SM 51

Service
Workshop Manual
Sharan 1996 ➤
4-cylinder diesel engine (1.9 l engine)
Engine ID ANU ASZ AUY BTB BVK
Edition 04.2014
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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
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system
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Technical information should always be available to the foremen and mechanics, because their
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg K0056763920

Sharan 1996 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 04.2014
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Additional information and assembly work for vehicles with air conditioner . . . . . . . . . . . . 10
13 - Crankshaft group . . . . . . . . . . . . a.ge. n.A.G.. V.o.lks.w.ag. e.n .AG. d.o. . . . . . . . . . . . . . . . . . . . . . . . 12

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1.1 Assembly overview - hpoly is V-belt drive . . . . . . . . . . . . . . . . . . .an.te. . . . . . . . . . . . . . . . . . . .
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1.2 Removing and installing
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1.3 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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1.4 Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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2 Sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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2.1 Assembly overview - sealing flanges and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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2.2 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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2.3 Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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2.4 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3 Checking dowel pin projection out of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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4.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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4.3 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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1.3 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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1.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.5 Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.3 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.4 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.5 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.1 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.2 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Contents i
Sharan 1996 ➤
2.1 Assembly overview - oil pump, sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

2.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3 Oil filter bracket, oil pressure, engine oil cooler and oil supply line . . . . . . . . . . . . . . . . . . 80
3.1 Assembly overview - oil filter bracket and engine oil cooler: Engine codes ANU, AUY, BVK
........................................................................ 80
3.2 Assembly overview - oil filter bracket and engine oil cooler: Engine codes ASZ, BTB . . . . 82
3.3 Assembly overview - oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.4 Removing and installing oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.5 Checking oil pressure and oil pressure switch . . . . . . . . . w. a.g.en. A. G. ..V.ol.ks. w. a.g.en. A. G. d. o.e. . . . . . . 86
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or.ise. . . . . . .
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1.1 Assembly overview - cooling system, body side: Engine codes ANU, AUY, BVK . . . . . . . . 89
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1.2 Assembly overview - cooling system, body side: Engine codes ASZ, BTB . . . . . . . . . . . . 91
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1.3 Assembly overview - cooling system, engine side: Engine codes ANU, AUY, BVK . . . . . . erm 92
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1.4 Assembly overview - cooling system, engine side: Engine codes ASZ, BTB . . . . . . . . . . 94
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1.5 Assembly overview - additional cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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1.6 Coolant hose schematic diagram: Engine code ANU . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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1.7 Coolant hose schematic diagram: Engine codes AUY, BVK . . . . . . . . . . . . . . . . . . . . . . . . 98
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1.8 Coolant hose schematic diagram: Engine codes ASZ, BTB . . . . . . . . . . . . . . . . . . . . . . . . 99
1.9 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.10 Removing and installing radiator and fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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1.11 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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1.12 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

1.13 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
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1.14 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 115

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1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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1.3 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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1.4 Assembly overview - fuel filter: Engine codes ANU, AUY, BVK . . . . . . . . . . . . . . . . . . . . . . 117
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1.5 Assembly overview - fuel filter: Engine codes ANU, ASZ, AUY, BTB, BVK . . . . . . . . . . . . 119
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1.6 Assembly overview - heat exchanger for fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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1.7 Removing and installing fuel cooler: Engine codes ANU, AUY, BVK . . . . . . . . . . . . . . . . . . 122
1.8 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.9 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.10 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.11 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.12 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.13 Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.14 Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.15 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.3 Hose connections with push-on connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.4 Assembly overview - turbocharger: Engine code ANU . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1.5 Assembly overview - turbocharger: Engine codes ASZ, BTB . . . . . . . . . . . . . . . . . . . . . . 145
1.6 Assembly overview - turbocharger: Engine codes AUY, BVK . . . . . . . . . . . . . . . . . . . . . . 147
1.7 Assembly overview - charge air cooling: Engine codes ANU, AUY, BVK . . . . . . . . . . . . . . 149
1.8 Assembly overview - charge air cooler: Engine codes ASZ, BTB . . . . . . . . . . . . . . . . . . . . 151
1.9 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
ii Contents
Sharan 1996 ➤
1.10 Charge pressure control hose routing diagram: Engine code ANU . . . . . . . . . . . . . . . . . . 153
1.11 Charge pressure control hose routing diagram: Engine codes ASZ, AUY, BTB, BVK . . . . 155
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

1 Repairing diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.3 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.4 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.5 Assembly overview - intake manifold flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.6 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.7 Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.8 Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.9 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
2.1 Reading and erasing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
2.2 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.1 Assembly overview - front exhaust pipe with catalytic converter . . . . . . . . . . . . . . . . . . . . 170
1.2 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2.1 Assembly overview - exhaust gas recirculation: Engine code ANU . . . . . . . . . . . . . . . . . . 173
2.2 Assembly overview - exhaust gas recirculation: Engine codes ASZ, AUY, BTB, BVK . . . . 175
2.3 Checking mechanical exhaust gas recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.1 Checking glow plugs
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Contents iii
Sharan 1996 ➤
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spec
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rrectness of i
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Prote AG.
iv Contents
AG. Volkswagen AG d
agen oes
olksw not
d byV gu
ara Sharan 1996 ➤
e
horis 4-cylinder diesel engine (1.9 l engine)
nte
eo - Edition 04.2014
aut ra
ss c
ce
e
00 – Technical data
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1 Technical data
wit
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(VRL006739; Edition 04.2014)
hole
spec
es, in part or in w
Engine number and engine code ⇒ page 1
t to the co
Engine data ⇒ page 1
1.1 Engine number
rrectness of i
l purpos
The engine number (“code letters” and “serial number”) can be

found on the joint between engine and gearbox.
nf
ercia
The engine number consists of up to nine characters (alphanu‐
orm
meric). The first part (maximum 3 characters) makes up the
m
atio
m
“engine code”, and the second part (6 characters), the “serial

o
n in
c
number”. If more than 999,999 engines with the same engine

or
thi
code are produced, the first of the six characters is replaced with
te
sd
iva
a letter.
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In addition, there is a sticker on the toothed belt guard with “engine
en
ng
t.
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code” and “serial number”.
Co
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The engine code can also be found on the vehicle data sticker.
rig ht
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Prote AG.
1.2 Engine data

Edition 02.2011 version 14.1
Engine code ANU ASZ AUY BTB BVK
Manufactured 01.99 ► 10.02 ► 06.00 ► 03.05 ► 10.05 ►
Emissions fulfil D3 standardEU3 stand‐ D3 standard EU3 stand‐ EU4 stand‐
ard ard ard
Capacity l 1.9 1.9 1.9 1.9 1.9
Output kW at rpm 66/4000 96/4000 85/4000 110/4000 85/4000
Torque Nm at rpm 240/1900 310/1900 310/1900 310/1900 310/1900
Bore ∅ mm 79.5 79.5 79.5 79.5 79.5
Stroke mm 95.5 95.5 95.5 95.5 95.5
Compression ratio 18.0 19.0 18.0 19.0 19.0
Fuel according DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
to
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Catalytic converter yes yes yes yes yes
Exhaust gas recirculation yes yes yes yes yes
Turbocharging/supercharging yes yes yes yes yes
Charge air cooling yes yes yes yes yes
1. Technical data 1
AG. Volkswagen AG d
agen oes
olksw not
V
Sharan 1996 ➤ d by gu
ara
ise nte
thor eo
au ra
ss c
ce
e
10 – Removing and installing engine
nl
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du
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itte
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erm
ab
ility
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1 Removing and installing engine
wit
, is n
h re
hole
Notes on removing ⇒ page 3 .
spec
es, in part or in w
Securing engine to assembly stand ⇒ page 6 .
t to the co
Notes on installing ⇒ page 7 .
rrectness of i
Assembly mountings ⇒ page 9
l purpos
Additional information and assembly work for vehicles with air
conditioner ⇒ page 10 .
nf
ercia
or
Special tools and workshop
m
m
atio
equipment required
om
n in
or c
♦ Lifting tackle - 2024A-
thi
te
sd
iva
♦ Support clamp - VW 313-
o
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♦ Engine and gearbox sup‐

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port - VW 540- Cop py
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♦ Engine bracket - T10012- p by
co Vo
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♦ Workshop hoist - V.A.G Prote AG.
1202/A- or workshop crane
- VAS 6100-
♦ Drip tray - V.A.G 1306- or
drip tray - VAS 6208-
2 Rep. gr.10 - Removing and installing engine

Sharan 1996 ➤
♦ Torque wrench (5... 50 Nm)

- V.A.G 1331-
♦ Torque wrench (40... 200
Nm) - V.A.G 1332-
♦ Engine and gearbox jack -
V.A.G 1383/A-
♦ Spring-type clip pliers -
VAS 5024-
♦ Stepladder - VAS 5085-
AG. Volkswagen AG d
agen oes
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byV gu
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spec
es, in part or in w
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Not illustrated
♦ Container for removed parts - V.A.G 1698-
rrectness of i
♦ Engine bung set - VAS 6122-

l purpos
♦ Grease - G 000 100- (vehicles with manual gearbox)

nform
ercia
♦ Cable ties
m
1.1 Notes on removing

com
tion in
r
te o
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The engine is removed from below with the gearbox

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iva
do
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– Read fault memories of all control units before removing

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⇒ page 168 .
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Prote AG.
1. Removing and installing engine 3

Sharan 1996 ➤
Note
♦ Before carrying out further work, disconnect battery earth

strap. Check whether a coded radio is fitted. Obtain anti-theft
coding first if necessary.
♦ Leave ignition key in ignition lock to prevent steering lock from
engaging.
♦ It is advisable to remove the front wheels before beginning
engine removal. The vehicle can then be lowered on hoist until
the brake disc splash plates are just above the floor. This pro‐
vides the most ergonomic working position regarding acces‐
sibility of engine compartment components.
♦ All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
♦ Some components cannot be removed, or removed only with
difficulty, with the engine installed. Therefore, you should de‐
termine all defective components before removing engine and
renew them while engine is removed.
♦ To prevent damage to removed components, place them in
the container for removed parts - V.A.G 1698- . AG. Volkswagen AG d
agen oes
olksw not
y V gu
– Observe rules for cleanliness ⇒ pageis115ed b . ara
nte
or eo
h
– All cable ties which are opened ora cut through when engine is
ut ra
c
s
removed must be replaced in thes same position when engine
ce
e
is installed.
nl
pt
du
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itte
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– First check whether a coded radio is fitted. If so, obtain anti-
erm
ab
theft coding.
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wit
– With ignition switched off, disconnect earth strap from battery.
, is n
h re
hole
– Remove engine cover. spec

es, in part or in w
– Remove battery and battery carrier.

t to the co
– Remove noise insulation ⇒ Body Repairs; Rep. gr. 50 ; Exte‐

rior; Body - front; Assembly overview - noise insulation (diesel
rrectness of i
engine)
l purpos
– Remove air filter housing together with intake manifold.

