalytic converter/front
silencer ⇒ page 172
7 - Lambda probe after catalyt‐
ic converter - G130- * 50 Nm
engine code AWC
❑ Remove and install us‐
ing ring spanner for
Lambda probe - 3337-
❑ Grease threads only
with high-temperature
paste - G 052 112 A3- ,
high-temperature paste
- G 052 112 A3- must
not get into the slots of
probe body.
open and renew.
❑ Checking ⇒ Rep. gr.
24 ; lambda probe and
lambda control after cat‐
alytic converter
1. Removing and installing parts of exhaust system 171

Sharan 1996 ➤
8 - Connector
❑ Black, 4-pin
❑ Contacts 3 and 4 gold-plated
❑ For Lambda probe after catalytic converter - G130- and Lambda probe heating 1 after catalytic converter
- Z29- .
9 - Shield
10 - 10 Nm
11 - Securing clip
12 - Lambda probe - G39- * 50 Nm
❑ Remove and install using ring spanner for Lambda probe - 3337-
❑ Grease threads only with high-temperature paste - G 052 112 A3- , high-temperature paste - G 052 112
A3- must not get into the slots of probe body.
❑ Checking (engine code AJH): ⇒ Rep. gr. 24 ; Checking functions; Checking Lambda control .
❑ Checking (engine code AWC) ⇒ Rep. gr. 24 ; Checking functions; Checking lambda probe and lambda
control before catalytic converter
13 - Connector
❑ For Lambda probe - G39- and Lambda probe heating - Z19-
Vehicles with engine code AJH:
❑ Black, 4-pin
Vehicles with engine code AWC:
❑ Black, 6-pin
❑ Gold-plated contacts
14 - From turbocharger
15 - Retaining ring
AG. Volkswagen AG d
❑ Renew if damaged agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
Insertion depth of catalytic converter/front silencer
s s c
ce
e
nl
– Insert catalytic converter pipe in front silencer pipe up to re‐

pt
du
an
itte
spective marking.
y li
erm
ab
Vehicles with manual gearbox: marking -S-

ility
ot p
wit
, is n
Vehicles with automatic gearbox: marking -A-

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
172 Rep. gr.26 - Exhaust system

Sharan 1996 ➤
1.2 Silencer with mountings
Note
Longitudinally, the exhaust system must be aligned so that the dimensions -a- and -b- are adhered to.
1 - Catalytic converter
❑ ⇒ Item 4 (page 171)
2 - Markings lkswage es n
o ot g
yV ua
❑ For insertion depth of ir se
d b ran
catalytic converter/front utho tee
or
silencer ⇒ page 172 ss
a ac
ce
e
3 - Clip
nl
pt
du
an
itte
y li
4 - Retaining ring
erm
ab
ility
ot p
wit
, is n
h re
sition
hole
spec
es, in part or in w
5 - Front silencer
t to the co
6 - Rear silencer
7 - Dimension -b- = approx. 50
rrectness of i
mm
l purpos
8 - Dimension -a- = approx. 5

mm
nform
ercia
9 - 40 Nm
m
at
❑ Renew
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Removing and installing parts of exhaust system 173

Sharan 1996 ➤
2 Secondary air system

Secondary air system: engine code AJH ⇒ page 174
Secondary air system: engine code AWC ⇒ page 177
WARNING

sitions.
hot components.
AG. Volkswagen AG d
agen oes
lksw not
2.1 Secondary air system: engine code AJH
Vo gu
d by ara
ise nte
or eo
h
Function aut ra
c
ss
During a cold start, air is blown in behind the exhaust valve by the
ce
e
nl
pt
du
secondary air system. This produces an oxygen rich exhaust gas,

an
itte
y li
causing afterburning and reducing the heat-up phase of the cat‐

erm
ab
alytic converter. The Motronic control unit - J220- activates the

ility
ot p
secondary air inlet valve - J299- and combination valve via the
wit
, is n
secondary air pump relay - N112- .

h re
hole
spec
2.1.1 Removing and installing parts of secon‐

es, in part or in w
t to the co
dary air system

rrectness of i
Note
l purpos
♦ Parts marked with * are checked via self-diagnosis ⇒ Rep. gr.