– Disconnect fuel supply and return lines at diesel fuel filter.
nf
ercia
orm
m
atio
WARNING
om
n in
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e
♦ The fuel and the fuel lines in the fuel system can become
t
sd
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very hot (danger of scalding)!

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♦ The fuel system is also under pressure! Before opening

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the system, place cloths around the connections. Then Cop py
carefully loosen connection to release the pressure!
t. rig
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♦ Wear eye and hand protection when performing any type
by lksw
cted agen
of repair work on the fuel system!
Prote AG.
– Seal lines so that fuel system is not contaminated by dirt.

Vehicles with 5-speed manual gearbox 006
– Pull pipe/hose off slave cylinder on gearbox: ⇒ 5-speed man‐
ual gearbox 006; Rep. gr. 30 ; Assembly overview - hydraulics
and clutch release mechanism

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara Sharan 1996 ➤
ise nte
r
ut
ho 4-cylinder diesel engine (1.9 l engine) - Edition eo
ra 04.2014
s a c
s
– Remove selector cables from gearbox: ⇒ 5-speed manual
ce
le
un
pt
gearbox 006; Rep. gr. 34 ; Repairing selector mechanism;
an
d
itte
y li
Removing and installing selector cables
erm
ab
ility
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Vehicles with 6-speed manual gearbox 02N
wit
is n
h re
– Pull pipe/hose off slave cylinder on gearbox: ⇒ 6-speed man‐
ole,
ual gearbox 02N; Rep. gr. 30 ; Assembly overview - hydraulics
spec
and clutch release mechanism
t to the co
– Remove selector cables from gearbox: ⇒ 6-speed manual
gearbox 02N; Rep. gr. 34 ; Repairing selector mechanism;
Removing and installing selector cables
rrectne
Vehicles with four-wheel drive
ss o
– Disconnect front propshaft tube from gearbox: ⇒ 6-speed
cial p
f i
gearbox 02N four-wheel drive; Rep. gr. 39 ; Final drive, rear
nform
differential; Removing and installing propshaft
mer
atio
m
Vehicles with automatic gearbox

o
n
c
i
or
n thi
– Disconnect selector lever cable from gearbox: ⇒ 5-speed au‐
te
sd
va
tomatic gearbox 09B; Rep. gr. 37 ; Repairing selector mech‐

i
o
pr
c
anism; Removing and installing selector mechanism .
um
r
fo
en
ng
t.
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Vehicles 06.00 ►
Co
Cop py
t. rig
gh
– Bring lock carrier into service position ⇒ Body Repairs; Rep.
ht
pyri by
Vo
o
gr. 50 ; Exterior; Body - front; Lock carrier service position . by c lksw
cted agen
Prote AG.
Continuation for all vehicles
– Removing radiator ⇒ page 103 .
– Remove air pipes between turbocharger/charge air cooler,
charge air cooler/inlet connection.
– Pull vacuum and breather hoses off engine.
– Pull off or disconnect all other electrical connections as nec‐
essary from engine and lay to side.
– Remove drive shafts: ⇒ Running gear, axles, steering, front
and four-wheel drive; Rep. gr. 40 ; Repairing drive shafts;
Removing and installing drive shafts .
Vehicles with air conditioner
– Observe additional information and installation work
⇒ page 10 .
– Remove poly V-belt ⇒ page 14 .
– Unbolt power-assisted steering vane pump and secure to
body with wire; hoses remain connected: ⇒ Running gear,
axles, steering, front and four-wheel drive; Rep. gr. 48 ; Vane
pump, reservoir, hydraulic lines .
– Remove front exhaust pipe ⇒ page 170 .
– Insert engine bracket - T10012- in engine and gearbox jack -
V.A.G 1383 A- .

Sharan 1996 ➤
– Fit engine bracket - T10012- onto cylinder block with securing

nut M10. Specified torque: 40 Nm
– Lift engine and gearbox lightly using engine and gearbox jack
- V.A.G 1383 A- .
– Remove pendulum support ⇒ Running gear, axles, steering,
front and four-wheel drive; Rep. gr. 40 ; Repairing front sus‐
pension .
– Unscrew right assembly mounting securing bolts -1-.
Note
To remove securing bolts, use stepladder - VAS 5085- .

AG. Volkswagen AG d
agen oes
ksw
Vehicles ► 05.00 byV
ol not
gu
d ara
ise nte
or eo
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aut ra
ss c
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nl
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du
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itte
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erm
ab
– Unscrew left assembly mounting securing bolts -A-.
ility
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wit
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hole
Note
spec
es, in part or in w
t to the co
Vehicles 06.00 ►
rrectness of i
l purpos
nform
mercia
at
– Unscrew left assembly mounting securing bolts -A-.

om
ion
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or
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ate
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Note
priv
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for
en
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t.
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Cop py
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Continuation for all vehicles py by
co Vo
by lksw
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– Carefully lower engine with gearbox. Prote AG.
Note
Engine with gearbox must be guided carefully when lowered to

prevent damage to bodywork.
1.2 Securing engine to assembly stand

When working on the engine, secure it with engine and gearbox
support - VW 540- to support clamp - VW 313- of the assembly
stand or to engine and gearbox support - VAS 6095- .

Sharan 1996 ➤
Procedure
– Unbolt gearbox.
– Secure torque converter against “falling out” after separating
engine from gearbox.
– Attach lifting tackle - 2024 A- as follows and lift from engine
and gearbox jack - 1202 A- using workshop crane - VAS 6100-
or workshop crane - V.A.G 1383 A- .
Belt pulley end: 1st hole in hook rail at position 1
Flywheel end: 4th hole in hook rail at position 8
WARNING
The hooks and locating pins must be secured

wage
nwith locking
AG. Volkswagpins.
en AG
doe
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yV t gu
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tho eo
au ra
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Note ss
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♦ The holes marked with 1 … 4 of the support bar point to the

itte
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rm
belt pulley.
ab
pe
ility
ot
♦ The holes in the hook rails are counted up from the hook.
wit
, is n
h re
hole
spec
– Secure engine to support clamp - VW 540- using engine and
es, in part or in w
gearbox support - VW 313- .
t to the co
Note
rrectness of i
l purpos
First loosen coolant pipe at flywheel end.

nform
ercia
1.3 Notes on installing

m
a
com
tio
Procedure
n in
r
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Installation is carried out in the reverse order. When installing,

s
iva
do
note the following:

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WARNING . Cop py
rig
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rig by
py
When doing any repair work, especially in the engine compart‐ co Vo
by lksw
ment, pay attention to the following due to the cramped condi‐
cted agen
Prote AG.
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
– Check whether dowel sleeves for centring engine/gearbox

have been fitted in cylinder block, insert if necessary.

Sharan 1996 ➤
– Hook intermediate plate onto sealing flange and slide onto

dowel sleeves -arrows-.
– Clean input shaft splines and lightly grease with grease - G
000 100- .
– Check clutch and clutch control and install: ⇒ 5-speed manual
gearbox 006; Rep. gr. 30 ; Assembly overview - hydraulics
and clutch release mechanism .
– Checking and installing clutch and clutch control: ⇒ 6-speed
manual gearbox 02N; Rep. gr. 30 ; Assembly overview - hy‐
draulics and clutch release mechanism .
– Screw in all bolts on assembly mountings by hand approx. 5…
6 turns.
– Align assembly mountings stress-free by rocking.
Note
Specified torques for assembly mountings ⇒ page 9 .
– Install pendulum support ⇒ Running gear, axles, steering,

front and four-wheel drive; Rep. gr. 40 ; Repairing front sus‐
pension .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Removing and installing compressor bracket .
– Connect pipe/hose on slave cylinder and secure with clip: ⇒
5-speed manual gearbox 006; Rep. gr. 30 ; Assembly over‐lkswage es n
view - hydraulics and clutch release mechanism d byV
o ot g
ua
e ran
ris tee
– Fit selector cables on gearbox, if necessary adjust:
ut ⇒ 5-speed
ho or
manual gearbox 006; Rep. gr. 34 ; Repairing ss selector mech‐
a ac
anism; Removing and installing selector cables .
ce
le
un
pt
an
d

itte
y li
rm
ab
– Connect pipe/hose on slave cylinder and secure with clip: ⇒

pe
ility
ot
6-speed manual gearbox 02N; Rep. gr. 30 ; Assembly over‐

wit
, is n
view - hydraulics and clutch release mechanism

h re
hole
spec
– Fit selector cables on gearbox, if necessary adjust: ⇒ 6-speed

es, in part or in w
manual gearbox 0062N; Rep. gr. 34 ; Repairing selector

t to the co
mechanism; Removing and installing selector cables .

Vehicles with four-wheel drive
rrectness of i
– Install propshaft tube: ⇒ 6-speed manual gearbox 02N four-

l purpos
wheel drive; Rep. gr. 39 ; Final drive, rear differential; Re‐

moving and installing propshaft
nform
ercia

m
– Install air conditioner compressor ⇒ Heating, air conditioning;

com
tio
Rep. gr. 87 ; Removing and installing compressor bracket .

n in
r
te o
thi

s
iva
do
r
rp
cum
– Install drive shafts: ⇒ Running gear, axles, steering, front and

fo
en
g
four-wheel drive; Rep. gr. 40 ; Repairing drive shafts; Remov‐

n
t.
yi Co
op
ing and installing drive shafts . C py
t. rig
gh ht
pyri by
Vo
co lksw
by
8
cted agen
Prote AG.
Rep. gr.10 - Removing and installing engine
AG. Volkswagen AG d
agen oes
olksw not
V
d by gu
ara Sharan 1996 ➤
ise nte
thor 4-cylinder diesel
eo engine (1.9 l engine) - Edition 04.2014
au ra
ss c
– Install power-assisted steering vane pump with bracket: ⇒
ce
le
un
pt
Running gear, axles, steering, front and four-wheel drive; Rep.
an
d
itte
gr. 48 ; Vane pump, reservoir, hydraulic lines.
y li
rm
ab
pe
ility
– Install poly V-belt ⇒ page 14 .
ot
wit
, is n
– Install air pipes between turbocharger/charge air cooler,
h re
hole
charge air cooler/inlet connection.
spec
es, in part or in w
t to the co
Note
rrectness of i
When installing ensure that locking lugs engage securely
⇒ page 141 .
l purpos
– Install front exhaust pipe ⇒ page 170 .
nform
ercia
– Install battery and battery tray.

m
a
com
tio
– Installing radiator ⇒ page 103 .
n in
r
te o
thi
– Install air filter housing together with intake manifold.
s
iva
do
r
rp
c
– Electrical connections and routing ⇒ Current flow diagrams,
um
fo
Electrical fault finding and Fitting locations.
en
ng
t.
yi Co
op py
– Replenish coolant ⇒ page 100 . t. C rig
gh ht
pyri by
– Install noise insulation ⇒ Body Repairs; Rep. gr. 50 ; Exterior;
co Vo
by lksw
cted
Body - front; Assembly overview - noise insulation (diesel en‐
agen
Prote AG.
gine)
– On vehicles with automatic gearbox the gearbox control unit
must also be adapted: ⇒ Self-diagnosis for 5-speed automatic
gearbox 09B; Repair group 01; Performing self-diagnosis; In‐
itiating basic setting .
– Carry out road test and read all fault memories ⇒ page 168 .
Observe applicable safety precautions during road test
⇒ page 156 .
Specified torques
Threaded connection Specified torque
Bolts, nuts M6 10 Nm
M7 15 Nm
M8 20 Nm
M10 40 Nm
M12 60 Nm
Deviations
Front exhaust pipe to turbocharger 25 Nm
Note
Specified torques for assembly mountings ⇒ page 9 .
1.4 Assembly mountings

Specified torques
(Bolts oiled)

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Sharan 1996 ➤ orise nte
eo
h
s aut
- Edition 04.2014 ra
c
s
ce
le
un
Right assembly mounting
pt
an
d
itte
y li
A = 60 Nm B = 55 Nm
rm
ab
pe
ility
Vehicles ► 05.00
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
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cum
fo
en
ng
Left assembly mounting on vehicles with manual gearbox:

t.
yi Co
Cop py
t. rig
A = 55 Nm; B = 100 Nm; C = 100 Nm; D = 20 Nm + 1/4 turn (90°)
gh ht
pyri by
Vo
further; E = 80 Nm
co lksw
by
cted agen
Prote AG.
Vehicles 06.00 ►
Assembly mounting, left on vehicles with manual gearbox and

automatic gearbox 09B:
A = 60 Nm + 1/4 turn (90°) further1); B = 90 Nm + 1/4 turn (90°)
further1); C = 50 Nm + 1/4 turn (90°) further1); D = 25 Nm
1) Renew securing bolt/nut.
Note
All threaded holes, where self-locking bolts are fitted must be

cleaned of locking material remnants using a thread cutting tap.
1.5 Additional information and assembly

work for vehicles with air conditioner
WARNING
The air conditioner refrigerant circuit must not be opened.

Sharan 1996 ➤
Note
♦ The opening of the refrigerant circuit can only be carried out

in workshops, which have trained personnel and the neces‐
sary range of tools and workshop equipment.
♦ To prevent damage to condenser or to refrigerant lines/hoses,
ensure that the lines and hoses are not stretched, kinked or
bent.
To facilitate removing and installing engine without opening re‐

frigerant circuit:
– Remove retaining clamp(s) for refrigerant lines.
– Remove alternator: ⇒ Electrical system; Rep. gr. 27 ; Re‐
moving and installing alternator with poly V-belt .
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Removing and installing compressor brack‐
et .
G. Volkswage
– Secure air conditioner compressor lto ksw
body
agen so that the refrig‐
A n AG d
oes
not
erant lines are not under tension.
by
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a
ed ran
ris tee
tho or
au ac
ss
ce
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un
pt
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d
itte
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rm
ab
pe
ility
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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
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
13 – Crankshaft group
1 Dismantling and assembling engine
AG. Volkswagen AG d
agen oes
olksw not
Note d byV gu
ara
ise nte
or eo
th
♦ When working on the engine, secure
s auit with engine and gear‐ ra
c
box support - VW 540- to support clamp - VW 313- of the s
ce
e
assembly stand or to engine and gearbox support - VAS
nl
pt
du
an
6095- .
itte
y li
erm
ab
♦ Finding metal shavings or a large quantity of small metal par‐
ility
ot p
ticles during engine repair could indicate that the crankshaft
wit
, is n
bearings or conrod bearings are damaged. To prevent this
h re
hole
from causing further damage, perform the following repairs:
spec
es, in part or in w
♦ Thoroughly clean oil channels.
t to the co
♦ Renew engine oil cooler
rrectness of i
♦ Renew oil filter element
♦ Renew oil spray jets
l purpos
Assembly overview - poly V-belt drive ⇒ page 12 .
nf
ercia
orm
Removing and installing poly V-belt ⇒ page 14 .
m
atio
om
n in
Assembly overview - toothed belt drive ⇒ page 15 .
or c
thi
te
Assembly overview - crankcase ⇒ page 17
sd
iva
o
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1.1 Assembly overview - poly V-belt drive
o
m
f
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ng
t.
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.
12 Rep. gr.13 - Crankshaft group

Sharan 1996 ➤
1 - Poly V-belt
❑ Mark direction of rota‐
tion before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing and installing
⇒ page 14 .
2 - 10 Nm + 1/4 turn (90°) fur‐
ther
3 - Belt pulley and vibration
damper
AG. Volkswagen AG d
❑ Can only be installed in agen oes
olksw not
one position, holes are d by V gu
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offset. rise nte
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4 - 25 Nm ss c
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un
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5 - Tensioning element for poly
an
d
itte
V-belt
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ab
❑ Swing with open-end
ility
ot p
spanner to slacken poly
wit
is n
V-belt ⇒ page 14
h re
ole,
spec
6 - Alternator
t to the co
⇒ Electrical system;
Rep. gr. 27 ; Removing
rrectne
and installing alternator
with poly V-belt .
s
7 - Bracket for ancillaries
s o
cial p
f
❑ For alternator, power-
inform
assisted steering vane
mer
pump and air condition‐
atio
m
er compressor
o
n
c
i
or
n thi
8 - 45 Nm
te
sd
iva
o
❑ Observe tightening sequence ⇒ page 14 .
pr
cum
r
fo
en
ng
9 - Banjo bolt, 30 Nm
t.
yi Co
Cop py
10 - Seal
t. rig
gh ht
pyri by
❑ Renew.
co Vo
by lksw
cted agen
Prote AG.
11 - Pressure line
12 - Vane pump
❑ For power-assisted steering
❑ Removing and installing: ⇒ Running gear, axles, steering, front and four-wheel drive; Rep. gr. 48 ; vane
pump, reservoir, hydraulic lines .
13 - Belt pulley
❑ For vane pump
1. Dismantling and assembling engine 13

Sharan 1996 ➤
Sequence for tightening ancillary bracket to cylinder block

Procedure
– Place ancillary bracket on cylinder block (observe dowel
sleeve between ancillary bracket and cylinder block).
– Tighten ancillary bracket as shown in following tightening se‐
quence:
1 - Tighten bolt -A- to 45 Nm
2 - Tighten bolt -B- to 45 Nm
3 - Tighten bolt -C- to 45 Nm
AG. Volkswagen AG d
agen oes
4 - Tighten bolt -D- to 45 Nm olksw not
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5 - Tighten bolt -E- to 45 Nm rise nte
tho eo
au ra
6 - Tighten bolt -F- to 45 Nm ss c
ce
le
un
pt
an
d
1.2 Removing and installing poly V-belt

itte
y li
rm
ab
pe
ility
Special tools and workshop equipment required
ot
wit
, is n
h re
♦ Locking pin - T10060A-
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
Removing
do
r
rp
cum
fo
en
ng
t.
yi Co
Note Cop py
t. rig
gh ht
pyri by
Before removing the poly V-belt mark the direction of rotation.
co Vo
by lksw
cted
When installing belt ensure it is correctly seated in pulleys.
agen
Prote AG.
– Mark direction of rotation of poly V-belt.

– Swing tensioning element in direction of arrow using a 16 mm
open jaw spanner until tensioning element can be locked.

Sharan 1996 ➤
– Lock tensioner with locking pin - T10060A- .

engine)
– Remove poly V-belt.
Installing
– Install in reverse order.
Note
♦ Ensure, before installing poly V-belt, that all ancillaries (alter‐

nator, air conditioner compressor, vane pump) are secured
tightly.
♦ When installing poly V-belt, check direction of belt rotation and
proper seating of belt in pulleys.
♦ For vehicles without air conditioning, fit poly V-belt on alterna‐
tor last.
♦ 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 that belt runs properly. agen
AG. Volkswagen AG d
oes
olksw not
– Install noise insulation ⇒ Body Repairs; Rep.e d by gr. 50 ; Exterior;
V gu
ara
Body - front; Assembly overview - noise horis insulation (diesel en‐ nte
eo
gine) aut ra
c
ss
Belt drive routing
ce
e
nl
pt
du
an
itte
y li
Belt drive without air conditioner compressor
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
Belt drive with air conditioner compressor

at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
1.3 Assembly overview - toothed belt drive

lkswage es n
Sharan 1996 ➤ byV
o ot g
ua
ed ran
4-cylinder diesel engine (1.9 l engine) - Edition 04.2014 horis tee
ut or
a ac
ss
1 - Toothed belt guard upper
ce
le
part
un
pt
an
d
itte
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2 - Toothed belt
rm
ab
pe
ility
ot
wit
, is n
h re
❑ Check for wear.
hole
spec
❑ Do not kink.
es, in part or in w
t to the co
❑ Removing, installing
and tensioning
⇒ page 42 .
rrectness of i
3 - 20 Nm + 1/8 turn (45°) fur‐
l purpos
ther
4 - Tensioning roller
nform
ercia
5 - 100 Nm m
a
com
tion in
6 - 25 Nm
r
te o
thi
s
iva
7 - Camshaft pulley
do
r
rp
cum
fo
8 - Hub
en
ng
t.
yi
❑ With sender wheel
Co
Cop py
t. rig
❑ Use counterhold tool -
gh ht
pyri by
T10051- to loosen and
co Vo
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cted
tighten.
agen
Prote AG.
❑ To remove, use puller -

T10052- .
⇒ page 67 .
9 - 10 Nm
10 - Rear toothed belt guard
11 - Sealing grommet
❑ Renew if damaged.
12 - Toothed belt tensioner
❑ Only for vehicles with hydraulic tensioning system
13 - Guide roller
14 - Coolant pump
❑ Installed in cylinder block
❑ Check for ease of movement.
❑ Note installation position.
❑ Removing and installing ⇒ page 105 .
15 - Crankshaft toothed belt pulley
16 - 120 Nm + 1/4 turn (90°) further
❑ Renew.
❑ Use counterhold for toothed belt pulley - 3099- to loosen and tighten
❑ Do not additionally oil or grease the threads and shoulder.
❑ Turning further can be done in several stages.
17 - 15 Nm
18 - 20 Nm
19 - Toothed belt guard lower part
20 - Belt pulley and vibration damper
❑ Can only be installed in one position, holes are offset.