01 ; Reading and erasing fault memory .
nf
ercia
or
♦ Parts marked with * are checked via final control diagnosis ⇒

m
m
atio
Rep. gr. 01 ; Final control diagnosis .

om
n in
or c
♦ Secondary air pump relay - J299- ** ⇒ page 176

thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
1 - O-ring
❑ Renew
2 - Connection
3 - Combination valve
4 - Air duct
❑ In cylinder head
5 - 10 Nm
6 - Secondary air inlet valve -
N112- */**
7 - Bracket
AG. Volkswagen AG d
❑ For secondary air inlet agen oes
olksw not
V
valve - N112- d by gu
ara
rise nte
❑ Bolted on bulkhead utho eo
ra
s a c
8 - Connector s
ce
le
un
pt
❑ Black, 2-pin
an
d
itte
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rm
9 - To intake manifold
ab
pe
ility
ot
wit
, is n
h re
❑ White connection points
hole
spec
to secondary air inlet
es, in part or in w
valve - N112- .
t to the co
11 - To vacuum unit
12 - Intake hose
rrectness of i
l purpos
❑ Press together at front

to release.
nform
ercia
❑ From air filter housing ⇒

m
Rep. gr. 24 .
a
com
tion in
13 - Secondary air pump motor
r
te o
thi
- V101- **
s
iva
do
r
rp
14 - Connector
um
fo
en
g
❑ Black, 2-pin
n
t.
yi Co
op py
❑ For secondary air pump motor - V101- t. C rig
gh ht
pyri by
15 - Bracket
co Vo
by lksw
cted agen
Prote
❑ For secondary air pump motor - V101-
AG.
❑ Secured to lock carrier.

16 - Pressure hose
❑ Press together at front to release.
17 - Washer
18 - Rubber bush
19 - Bush
20 - Connection
❑ For combination valve
21 - Seal
❑ Renew
22 - 5 Nm
2. Secondary air system 175

Sharan 1996 ➤
Secondary air pump relay - J299- ** -arrow 1-

♦ With secondary air pump fuse - S130- -arrow 2-
Note

2.1.2 Checking combination valve

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Test conditions
• No fault may be stored in fault memory ⇒ Rep. gr. 01 ; Inter‐
rrectne
rogating and erasing fault memory .
final control diagnosis . ss o
cial p
f inform
• Vacuum lines and hose connections must be free of leaks

mer
atio
• Vacuum lines not blocked or kinked

om
n
c
i
or
Test sequence
thi
te
sd
va
– Remove engine cover panel ⇒ Rep. gr. 50 .

i
o
pr
cum
r
fo
en
– Pull vacuum hose from secondary air inlet valve - N112- .

ng
t.
yi Co
op py
– Connect hand vacuum pump - V.A.G 1390- on vacuum hose
. C rig
ht ht
rig
to combination valve. py by
co Vo
by lksw
cted agen
Prote AG.
Note
Do not use compressed air during the following check!

Sharan 1996 ➤
– Remove intake hose on upper part of air filter -arrow- and blow
inside with light pressure. Combination valve must be closed.
Note
olkswagen AG
en AG. V
To release, press buttons on hose
Vol
coupling
ksw
ag
together. does
not
y gu
db ara
rise nte
– Operate hand vacuum ut
ho pump - V.A.G 1390- . Combination eo
ra
valve must open.ss a c
ce
le
If the combination valve does not open, or is constantly open:

un
pt
an
d
itte
y li
– Renew combination valve ⇒ Item 3 (page 175) .
rm
ab
pe
ility
ot
wit
2.2 Secondary air system: engine code
, is n
h re
hole
AWC
spec
es, in part or in w
t to the co
Function
During a cold start, air is blown in behind the exhaust valve by the
secondary air system. This produces an oxygen rich exhaust gas,
rrectness of i
causing afterburning and reducing the heat-up phase of the cat‐
l purpos
alytic converter. The activation is initiated by the Motronic control

unit - J220- via secondary air pump relay - J299- to combination
valve.
nform
ercia
2.2.1 Removing and installing parts of secon‐

m
a
com
ti
dary air system
on in
r
te o
thi
s
iva
do
r
rp
c
Note
um
fo
en
ng
t.
yi Co
op
♦ Components marked with * are checked via self diagnosis ⇒ C py
t. rig
Rep. gr. 01 ; Reading and erasing engine control unit fault
gh ht
yri by
memory cop Vo
by lksw
cted agen
Prote AG.
♦ Components marked with ** are checked via final control di‐
agnosis ⇒ Rep. gr. 01 ; Final control diagnosis
♦ Secondary air pump relay - J299- ** ⇒ page 179

Sharan 1996 ➤
1 - Air duct
2 - Seal
❑ Renew
4 - O-ring
Volkswagen AG
5 - Pressure hose agen
AG. does
olksw not
❑ Ensure firm seating db
yV gu
ara
ise nte
❑ Press together ut
hoat front
r eo
to release.ss a ra
c
ce
e
6 - Exhaust gas recirculation

nl
pt
du
an
valve - N18- */** with exhaust
itte
y li
gas recirculation potentiome‐
erm
ab
ter - G212-
ility
ot p
wit
, is n
❑ Checking exhaust gas
h re
recirculation valve -
hole
spec
N18- ⇒ Rep. gr. 01 ;
es, in part or in w
t to the co
recirculation potentiom‐
eter - G212-
rrectness of i
⇒ page 183 .
l purpos
7 - Connector
❑ Grey, 6-pin
nform
ercia
8 - Breather hose
m
at
om
io
❑ To air pipe
n
c
in t
r

o
his
ate
do
riv
9 - 25 Nm
p
cum
for
10 - 10 Nm
en
ng
t.
yi Co
op py
11 - 15 Nm t. C rig
gh ht
pyri by
12 - Clamp
o Vo
by c lksw
cted agen
Prote AG.
13 - Connecting pipe
14 - Connector
❑ Black, 2-pin
15 - Bracket
❑ For secondary air pump motor - V101-
❑ Attached to cylinder block
16 - Rubber bush
17 - Secondary air pump motor - V101-
18 - Intake hose
❑ Press together at front to release.
❑ From air filter housing ⇒ Rep. gr. 24 .

Sharan 1996 ➤
19 - Connection
❑ With bracket for combination valve and exhaust gas recirculation valve
lkswage es n
Relay for secondary d by V air pump - J299- ** - relay position
o ot g
ua 22 -
ran
ir se tee
Relay is located
tho on lower multifunctional unit relay holder.or
au ac
ss
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.2.2 Checking secondary air pump motor -
rrectness of i
V101-
l purpos
nf
ercia
o
rm
m
1552-
atio
om
n in
c

or
thi
te
sd
iva
o
r
rp
cu
Note
o
m
f
en
ng
t.
yi Co
op py
t. C rig
gh ht
yri
p by
co Vo
by lksw
cted agen
Prote AG.
Test conditions
• No fault may be stored in fault memory ⇒ Rep. gr. 01 ; Inter‐
rogating and erasing engine control unit fault memory .
• Secondary air pump relay - J299- fuse OK ⇒ Current flow di‐
agrams, Electrical fault finding and Fitting locations
• Secondary air pump intake hose not blocked or kinked.
Test sequence

Sharan 1996 ➤
– Remove pressure hose -arrow- from secondary air pump mo‐

tor.
Note
To release, press buttons on hose coupling together.
– Using final control diagnosis, actuate secondary air pump re‐

lay - J299- ⇒ Rep. gr. 01 ; Final control diagnosis .
The secondary air pump motor - V101- should run at intervals and
air should escape from the outlet point.
If engine runs but no or little air is delivered:
– Proceed with final control diagnosis until completed.
– Renew secondary air pump motor - V101-
⇒ Item 17 (page 178) . swa
gen AG
. Volkswagen AG
does
k not
Vol gu
If secondary air pump motor
se
d b- V101- does not run at intervals:
y ara
nte
i
or eo
– Check activation ofautsecondary
h
air pump motor - V101- ⇒ Rep. ra
gr. 01 ; Final control
ss diagnosis . c
ce
e
nl
pt
du
an
itte
2.2.3 Checking combination valve

y li
erm
ab
ility
ot p
Test conditions
wit
, is n
h re
• There should be no faults stored in the fault memory ⇒ Rep.

hole
gr. 01 ; Fault memory; Reading and erasing fault memory of

spec
es, in part or in w
engine control unit .

t to the co

rrectness of i
• Hose connections must be free of leaks.

l purpos
Test sequence
nform
ercia
Note
m
at
om
ion
c
Do not use compressed air during the following check!

in t
or
his
ate
do
riv

p
cum
for
en
g
– Remove pressure hose -arrow- from secondary air pump mo‐

n
t.
yi Co
op
tor - V101- . C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Note Prote AG.
To release, press buttons on hose coupling together.
– Gently blow into pressure hose to combination valve. Combi‐

nation valve must be closed.
– Blow with great pressure into pressure hose to combination
valve. Combination valve must open.
If the combination valve does not open, or is constantly open:
– Renew combination valve ⇒ Item 3 (page 178) .