Sharan 1996 ➤
21 - 10 Nm + 1/4 turn (90°) further

22 - Cover
❑ Fitted according to version
23 - Toothed belt guard centre part
24 - 30 Nm
25 - 45 Nm
26 - Engine support AG. Volkswagen AG d
agen oes
lksw not
27 - 45 Nm d by Vo gu
ara
rise nte
tho eo
au ra
ss c
1.4 Assembly overview - crankcase
ce
le
un
pt
an
d
itte
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erm
ab
1 - Cylinder block
ility
ot p
wit
is n
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sealing flanges and fly‐
ole,
spec
wheel/drive plate
⇒ page 19 .
t to the co
crankshaft
⇒ page 29 .
rrectne
❑ Dismantling and assem‐
bling pistons and con‐
ss
rods ⇒ page 32
o
cial p
f inform
2 - Gasket
mer
❑ Renew.
atio
om
n
c
3 - Oil filter bracket
i
or
n thi
te
❑ Ensure clearance to ad‐
sd
iva
o
r
jacent components.
p
cum
r
fo
en
ng

t.
yi Co
bling: Cop py
t. rig
gh
❑ Engine codes ANU,
ht
pyri by
Vo
o
AUY, BVK ⇒ page 80
c by lksw
cted agen
Prote AG.
❑ Engine codes ASZ, BTB
⇒ page 82
4 - 15 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew.
❑ First fit upper left and
lower right bolts and
then tighten all four bolts
diagonally.
5 - 15 Nm
6 - Engine speed sender -
G28-
7 - Connection
❑ For thermostat.
8 - 15 Nm
9 - O-ring
❑ Renew.
10 - Thermostat

Sharan 1996 ➤
❑ Note installation position ⇒ page 107 .
❑ Checking: heat thermostat in water.
❑ Opening begins at approx. 87 °C.
❑ Ends at approx. 102 °C.
❑ Opening lift at least 7 mm.
11 - 45 Nm
12 - Bracket for ancillaries
❑ For alternator, power-assisted steering vane pump and air conditioner compressor
13 - Oil sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant - D 176 404 A2- .
14 - 15 m
AG. Volkswagen AG d
agen oes
olksw not
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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 ➤
2 Sealing flange andVolflywheelA G. Volkswagen AG d

agen oes
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db ara
rise nte
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Note au ra
c
ss
ce
le
un
pt
♦ When working on the engine, secure it with engine and gear‐
an
d
itte
box support - VW 540- to support clamp - VW 313- of the
y li
rm
ab
pe
ility
6095- .
ot
wit
, is n
h re
♦ Repair measures to clutch (vehicles with 5-speed manual
hole
gearbox 006): ⇒ 5-speed manual gearbox 006; Rep. gr. 30 ;
spec
Repairing clutch
es, in part or in w
t to the co
♦ Repair measures to clutch (vehicles with 6-speed manual
gearbox 02N): ⇒ 6-speed manual gearbox; Rep. gr. 30 ; Re‐
pairing clutch .
rrectness of i
l purpos
Assembly overview - sealing flange and flywheel ⇒ page 19

Renewing crankshaft oil seal - belt pulley end ⇒ page 21 .
nform
ercia
Removing and installing sealing flange - pulley end

m
a
com
t
⇒ page 23 .
ion in
r
te o
Removing and installing drive plate ⇒ page 27 .
thi
s
iva
do
2.1 Assembly overview - sealing flanges and flywheel
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.
2. Sealing flange and flywheel 19

Sharan 1996 ➤
1 - Seal
AG. Volkswagen AG d
❑ Do not additionally ksw
aoil
genor oes
not
l
grease the oil by Vseal seal‐
o gu
ara
ing lip. rised
nte
tho eo
❑ Notes audiffering versions ra
c
of seal.
s
ce
e
nl
pt
❑ PTFE seal with no inner
du
an
itte
coil spring
y li
erm
ab
❑ Before installing, re‐
ility
ot p
move oil residue from
wit
, is n
crankshaft journal using
h re
hole
a clean cloth.
spec
es, in part or in w
❑ Renewing crankshaft oil
t to the co
seal - belt pulley end
⇒ page 21 .
rrectness of i
2 - Sealing flange
❑ Must seat on dowel
l purpos
sleeves.
nform
ercia
⇒ page 23 .
m
❑ Install with silicone seal‐
at
om
io
ant - D 176 404 A2- .
n
c
in t
or
his
e
3 - Cylinder block
at
do
riv

p
cum
or
crankshaft
f
en
ng
t.
yi
⇒ page 29 .
Co
Cop py
. rig
ht ht
rig by
py
bling pistons and con‐ co Vo
by lksw
rods ⇒ page 32
cted agen
Prote AG.
4 - Flywheel/drive plate
flywheel, vehicles ►
05.00: lock with counter‐
hold - 3067- .
❑ Removing and installing flywheel, vehicles 06.00 ►: lock with counterhold - 3415- .
❑ Removing and installing drive plate ⇒ page 27 .
5 - 60 Nm + 1/4 turn (90°) further
❑ Renew.
6 - Intermediate plate
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
7 - 15 Nm
8 - Sealing flange with oil seal
❑ Renew complete only.
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Use support sleeve supplied when installing
❑ Do not remove support sleeve until sealing flange has been slid onto crankshaft journal

Sharan 1996 ➤
2.2 Renewing crankshaft oil seal - pulley end

equipment required
♦ Oil seal extractor - 3203-
♦ Counterhold - 3415- (only
vehicles 06.00 ►)
♦ Assembly tool - T10053-
- V.A.G 1331-
Nm) - V.A.G 1332-
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
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erm
ab
ility
ot p
wit

, is n
h re
hole
♦ Counterhold - 3099- (only vehicles ► 05.00)

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
Removing
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
– Remove toothed belt ⇒ page 42 . rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
Vehicles ► 05.00
– Remove crankshaft toothed belt pulley. To do this, lock tooth‐
ed belt pulley using counterhold - 3099- .
Note
When bolting on counterhold, place two washers between tooth‐

ed belt pulley and counterhold.
Vehicles 06.00 ►
– Remove charge air pipe ⇒ Item 1 (page 150) or
⇒ Item 9 (page 151) .
– Unbolt charge air pipe bracket from sump
⇒ Item 14 (page 150) or ⇒ Item 11 (page 151) .

– To guide seal extractor, screw centre bolt into crankshaft to
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.
– Lubricate threaded head of oil seal extractor, place it in posi‐

tion and, exerting firm pressure, screw it into oil seal as far as
possible. AG. Volkswagen n AG do
wage es n
– Loosen knurled screw and turn inner part against
Vol
ks crankshaft ot g
by ua
until the oil seal is pulled out. ris
ed ran
tee
ho
Installing aut or
ac
ss
ce
le
un
pt
an
d
Note
itte
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erm
ab
ility
ot p
The oil seal sealing lip must not be additionally oiled or greased.
wit
is n
h re
ole,
– Remove oil residue from crankshaft journal using clean cloth.

spec
t to the co
– Fit guide sleeve - T10053/1- onto crankshaft journal.

– Slide oil seal over guide sleeve onto crankshaft journal.
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 ➤
– Using press sleeve - T10053- , press in onto stop with central

bolt.
Vehicles ► 05.00
– Install crankshaft toothed belt pulley and lock with counterhold

- 3099- .
Note

Vehicles 06.00 ►

- 3415- .
Continuation for all vehicles AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
o eo
Note auth
ra
ss c
ce
le
♦ The contact surface between toothed belt pulley and crank‐

un
pt
an
d
shaft must be free of oil.

itte
y li
rm
ab
♦ The centre bolt must be renewed.
pe
ility
ot
wit
♦ Thread and shoulder must be free of oil and grease.
, is n
h re
hole
spec
– Tighten new centre bolt to 120 Nm and then 1/4 turn (90°) fur‐
es, in part or in w
t to the co
ther (turning further can be done in several stages).
Further assembly is basically the reverse of the dismantling se‐
quence.
rrectness of i
– How to install and tension toothed belt ⇒ page 42 .

l purpos

nform
ercia
2.3 Removing and installing sealing flange - pulley end

m
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 ➤

equipment required
♦ Counterhold - 3415- (only
vehicles 06.00 ►)
♦ Assembly tool - T10053-
- V.A.G 1331-
Nm) - V.A.G 1332-
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
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
♦ Counterhold - 3099- (only vehicles ► 05.00) rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Not illustrated
Silicone sealant - D 176 404 A-
Hand drill with plastic brush attachment
Flat scraper
Eye protection

n AG. Volkswagen AG do Sharan 1996 ➤
wage
4-cylinder
Volksdiesel engine (1.9 l engine)
es n
ot -
g
Edition 04.2014
y ua
db ran
rise tee
Removing tho or
s au ac
– Remove poly V-belt ⇒ page 14 . s
ce
le
un
pt
– Remove toothed belt ⇒ page 42 .
an
d
itte
y li
rm
ab
Vehicles ► 05.00
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
Vehicles 06.00 ►
nform
ercia
– Remove charge air pipe ⇒ Item 1 (page 150) or

⇒ Item 9 (page 151) .
m
a
com
tion in
– Unbolt charge air pipe bracket from sump
r
te o
⇒ Item 14 (page 150) or ⇒ Item 11 (page 151) .
thi
s
iva
do
r
rp
cum
fo
en
ng

t.
yi Co
Cop py
t.
rig
gh ht
pyri by
Vo
co
– Drain engine oil.
by lksw
cted agen
Prote AG.
Note
Observe environmental regulations for disposal.
– Remove sump ⇒ page 77 .

– Unbolt front sealing flange.
– Remove sealing flange; if necessary, loosen using light blows
with a rubber headed hammer.
– Remove sealant residue from cylinder block with a flat scraper.
WARNING
Wear eye protection.
– Use rotating plastic brush to remove sealant residue on seal‐

ing flange.
– Clean sealing surfaces. They must be free of oil and grease.
Installing
Note
♦ Observe expiry date of sealing compound.

♦ The sealing flange must be installed within 5 minutes of ap‐
plying the silicone sealant.

Sharan 1996 ➤
AG. Volkswagen
– Cut off tube nozzle at forward marking (∅lksof
wanozzle
gen approx. 3AG does n
mm). db
y Vo ot g
ua
e ran
ris tee
– Apply silicone sealing compound,
ut
ho as shown, to clean sealing or
surface on sump. Sealant bead
ss
a must be: ac
ce
le
♦ 2 ... 3 mm thick.
un
pt
an
d
itte
y li
♦ Run bead along inner side of bolt holes -arrows-.
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
es, in part or in w
♦ Sealant bead should not be thicker because otherwise excess
t to the co
sealant can enter sump and plug up strainer in oil pump suc‐
tion pipe, as well as drip onto crankshaft oil seal.
rrectness of i
♦ Before applying sealant bead, cover sealing surface of oil seal
with a clean cloth.
l purpos
– Apply silicone sealant bead as shown to clean sealing surface
nform
ercia
of sealing flange.
m
a
com
t
– Fit sealing flange immediately and lightly tighten all bolts.
ion in
r
te o
thi
s
iva
do
Note
r
rp
cum
fo
en
ng
t.
When fitting sealing flange with oil seal installed use guide sleeve
yi Co
op py
- T10053/1- . t. C rig
gh ht
pyri by
Vo
co lksw
by
– Tighten sealing flange securing bolts diagonally and alternate‐ cted agen
Prote AG.
ly. Specified torque:15 Nm
– Install sump ⇒ page 77 .
Note
Sealing compound must dry for approx. 30 minutes after instal‐

lation. Only then fill with engine oil.
Vehicles ► 05.00

- 3099- .
Note

Vehicles 06.00 ►

Sharan 1996 ➤

- 3415- .
Note
♦ The contact surface between toothed belt pulley and crank‐

shaft must be free of oil.
♦ The centre bolt must be renewed.
♦ Thread and shoulder must be free of oil and grease.
– Tighten new centre bolt to 120 Nm and then 1/4 turn (90°) fur‐
ther (turning further can be done in several stages).
quence.
– Install toothed belt and adjust valve timing ⇒ page 42 .
2.4 Removing and installing drive plate