Sharan 1996 ➤
3 Exhaust gas recirculation system:

engine code AWC
WARNING

sitions.
hot components.
lkswage es n
Note byV
o ot g
ua
d ran
ir se tee
o
♦ Operation and control of the exhaust gas recirculation system
th or
au ac
is checked via self-diagnosis of the Motronic control unit - ss
ce
le
J220- .
un
pt
an
d
itte
♦ Pulsed control enables every conceivable valve position.
y li
erm
ab
ility
♦ The cone shaped plunger in the exhaust gas recirculation
ot p
wit
valve ensures that various cross sectional openings are pos‐
is n
h re
sible at different plunger lifts.
ole,
spec
3.1 Repairing parts of exhaust gas recircu‐
t to the co
lation system
rrectne
Note
ss o
cial p
f
♦ Components marked with * are checked via self diagnosis ⇒
inform
Rep. gr. 01 ; Fault memory; Interrogating and erasing engine
mer
control unit fault memory
atio
om
n
c
♦ Components marked with ** are checked via final control di‐
i
or
n thi
e
agnosis ⇒ Rep. gr. 01 ; Final control diagnosis

t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Exhaust gas recirculation system: engine code AWC 181

Sharan 1996 ➤
1 - Air duct
2 - Seal
❑ Renew
❑ For secondary air sys‐
tem ⇒ page 177 , Sec‐
ondary air system: en‐
gine code AWC

4 - O-ring
5 - Pressure hose
❑ Press together at front
to release.
❑ From Secondary air n AG. Volkswagen AG do
swage es n
pump motor b-y V101-
Vo lk ot g
ua
⇒ Item 17rise(page
d 178) . ran
te
tho eo
6 - Exhaustss
agas
u
recirculation ra
c
valve - N18- */** with exhaust
ce
le
un
gas recirculation potentiome‐

pt
an
d
ter - G212- *
itte
y li
rm
ab

pe
ility
recirculation valve -
ot
wit
, is n
N18- ⇒ Rep. gr. 01 ;

h re

hole
spec

es, in part or in w
t to the co
recirculation potentiom‐
eter - G212-
⇒ page 183 .
rrectness of i
7 - Connector
l purpos
❑ Grey, 6-pin
8 - Breather hose
nform
ercia
❑ To air pipe ⇒ Item 11 (page 152)

m
a
com
ti
9 - 25 Nm
on in
r
te o
thi
10 - 15 Nm
s
iva
do
r
rp
11 - Clamp
um
fo
en
ng
t.
12 - Connecting pipe
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
13 - 10 Nm
c by lksw
cted agen
Prote AG.
14 - Connection
❑ With bracket for combination valve and exhaust gas recirculation valve

Sharan 1996 ➤
3.2 Checking exhaust gas recirculation potentiometer - G212-

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
♦ Hand multimeter - V.A.G 1526A- or hand multimeter - V.A.G

thi
s
iva
1526C-
do
r
rp
cum
fo

en
ng
t.
yi Co
op
♦ Auxiliary measuring set - V.A.G 1594 A- or auxiliary measuring C py
t. rig
set - V.A.G 1594C-
gh ht
pyri by
Vo
co lksw
by
♦ Adapter cable, 121-pin - V.A.G 1598/31- Prote
cted AG.
agen
Not illustrated

Sharan 1996 ➤
Test conditions
switched off.
Test sequence
– Pull off 6-pin connector (grey) from exhaust gas recirculation

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
– To measure voltage, connect hand multimeter - V.A.G
ss 1526A- c
or hand multimeter - V.A.G 1526C- with adapter leads from
ce
e
nl
pt
du
an
itte
y li
set - V.A.G 1594C- to contact 2 (positive) + 4 (earth) of con‐
erm
ab
nector.
ility
ot p
wit
, is n
– Switch ignition on. Specification: at least 4.5 V
h re
hole
spec
es, in part or in w
t to the co
If no voltage is present:
theft coding.
rrectness of i
– Remove battery.
l purpos

nf
ercia

orm
nected.
m
atio
om
n in
or c

thi
te
sd
iva

r
rp
cu
o
m
f
en
ng

t.
yi Co
Cop py
Contact 6 and test box socket 100 ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
Cable resistance: max. 1.5 Ω.

– Also check wiring for short to one another, short to vehicle
earth and short to battery positive. Specification: ∞ Ω.
If no wiring faults are detected and voltage is present between
contacts 2 + 4:
– Also fit 121-pin adapter lead - V.A.G 1598/31- to engine control
unit and 6-pin connector to exhaust gas recirculation valve.
– Install battery.
– Connect fault reader - V.A.G 1551- ( vehicle system tester -
V.A.G 1552- ). Then switch on ignition and select engine
control unit via “address word” 01 ⇒ Rep. gr. 01 .
– Initiate final control diagnosis and select exhaust gas recircu‐
lation valve - N18- , ⇒ Rep. gr. 01 ; Final control diagnosis .
– Connect voltage tester - V.A.G 1527B- to test box socket 100
and earth using auxiliary leads from auxiliary measuring set -
V.A.G 1594 A- or auxiliary measuring set - V.A.G 1594C- . The
. Volkswagen AG
LED should flash. swagen AG does
k not
y Vol gu
– Proceed with final control diagnosis until
se
d b completed. ara
nte
ri
ho eo
– Press buttons 0 and 6 for function
ut “End output” and confirm ra
sa c
entry with Q button. s
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Renew following components depending on scenario:
ility
ot p
wit
LED flashes:
, is n
h re
hole
– Renew exhaust gas recirculation valve - N18- with exhaust
spec
gas recirculation potentiometer - G212- ⇒ Item 6 (page 182) .
es, in part or in w
t to the co
– Adapt engine control unit ⇒ Rep. gr. 24 .
If no faults are found in the wiring and the LED does not flash:
rrectness of i
– Renew engine control unit ⇒ Rep. gr. 24 .
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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Service

Service Department. Technical Information

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Copyright © 2019 Volkswagen AG, Wolfsburg K0056763820

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3.1 Colour coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4.1 Checking pistons, piston rings and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 t to the co

1.1 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

1.3 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

2.2 Renewing camshaft oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2.3 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

2.4 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

2.5 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

2.6 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

4.4 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

1.1 Removing and installing turbocharger with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . 148

1.2 Removing and installing parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

1.3 Schematic diagram of turbocharging system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

2 Checking charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

2.2 Checking charge pressure system: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

1.2 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

1.1 Engine number

The engine number (“code letters” and “serial number”) can be

Additionally there is a sticker on the toothed belt guard with “en‐

“engine code”, and the second part (6 characters), the “serial

1.2 Engine data

1) in exceptional circumstances at least 91 RON, but with reduced output

Engine code AJH AWC

10 – Removing and installing engine

Special tools and workshop

♦ Lifting tackle - 2024 A-

2 Rep. gr.10 - Removing and installing engine

♦ Engine support - T10012-

♦ Torque wrench - V.A.G 1331- (5…50 Nm)

♦ Torque wrench - V.A.G 1332- (40…200 Nm)

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

♦ Pliers for spring-type clips - VAS 5024A-

♦ Step ladder - VAS 5085-

♦ Grease - G 000 100-

1. Removing and installing engine 3

1.1 Notes on removing

The engine is removed downwards together with the gearbox. To

– With ignition switched off, disconnect battery earth strap.

– Remove trim panel/air duct -1-.

– During remaining disassembly, disconnect connectors

– Disconnect throttle cable at throttle valve control module cable

4 Rep. gr.10 - Removing and installing engine

– Unclip fuel hoses from bracket.

Press buttons on hose couplings to do this.

Press buttons on hose couplings to do this.

– Remove air pipes between turbocharger/charge air cooler,

turbocharger/air filter and charge air cooler/throttle valve con‐

trol module ⇒ page 152 , Removing and installing parts of the

charge air cooling system: engine code AWC.