♦ Clutch counterhold - VW 558- AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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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
♦ Hexagon bolt M8×45 and two M10 hexagon nuts
rrectness of i
♦ Depth gauge
l purpos
Loosening and tightening drive plate

– Secure clutch counterhold - VW 558- to drive plate with hex‐
nform
ercia
agon bolt M8x45. Insert two M10 hexagon nuts between coun‐
m
terhold and drive plate.

at
om
ion
c
Installation position of counterhold: A - To loosen, B - To tighten.

in t
or
his
ate
– Loosen drive plate bolts.

do
priv
cum
or
Installing drive plate

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

Sharan 1996 ➤
olkswagen AG
4-cylinder diesel engine (1.9 l gengine)
swa
en AG. V - Edition 04.2014
does
k not
Vol gu
d by ara
– Fit drive plate using packing
ris
e plate with recesses -1-. nte
utho eo
ra
– Fit new bolts -3- andss tighten to 30
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
– Check dimension -a- at three points and calculate average.
Specification: 19.5… 21.1 mm
l purpos
nform
ercia
Note
m
at
om
io
Measure through hole in drive plate to milled surface of cylinder
n
c
in t
block.
or
his
ate
do
priv
c
If specification is not attained:
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Remove drive plate again and fit shim -2-. Tighten bolts -3- cted agen
Prote AG.
again to 30 Nm.
– Tighten bolts -3- to 60 Nm and turn 90° (1/4 turn) further (the
additional 1/4 turn can be done in several stages).

Sharan 1996 ➤
AG. Volksw4-cylinder
agen AG
doediesel engine (1.9 l engine) - Edition 04.2014
agen
olksw s no
t gu
y V
b ara
ed nte
ris
3 Crankshaft s autho eo
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s
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nl
pt
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an
Note
itte
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erm
ab
ility
ot p
wit
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h re
hole
spec
6095- .
es, in part or in w
t to the co
♦ Before removing crankshaft, ensure that a suitable surface for
storing crankshaft is prepared to ensure that sender wheel
⇒ Item 6 (page 30) is not damaged or lies against any other
rrectness of i
item.
l purpos
Assembly overview - crankshaft ⇒ page 29 .

Crankshaft dimensions ⇒ page 30 .
nform
ercia
Checking fitted pin projection out of crankshaft ⇒ page 30 .

m
at
om
ion
c
3.1 Assembly overview - crankshaft
in t
or
his
ate
do
priv
cum
or
1 - Bearing shells 1, 2, 4 and 5

f
en
ng
t.
yi
❑ For bearing cap without
Co
Cop py
oil groove.
t. rig
gh ht
yri by
❑ For cylinder block with
cop Vo
by lksw
cted
oil groove.
agen
Prote AG.
❑ Do not interchange
used bearing shells
(mark).
2 - 65 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew.
❑ Threaded along com‐
plete length.
❑ To measure radial clear‐
ance, tighten to 65 Nm
but not further.
3 - Bearing cap
❑ Bearing cap 1 - belt pul‐
ley end
❑ Bearing cap 3 with re‐
cesses for thrust wash‐
ers.
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
4 - Bearing shell 3
❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove.
5 - Thrust washer
❑ For bearing cap, bear‐
ing 3.
❑ Note fixing arrangement.
3. Crankshaft 29
Sharan 1996 ➤
6 - Sender wheel
❑ For engine speed sender - G28- .
wage
❑ Always renew sender wheeloiflkssecuring bolts ( ⇒ Item 7es(page
not 30) ) have been loosened.
yV gu
ise
d⇒b page 31 . ara
n r tee
tho
7 - 10 Nm + 1/4 turn (90°)
or
s a further
u ac
s
ce
le
❑ Renew.
un
pt
an
d
itte
8 - Dowel pin
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rm
ab
❑ Check projection from crankshaft ⇒ page 30
pe
ility
ot
wit
, is n
9 - Crankshaft
h re
hole
❑ Axial clearance new: 0.07 … 0.17 mm, wear limit: 0.37 mm
spec
es, in part or in w
❑ Check radial clearance using Plastigage; new: 0.03… 0.08 mm; wear limit: 0.17 mm.
t to the co
❑ Do not rotate crankshaft when checking radial clearance.
❑ Crankshaft dimensions ⇒ page 30 .
rrectness of i
10 - Thrust washer
l purpos
❑ For cylinder block, bearing 3
nform
mercia
3.2 Crankshaft dimensions
a
com
tion in
r
te o
Honing Crankshfaft main Conrod
thi
s
iva
dimension in mm journal ∅ journal ∅

do
r
rp
cum
fo
Basic dimension -0.022 -0.022

en
ng
t.
54.00 op
yi
47.80 Co
-0.042 -0.042
C py
t. rig
gh ht
yri
Stage I -0.022 -0.022
p by
co Vo
by lksw
53.75 Prote
cted 47.55 AG.
agen
-0.042 -0.042
Stage II -0.022 -0.022
53.50 47.30
-0.042 -0.042
Stage lll -0.022 -0.022
53.25 47.05
-0.042 -0.042
3.3 Checking dowel pin projection out of

crankshaft
♦ Depth gauge
Test procedure
– Use depth gauge to check fitted pin projection -a- with sender
wheel -1- removed.
1 - Sender wheel
2 - Securing bolt
3 - Projection of dowel pin -3- out of crankshaft a = 2.5… 3.0 mm

Sharan 1996 ➤
Removing and installing sender wheel

. Volkswagen AG
gen AG does
– Renew sender wheel -2- each time bolts -1- are loosened.Vol
ksw
a
not
Specified torque: 10 Nm + 90° (1/4 turn) ed by gu
ara
ris nte
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aut ra
ss c
Note
ce
le
un
pt
an
d
itte
The second time the bolts are tightened, the contact points in the
y li
rm
ab
sender wheel for the countersunk heads are deformed so far that
pe
ility
the bolt heads seat on the crankshaft -3-, -arrows- and the sender
ot
wit
, is n
wheel is loose under the bolts.
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.
3. Crankshaft 31
Sharan 1996 ➤
4 Pistons and conrods
Note

6095- .
♦ All bearing and running surfaces must be oiled before assem‐
bly.
Assembly overview - pistons and conrods ⇒ page 32 .

Piston and cylinder dimensions ⇒ page 35 .
Checking piston projection at TDC ⇒ page 35 .
4.1 Assembly overview - pistons and conrods
1 - Piston rings
❑ Offset gaps by 120°.
❑ Use piston ring pliers to
remove and install.
❑ “TOP” faces towards AG. Volkswagen AG d
piston crown. agen oes
olksw not
V gu
❑ Checking ring gap d by ara
ise nte
⇒ page 33 . hor eo
aut ra
❑ Checking ring-to-groove ss c
clearance ⇒ page 34 .
ce
e
nl
pt
du
an
itte
2 - Piston
y li
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ab
❑ With combustion cham‐
ility
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ber.
wit
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❑ Mark installation posi‐ h re

hole
tion and cylinder num‐

spec
es, in part or in w
ber.
t to the co
❑ Installation position and

allocation of piston to
cylinder ⇒ page 35 .
rrectness of i
❑ Arrow on piston crown

l purpos
points to belt pulley end.

❑ Install using piston ring
nform
ercia
clamp.
❑ If piston skirt is cracked,
m
at
om
renew piston.
ion
c
in t
r
❑ Checking piston projec‐

o
his
te
tion at TDC
a
do
riv
⇒ page 35 .
p
cum
for
en
ng
3 - Piston pin
t.
yi Co
op py
❑ If difficult to remove,
t. C rig
gh ht
yri
heat piston to 60 °C. p by
o Vo
by c lksw
❑ Remove and install us‐
cted agen
Prote AG.
ing drift - VW 222A- .
4 - Circlip
5 - Conrod
❑ Renew as set only.
❑ Mark cylinder allocation -A- with coloured pen.

lkswage es n
o ot g
byV ua
d ran
ir se
tho tee
or Sharan 1996 ➤
u
ss
a
4-cylinder dieselac engine (1.9 l engine) - Edition 04.2014
ce
e
nl
pt
❑ Installation position: Marking -B- faces towards pulley end.
du
an
itte
y li
6 - Bearing shell
erm
ab
ility
ot p
wit
, is n
❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi‐
h re
hole
cation: Black line on bearing surface in area of joint.
spec
es, in part or in w
❑ Do not interchange used bearing shells.
t to the co
❑ Insert bearing shells centrally.
❑ Check for secure seating.
rrectness of i
❑ Axial clearance, wear limit: 0.37 mm
l purpos
❑ Check radial clearance with Plastigage; wear limit: 0.08 mm.

❑ Do not rotate crankshaft when checking radial clearance.
nform
ercia
7 - Cylinder block
m
at
❑ Checking cylinder bores ⇒ page 34 .
om
ion
c
❑ Piston and cylinder dimensions ⇒ page 35 .
in t
or
his
ate
8 - Conrod bearing cap
do
priv
cum
or

f
en
ng
t.
yi Co
9 - Oil spray jet Cop py
t. rig
gh
❑ For piston cooling.
ht
pyri by
Vo
co lksw
by
cted
10 - 25 Nm
agen
Prote AG.
❑ Insert without sealant.

11 - Conrod bolt, 30 Nm + 1/4 turn (90°) further
❑ Renew.
❑ Oil threads and contact surface.
❑ Use old bolt for measuring radial clearance.
Checking piston ring gap

♦ Feeler gauges
– Insert ring at right angles from above and push down into cyl‐
inder approx. 15 mm from bottom end of cylinder.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.20 ... 0.40 1.0
2nd compression ring 0.20 ... 0.40 1.0
Oil scraper ring 0.25 ... 0.50 1.0
4. Pistons and conrods 33

Sharan 1996 ➤
Checking ring-to-groove clearance

♦ Feeler gauges
– Clean ring groove before checking.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.06 ... 0.09 0.25
AG. Volkswagen AG d
agen oes
2nd compression ring 0.05 ... 0.08Volksw
0.25 not
gu
by ara
Oil scraper ring 0.03 ...
oris0.06
ed
0.15 nte
th eo
au ra
Checking cylinder bores 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.
♦ Inside caliper 50 … 100 mm
yi Co
Cop py
t. rig
– Take measurements at 3 positions in both lateral direction gh ht
yri by
-A- and longitudinal direction -B-. Difference between actual
op Vo
by c lksw
cted
and nominal diameter max. 0.10 mm.
agen
Prote AG.

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

mounted on a repair stand with engine support bracket - VW 540- ,
as measurements may then be incorrect.
Piston installation position and allocation of piston to cylinder

Piston in cylinders 1 and 2:
Larger inlet valve recess -arrows- towards flywheel.
Piston in cylinders 3 and 4:
Larger inlet valve recess -arrows- towards belt pulley end.
Note
♦ New piston allocation to cylinders is shown by a coloured

marking on piston crown.
♦ Piston for cylinders 1 and 2: marked 1/2
♦ Piston for cylinders 3 and 4: marked 3/4
4.2 Piston and cylinder dimensions

Honing dimension Piston ∅ Cylinder bore ∅
Basic dimension mm 79.47 79.51
Stage I mm 79.72 79.76
Stage II mm
agen
AG. Vo79.97
lkswagen AG
do 80.01
ksw es n
Vol ot g
by
4.3 Checking piston projection at TDC
d ua
e ran
ris tee
utho or
Special tools
ss
a and workshop equipment required ac
ce
e
nl
♦ Measuring bridge - VW 382/7-

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 AG.
4. Pistons and conrods 35

Sharan 1996 ➤
♦ End dimension plate - VW 385/17-
♦ Dial gauge
4.3.1 Test procedure

Piston projection at TDC must be measured on all pistons when
installing new pistons or a short engine. Install the appropriate
cylinder head gasket depending upon piston projection, accord‐
ing to following table:
Note
Turn engine clockwise to measure piston projection at TDC.
Piston projection Identification n AG. Volkswagen AG do

Holes/notches lkswage es n
Vo ot g
y ua
db ran
0.91 mm … 1.00 mm o1rise tee
th or
1.01 mm … 1.10 mm au 2 ac
ss
1.11 mm … 1.20 mm 3
ce
e
nl
pt
du
an
itte
y li
erm
4.3.2 Cylinder head gasket identification ab

ility
ot p
wit
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♦ Part No. = -arrow 1- h re

hole
♦ Production control code = -arrow 2- (disregard)

spec
es, in part or in w
t to the co
♦ Holes = -arrow 3-
♦ Installation position: identification faces upwards.
rrectness of i
l purpos
Note
If different values are determined during the projection measure‐

nf
ercia
ment, use the largest dimension for selecting the gasket.

orm
m
atio
om
n in
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thi
te
sd
iva
o
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o
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f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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 replaced, all the coolant in the system
must also be renewed.
Assembly overview - cylinder head ⇒ page 37 .

Removing and installing cylinder head cover ⇒ page 40 .
Removing, installing and tensioning toothed belt ⇒ page 42 .
Removing and installing cylinder head ⇒ page 55 .
Compression test ⇒ page 59 AG. Volkswagen AG d
agen oes
ksw
1.1 Assembly overview - cylinder head ol 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
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Cylinder head 37
Sharan 1996 ➤
1 - Toothed belt guard upper

part
2 - Toothed belt
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing
and tensioning
⇒ page 42 .
3 - 10 Nm
❑ Renew.
4 - 25 Nm
5 - 100 Nm
6 - Camshaft pulley
7 - Hub
❑ With sender wheel
❑ Use counterhold tool -
T10051- to loosen and
tighten.
❑ To remove, use puller -
T10052- .
⇒ page 67 .
AG. Volkswagen AG d
8 - Rear toothed belt guard agen oes
olksw not
V gu
d by ara
9 - Sealing grommet orise nte
h eo
❑ Renew if damaged. aut ra
ss c
ce
e
10 - Hall sender - G40-

nl
pt
du
an
❑ For camshaft position.

itte
y li
erm
ab
❑ To remove, unbutton
ility
ot p
sealing grommet ⇒ Item 9 (page 38) from rear toothed belt guard.
wit
, is n
h re
11 - Cylinder head bolt

hole
spec
❑ Renew.
es, in part or in w
t to the co
❑ Observe sequence when loosening and tightening ⇒ page 55 .

❑ Before installing, place washers in cylinder head ⇒ Item 4 (page 62) .
rrectness of i
12 - Cylinder head cover

l purpos
❑ Before fitting, thoroughly clean sealing surface of cylinder head with clean cloth.
nf
ercia
13 - Pressure regulating valve

orm
m
❑ For crankcase ventilation.

atio
om
n in
c
14 - Crankcase breather hose

or
thi
te
sd
❑ To intake manifold between air filter housing and turbocharger

iva
o
r
rp
cu
15 - Cap
o
m
f
en
ng
t.
yi
❑ Renew seal if damaged.
Co
Cop py
t. rig
gh
16 - Seal
ht
pyri by
Vo
o
by c lksw
❑ Renew if damaged. Prote
cted AG.
agen
17 - 10 Nm
❑ With spacer sleeve and seal.
❑ Renew seal if damaged.
38 Rep. gr.15 - Cylinder head, valve gear

Sharan 1996 ➤
18 - Gasket for cylinder head cover
❑ Before fitting gasket, seal transition points of bearing cap 1 and 5 to cylinder head with sealant - AMV
174 004 01- ⇒ page 40 .
19 - 20 Nm
20 - Lifting eye
21 - Unit injector
22 - 10 Nm
23 - Central connector
❑ For unit injector - N240 - . -243-
24 - From brake servo
25 - Tandem pump
❑ For fuel and vacuum supply.
❑ Must not be dismantled.
26 - Supply line
❑ From fuel filter: olkswagen AG
en AG. V
wagANU, does
❑ Engine Vcodesolks AUY, BVK: with nfuel
ot g cooler at underbody ⇒ Item 14 (page 119)
y ua
❑ Engine
ris
ed codes ANU, ASZ, AUY, BTB, BVK:
b ranwithout fuel cooler at underbody ⇒ Item 1 (page 119)
tee
o
❑ auWhite or with white marking.
th or
ac
ss
ce
le
un
pt
❑ Secure with spring-type clips.

an
d
itte
y li
erm
ab
27 - Return line
ility
ot p
❑ To fuel filter (engine codes ANU, AUY, BVK: with fuel cooler at underbody) ⇒ Item 10 (page 118)
wit
is n
h re
❑ To heat exchanger (engine codes ANU, ASZ, AUY, BTB, BVK: without fuel cooler at underbody)
ole,
⇒ Item 10 (page 121)

spec
❑ Blue or with blue marking.

t to the co

❑ Secure with spring-type clips.
rrectne
28 - Gasket
s
❑ Renew.
s o
cial p
f i
29 - Bolt
nform
mer
30 - Cylinder head
atio
om

n
c
i
or
n thi
❑ After renewing, renew entire coolant.

te
sd
iva
o
pr
31 - Cylinder head gasket

um
r
fo
en
ng
❑ Renew.
t.
yi Co
op py
❑ Note marking ⇒ page 40 .
. C rig
ht ht
rig by
❑ After renewing, renew entire coolant.
copy Vo
by lksw
cted agen
Prote
32 - Glow plug
AG.
❑ 15 Nm
❑ Check ⇒ page 178 .
33 - Tensioning roller
34 - 20 Nm + 1/8 turn (45°) further
1. Cylinder head 39
Sharan 1996 ➤
Checking cylinder head for distortion

♦ Straight edge
♦ Feeler gauges
Max. permissible distortion: 0.1 mm.
Note AG. Volkswagen AG d

agen oes
olksw not
y V gu
d b ara
Reworking diesel cylinder heads is not permissible.orise nte
eo
th
au ra
s c
Cylinder head gasket identification s
ce
le
un
pt
♦ Part No. = -arrow 1-
an
d
itte
y li
erm
ab
♦ Production control code = -arrow 2- (disregard)
ility
ot p
wit
♦ Holes = -arrow 3-
is n
h re
ole,
♦ Installation position: identification faces upwards.
spec
t to the co
Note
rrectne
Different thicknesses of cylinder head gasket are fitted depending
on the piston projection. When renewing gasket, install new gas‐
s
ket with same identification.
s o
cial p
f inform
mer
1.2 Removing and installing cylinder head

atio
m
cover
o
n
c
i
or
n thi
te

sd
iva
o
pr
cum
r
♦ Torque wrench (5... 50 Nm) - V.A.G 1331-

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

Sharan 1996 ➤
♦ Spring-type clip pliers - VAS 5024 A-
♦ Sealant - AMV 174 004 01-

Removing
– Observe rules for cleanliness ⇒ page 115 .
– Remove engine cover.
– Remove upper toothed belt guard.
– Disconnect crankcase breather hose at union of rear intake
manifold.
– Remove cylinder head cover.
Installing
Install in reverse order. In the process, note the following:
WARNING
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐ AG. Volkswagen A
tions: lksw
agen G do
es n
o Vo t gu
by
♦ Route all the various lines (e.g. for fuel, hydraulics,
ris
ed acti‐
ara
nte
vated charcoal filter system, coolant and refrigerant,
tho brake eo
fluid and vacuum) and electrical wiring in their
s au original po‐ ra
c
s
sitions. ce
e
nl
pt
du
an
itte
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hot components.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ Renew cylinder head cover if damaged.

♦ Renew cylinder head cover gasket and bolt seal if damaged
rrectness of i
or leaking.
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.
1. Cylinder head 41
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
lksw not
– Place a drop of sealant - AMV 174 004 01- (∅ approx. b5y Vmm) o gu
ara
-arrows- on edges of both sealing surfaces of bearing ris cap and
ed
nte
cylinder head at front of engine. aut
ho eo
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
– Place a drop of sealant - AMV 174 004 01- (∅ approx. 5 mm)
rrectness of i
-arrows- on edges of both sealing surfaces of bearing cap and
cylinder head at rear of engine.
l purpos
nform
ercia
Note
m
a
com
ti
on in
r
te o
thi
♦ Cylinder head cover must be installed within 5 minutes of ap‐
s
iva
plying sealant.
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
– Install cylinder head cover immediately and tighten all secur‐ py by
co Vo
ing bolts hand-tight in illustrated sequence.
by lksw
cted agen
Prote AG.
– Tighten securing bolts in illustrated sequence. Specified tor‐
que: 10 Nm
quence.
1.3 Removing, installing and tensioning toothed belt

Sharan 1996 ➤

equipment required
AG. Volkswagen AG d
♦ Support bracket - 10-222A- lksw
agen oes
not
with legs -10-222A/5- (ve‐ d byV
o gu
ara
hicles ► 05.00) or orise nte
-10-222A14- and aut
h eo
ra
-10-222A15- (vehicles ss c
06.00 ►).
ce
le
un
pt
an
d
itte
♦ Locking pin - 3359-
y li
erm
ab
ility
♦ Pin wrench - 3387- or hex‐
ot p
wit
agon wrench is n
h re
ole,
♦ Locking plate - T10008-
spec
(vehicles with hydraulic ten‐
t to the co
sioning system)
♦ Crankshaft stop - T10050-
rrectne
♦ Locking pin - T10115-
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
For vehicles with oval crankshaft pulley

♦ Crankshaft stop - T10100-
1. Cylinder head 43
Sharan 1996 ➤

equipment required
- V.A.G 1331-
♦ Torque wrench (40...
200 Nm) - V.A.G 1332-
VAS 5024 A-
♦ Drill bit ∅ 4 mm (vehicles
with hydraulic tensioning
system)
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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le
un
pt
an
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itte
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erm
ab
ility
ot p
wit
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ole,
spec
t to the co
1.3.1 Removing
rrectne
Note
ss o
If the toothed belt is renewed during a repair measure, enter this

cial p
f in
in the service schedule of vehicle wallet.

form
mer
atio
m
– Observe rules for cleanliness ⇒ page 115 .

o
n
c
i
or
n thi

te
sd
va

i
o
pr
cum
engine)
r
fo
en
ng
t.
yi
– Remove air filter housing together with intake manifold.
Co
Cop py
t. rig
gh ht
– Remove poly V-belt ⇒ page 14 . yri
p by
co Vo
by lksw
cted
– Remove poly V-belt tensioning device from ancillary bracket.
agen
Prote AG.

Sharan 1996 ➤
Vehicles ► 05.00
– Install spindles -A- in installation position as illustrated and fit
support bracket 10-222A with legs 10-222A/5.
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
rrectne
– Secure legs 10-222A/5 with body bolts -arrows-.
ss o
cial p
Vehicles 06.00 ►
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.
– Separate the plug connector between turbocharger and
charge air cooler by pulling the securing clamp -arrow-.
– Remove air duct trim.
– Remove 10 mm bolts -arrows- and pull trim out forwards.

– Remove both outer bolts of battery tray.
1. Cylinder head 45
Sharan 1996 ➤
– Assemble engine support bracket 10-222 A with legs 10-222

A/14 and 10-222 A/15 as shown.
– Bolt leg 10-222 A/14 to battery tray with bolts M8×35

-arrows-. Specified torque: 25 Nm
– Take up weight of engine in its installation position.
– Release load on engine mounting by lifting engine slightly.
– Unscrew securing bolts -arrows- and remove bracket -1-.

– Unbolt assembly mounting -2- from longitudinal member.
– Remove engine support at cylinder block.
Note
♦ When loosening the upper engine mounting bolts the engine

must be raised with the support bracket. agen
AG. Volkswagen AG d
oes
olksw not
♦ When loosening the lower engine mounting by V bolts the engine gu
ara
ed
must be lowered with the supportthbracket.
oris nte
eo
au ra
ss c
– Remove vibration damper/belt pulley.
ce
e
nl
pt
du
an
– Remove centre and lower toothed belt guards.

itte
y li
erm
ab
– Turn crankshaft to TDC No. 1 cylinder.

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
46
co Vo
by lksw
cted
Rep. gr.15 - Cylinder head, valve gear
agen
Prote AG.
Sharan 1996 ➤
Note
Turn the crankshaft until the mark on the crankshaft toothed belt
pulley is on the top and the arrow on the rear toothed belt guard
aligns with the lug on the hub sender wheel -arrows-.
– Lock hub using locking pin - 3359- . To do this, slide locking

pin through the free elongated hole on left into hole in cylinder
head.
Note
Gradual introduction of oval crankshaft toothed belt pulleys.

When installing this toothed belt pulley, the crankshaft stop -
T10100- must be installed to determine the TDC position.
Characteristics of crankshaft toothed belt pulley

A = round belt pulley, lock using crankshaft stop - T10050- , TDC
marking at 12 o'clock
B = oval belt pulley, lock using crankshaft stop - T10100- . TDC
marking at 1 o'clock
– Lock crankshaft toothed belt pulley with crankshaft stop -
T10050- or crankshaft stop - T10100- . To do this, push
crankshaft stop into teeth of belt pulley from face side.
Note
The marks on the crankshaft toothed belt pulley and the crank‐
shaft stop must align. When doing this, the pin of the crankshaft
stop must engage in the drilling of sealing flange.
n AG. Volkswagen A G do
wage es n
olks ot g
yV
– Mark direction of rotationseofd toothed belt.
b ua
ran
ri tee
tho or
au ac
ss
ce
le
1.3.2 Vehicles with hydraulic belt tensioning

un
pt
an
d
itte
system
y li
erm
ab
ility
ot p
Vehicles with friction dampened tensioning system ⇒ page 51 .

wit
is n
h re
Identification: with toothed belt tensioner -arrow-.

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
47
co Vo
by lksw
cted 1. Cylinder head
agen
Prote AG.
Sharan 1996 ➤
– Insert a hexagon key into the hexagon hole onto stop and use
it to press the tensioning roller anti-clockwise in -direction of
arrow- until the toothed belt tensioner can be locked with the
locking plate - T10008- .
Note
swage es n
If the hexagon key is not inserted by V deeply enough there is a great
olk ot g
ua
danger that key will slip out.ir se
d ran
tee
tho
u or
s a ac
– Loosen tensioning roller securing nut.
s
ce
e
nl
pt
du
an
itte
y li
– Unscrew and remove securing bolts -1- of toothed belt ten‐
erm
ab
sioner and remove tensioning element.
ility
ot p
wit
, is n
– Remove toothed belt.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
1.3.3 Installing
atio
om
n in
or c
thi
te
WARNING
sd
iva
o
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f

en
ng
t.
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Co
op py
tions:
t. C rig
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pyri by
Vo
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c by lksw
cted agen
vated charcoal filter system, coolant and refrigerant, brake Prote AG.

sitions.
hot components.
• Camshaft locked with locking pin - 3359- .

• Crankshaft locked with crankshaft stop - T10050- or crank‐
shaft stop - T10100- .
• Tensioning roller locked with locking pin - T10115- and se‐
cured to right stop.
Note
Always perform adjustment work on toothed belts only on cold

engines.

Sharan 1996 ➤
– Loosen securing bolts -1- of camshaft pulley until the camshaft

pulley can be moved within the elongated holes.
– Turn camshaft pulley clockwise -direction of arrow- in elonga‐
ted holes onto stop.
AG. Volkswagen AG d
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
– Now carefully turn eccentric clockwise using pin wrench -
ab
ility
3387- until eccentric lug lies directly before limit stop -B-.
ot p
wit
, is n
– Fit toothed belt on camshaft belt pulley, tensioning roller,
h re
hole
crankshaft belt pulley and finally on coolant pump belt pulley.
spec
es, in part or in w
– Install toothed belt tensioning device.
t to the co
rrectness of i
l purpos
nform
mercia
– Turn eccentric anti-clockwise using pin wrench - 3387- (lug of

at
om
eccentric moves in direction of limit stop -A-), until the locking ion
c
in t
r
plate - T10008- is not under tension and can be pulled out.

o
his
ate
do
riv
– Release force of tensioning element in clockwise direction (lug

p
cum
or
of eccentric moves towards stop -B-) until dimension -a- has

f
en
g
been attained. Specification dimension -a-: 4 ± 1 mm.

n
t.
yi Co
Cop py
t. rig
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pyri by
Vo
Note
o
by c lksw
cted agen
Prote AG.
♦ Dimension -a- reduces when the tensioning roller securing nut

is tightened. Therefore adjust generously using ∅ 4 mm drill
bit.
♦ Measurement -a- may be reduced to 1 mm at operating tem‐
perature.
– Hold tensioning roller in this position and tighten tensioning

roller securing nut as follows: 20 Nm and 45° (1/8 turn) further.
1. Cylinder head 49
Sharan 1996 ➤
– Tighten securing bolts -1- of camshaft pulley to 25 Nm.

– Remove locking pin - 3359- and crankshaft stop - T10050- or
crankshaft stop - T10100- .
– Turn crankshaft two rotations in engine direction of rotation
and set again to TDC no. 1 cylinder.
Note
♦ When doing this, the pin of the crankshaft stop must engage
in the sealing flange from the rotational movement.
en AG. V
olkswagen AG
does ag
lksw
♦ If the crankshaft is turned past
by TDC No. 1 cylinder and the
not
Vo gu
ara
crankshaft stop could not ris engage in the sealing flange, turn
ed
nte
the crankshaft back a1/4
ut turn to be able to turn the crankshaft
ho eo
ra
in engine direction sof rotation again to set it to TDC No. 1 cyl‐
s c
inder. Corrections to the position by turning against engine
ce
e
nl
pt
du
direction of rotation in order to insert the crankshaft stop are
an
itte
not permissible.
y li
erm
ab
ility
ot p
– Once crankshaft stop - T10050- or crankshaft stop - T10100-
wit
, is n
h re
has been inserted, check whether:
hole
spec
♦ Dimension -a- is attained and
es, in part or in w
t to the co
♦ the hub can be locked with locking pin - 3359- .
If dimension -a- is not attained:
rrectness of i
– Tension the tensioning roller again. To do this, hold tensioning
l purpos
roller with pin wrench - 3387- , loosen securing nut and release
force of tensioning device until dimension -a- is attained. Spec‐
ification dimension -a-: 4 ± 1 mm. nf
ercia
or
– Tighten securing nut to 20 Nm and 45° (1/8 turn) further.

m
m
atio
om
If the hub cannot be locked:

n in
or c
thi
e
– Pull crankshaft stop pin out of drilling in sealing flange and turn
t
sd
iva
crankshaft until hub can be locked with locking pin.

o
r
rp
cu
o
m
f
en
ng
t.
yi
– Loosen securing bolts -1- of camshaft pulley.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Turn crankshaft slightly against engine direction of rotation

until the pin of the crankshaft stop is positioned just before the
hole in the sealing flange -arrow-.
n AGuntil crank‐ . Volkswage
– Now turn crankshaft in engine direction ofksrotation
wage
n AG d
oes
not
l
shaft stop pin engages in sealing flange
by whilst turning.
Vo gu
a d ran
ise
– Tighten securing bolts of camshaft
ut
ho belt pulley to 25 Nm.
r tee
or
sa ac
– Remove locking pin - 3359- sand crankshaft stop - T10050- or
ce
e
nl
pt
du
an
itte
y li
erm
ab
until crankshaft is set to TDC No. 1 cylinder again.
ility
ot p
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
♦ If the crankshaft is turned past TDC No. 1 cylinder and the
rrectness of i
crankshaft stop could not engage in the sealing flange, turn
l purpos
the crankshaft back 1/4 turn to be able to turn the crankshaft

in engine direction of rotation again to set it to TDC No. 1 cyl‐
nform
ercia

not permissible.
m
at
om
ion
c
in t
or
– Repeat check.
his
ate
do
priv
cum
1.3.4 Vehicles with friction dampened ten‐
for
en
ng
t.
yi
sioning system
Co
Cop py
t. rig
gh ht
yri
– Loosen tensioning roller securing nut. p by
o Vo
by c lksw
cted agen
– Loosen securing bolts -1- of camshaft pulley until the camshaft Prote AG.
pulley can be moved within the elongated holes.
– Turn pin wrench - 3387- anti-clockwise (opposite direction of

arrow) until toothed belt tensioning roller can be locked with
locking pin - T10115- .
– Now turn pin wrench in direction of arrow onto stop and tighten
securing nut hand-tight.
– Remove toothed belt first from coolant pump and then from
remaining pulleys.
1. Cylinder head 51
Sharan 1996 ➤
1.3.5 Installing
WARNING

tions:
sitions.
hot components.
lkswage es n
o ot g
byV ua
d ran
ir se tee
Note utho
or
a ac
ss
♦ Adjustment work on toothed belts must be performed only on
ce
e
nl
pt
du
cold engines, as the indicator position on the tensioning ele‐
an
itte
y li
ment varies depending on the engine temperature.
erm
ab
ility
ot p
♦ The tensioning roller must be locked with locking pin - T10115-
wit
and secured to right limit stop.
, is n
h re
hole
spec
– Turn camshaft pulley in elongated holes anti-clockwise -direc‐
es, in part or in w
t to the co
tion of arrow- onto stop.
– Fit toothed belt to crankshaft toothed belt pulley, tensioning
roller and camshaft pulley.
rrectness of i
– Then fit toothed belt on coolant pump toothed belt pulley.

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri
Ensure that tensioning roller seats correctly in rear toothed belt
p by
co Vo
by lksw
guard -arrow-. Prote
cted AG.
agen
– Loosen tensioning roller securing nut.

– Release tension on tensioning roller by turning with pin wrench
in opposite direction of arrow and remove locking pin from
tensioning roller.

Sharan 1996 ➤
– Now carefully turn tensioning roller in direction of arrow using

pin wrench - 3387- until indicator is in middle of gap in the base
plate -arrow-.
– Hold tensioning roller in this position and tighten tensioning
roller securing nut as follows: 20 Nm and 45° (1/8 turn) further.
– Tighten securing bolts of camshaft belt pulley to 25 Nm.
and set again to TDC no. 1 cylinder.
Note
inder. Corrections to the position by turning
swa
gen Aagainst
G. Volkswengine
agen AG
does
direction of rotation in order to insert
y V the crankshaft stop are
olk not
gu
not permissible. ris
edb ara
nt ee
tho or
au ac
– Once crankshaft stop or crankshaft stop - T10100- - sT10050-
s
ce
le
has been inserted, check whether:

un
pt
an
d
itte
♦ tensioning roller indicator is positioned centrally in the gap of
y li
rm
ab
base plate and
pe
ility
ot
wit
♦ the hub can be locked with locking pin - 3359- .
, is n
h re
hole
If the hub cannot be locked:

spec
es, in part or in w
– Pull the pin of crankshaft stop - T10050- or crankshaft stop - t to the co

T10100- out of the drilling in the sealing flange and turn the
crankshaft until the hub can be locked with the locking pin -
3359- .
rrectness of i
l purpos
– Loosen securing bolts -1- of camshaft pulley.

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.
1. Cylinder head 53
Sharan 1996 ➤
– Turn crankshaft slightly against engine direction of rotation

until the pin of the crankshaft stop is positioned just before the
hole in the sealing flange -arrow-.
– Now turn crankshaft in engine direction of rotation until crank‐
shaft stop pin engages in sealing flange whilst turning.
– Tighten securing bolts of camshaft belt pulley to 25 Nm.
until crankshaft is set to TDC
wagNo. 1. cylinder
en AG again.
Volkswagen AG
does
ks not
Vol gu
d by ara
e nte
ris
Note utho eo
ra
a 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
not permissible.
rrectness of i
– Repeat check.
l purpos

– Install lower toothed belt guard and pulley vibration damper.
nform
ercia
– Install centre toothed belt guard.

m
at
om
– Fit engine support to cylinder block. Specified torque for -M8- :

ion
c
30 Nm; specified torque for -M10- : 45 Nm

in t
or
his
ate
– Bolt poly V-belt tensioning device to ancillary bracket. Speci‐

do
priv
fied torque: 25 Nm.

um
for
en
ng
t.
yi
Co
Cop py
t. rig
– Install engine assembly mounting. Specified torque: 60 Nm.
gh ht
pyri by
Vo
co lksw
by
– Install bracket for engine assembly mounting. Specified torque cted agen
Prote AG.
for bolts: 60 Nm; specified torque for nuts: 55 Nm
– Remove support bracket - 10-222A- .
– Install air filter housing together with intake manifold.
Vehicles 06.00 ►
– Install air duct trim.

Sharan 1996 ➤
– Install the plug connector between turbocharger and charge

air cooler by pulling the securing clamp -arrow-.
AG. Volkswagen AG d
agen
Note Volksw
oes
not
by gu
d ara
ise nte
When installing ensure that locking
ut
hor
lugs engage securely eo
⇒ page 141 . ss a ra
c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
gine)
h re
hole
– Read fault memory ⇒ page 168 .
spec
es, in part or in w
t to the co
1.4 Removing and installing cylinder head
rrectness of i
l purpos
equipment required
nform
ercia

m
a
com
tio
- V.A.G 1331-
n in
r
te o
thi
s
iva
do
200 Nm) - V.A.G 1332-
r
rp
cum
fo
en
g
♦ Hand vacuum pump -

n
t.
yi Co
op
V.A.G 1390- C py
t. rig
gh ht
yri
♦ Water drainage container -
p by
o Vo
by c lksw
V.A.G 1390/1- Prote
cted AG.
agen
♦ Bracket - T10014-
Prerequisite
• The engine must be no more than warm to touch.
1. Cylinder head 55
Sharan 1996 ➤
1.4.1 Removing
WARNING

tions:
sitions.
♦ Ensure that there is sufficient
wage
nclearance
AG. Volkswato
genall
AGmoving
does or
hot components. y Volks not
gu b ara
ed nte
oris e
th or
au ac
– With ignition switched
ss off, disconnect earth strap from battery.
ce
le
un
pt
an
d
itte
y li
– Before removing cylinder head extract fuel using hand vacuum
erm
ab
pump - V.A.G 1390- and fluid receptacle - V.A.G 1390/1- on
ility
ot p
the tandem pump ⇒ page 136 .
wit
is n
h re
ole,
spec
– Remove hub for camshaft pulley ⇒ page 67 .
t to the co
– Remove front exhaust pipe from turbocharger ⇒ page 170 .
– Drain coolant ⇒ page 100 . rrectne
– Pull off or disconnect all other electrical connections as nec‐

s
essary from cylinder head and lay to side.

s o
cial p
f i
– Separate all connecting, coolant and vacuum hoses from cyl‐

nform
inder head.
mer
atio
m
– Remove engine support -1- and in place screw retainer -

o
n
c
T10014- into cylinder block.

or
n thi
te
sd
a
– Tighten securing bolt -2- of retainer - T10014- to 20 Nm.

iv
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 ➤
– Secure the spindle -A- to retainer - T10014- and slightly lift

engine until the spindle -B- is relieved.
– Remove spindle -B-.
– Remove cylinder head cover ⇒ page 40 .
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
– Loosen cylinder head bolts in the sequence given starting at
rrectness of i
the outside and working inwards and then remove completely.
l purpos
– Carefully remove cylinder head.

– Place clean cloths in cylinders so that no dirt or emery cloth
nf
ercia
particles can get in between cylinder wall and piston.
orm
m
atio
– Also prevent dirt and emery cloth particles from getting into
om
n in
coolant.
or c
thi
te
– Now carefully clean sealing surfaces of cylinder head and cyl‐
sd
iva
o
inder block. When doing this, ensure that surfaces are not
r
rp
cu
o
m
scored or scratched (if abrasive paper is used, grade must not
f
en
ng
t.
be less than 100).
yi Co
Cop py
ht. rig
rig ht
by
1.4.2 Installing copy Vo
by lksw
cted agen
Prote AG.
WARNING

tions:
sitions.
hot components.
1. Cylinder head 57
Sharan 1996 ➤
Note
♦ Always renew cylinder head bolts. AG. Volkswagen AG d

agen oes
ksw
If repairing, carefully remove any Vremaining gasket material
l not
♦ by
o gu
ara
from the cylinder block andocylinder
ris
ed
head. Ensure that no long nte
scores or scratches are amade
ut
h on the surfaces. When using eo
ra
abrasive paper do not suses a grade less than 100. c
ce
e
nl
♦ Do not remove new cylinder head gasket from packaging until
pt
du
an
it is ready to be fitted.
itte
y li
erm
ab
♦ Handle gasket very carefully. Damage to the silicone layer or
ility
ot p
the indented area will lead to leaks.
wit
, is n
h re
♦ Carefully remove remains of emery and abrasives.
hole
spec
es, in part or in w
t to the co
– Turn crankshaft to TDC marking before fitting cylinder head.
– Turn crankshaft against engine direction of rotation until all
pistons are about the same distance below TDC.
rrectness of i
– Position cylinder head gasket.
l purpos
– Fit cylinder head and hand tighten all cylinder head bolts (Qty.
nf
ercia
o
– Tighten cylinder head in four stages in sequence shown as
rm
m
follows:
atio
om
n in
c
– 1. Tighten initially with torque wrench: stage I = 40 Nm; stage

or
thi
II = 60 Nm
te
sd
iva
o
r
rp
– 2. Turn further with rigid spanner: stage III = 1/4 turn (90°), cu
o
m
f
en
ng
stage IV = 1/4 turn (90°)

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Note
by lksw
cted agen
Prote AG.
After repair work it is not necessary to retighten the cylinder head

bolts.
– After tightening cylinder head, turn camshaft so that cams for

No. 1 cylinder point equally upwards. Turn crankshaft, in en‐
gine direction of rotation, to TDC marking before fitting toothed
belt ⇒ page 42 .
– Install cylinder head cover ⇒ page 40 .
– Install camshaft pulley and hub ⇒ page 67 .

Sharan 1996 ➤
– Secure spindle -B- to lifting eye and slightly lift engine until the
spindle -B- is relieved.
– Remove spindle -A-.
– Remove retainer - T10014- . AG. Volkswagen AG d
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– Fit engine support -1- so that the boss cast on the engine
bracket faces towards the locking lug of the rear toothed belt
ss
guard -arrows-.
o
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– Tighten securing bolt -2- hand tight.
mer
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– Fit engine support -1- to cylinder block. Specified torque for - Prote AG.
M8- : 30 Nm; specified torque for -M10- : 45 Nm
– Tighten securing bolt -2-. Specified torque: 45 Nm.
– Carry out road test and read fault memories ⇒ page 168 .
Observe applicable safety precautions during road test
⇒ page 156 .
1.5 Compression test
1. Cylinder head 59
Sharan 1996 ➤

equipment required
♦ 10 mm jointed spanner -
3220-
- V.A.G 1331-
♦ Adapter - V.A.G 1381/12-
♦ Compression tester -
V.A.G 1763-
AG. Volkswagen AG d
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Test prerequisites
hole
spec
• Engine oil temperature must be at least 30 °C.

es, in part or in w
t to the co
• The battery voltage must be at least 11.5 V.

• All electrical consumers, e.g. lights and rear window heating,
rrectness of i
must be switched off.

l purpos
• If the vehicle is equipped with an air conditioner, it must be

switched off.
nform
ercia
Test procedure
m
– Note safety precautions before beginning work ⇒ page 156 .

com
tion in

r
te o
thi
s
iva
do
– Pull off central connector for unit injectors.

r
rp
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– Remove all glow plugs using 10 mm jointed wrench - 3220- .

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rig ht
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Prote AG.

Sharan 1996 ➤
– Screw in adapter - V.A.G 1381/12- in place of the glow plugs.

– Check compression using compression tester - V.A.G 1763- .
Note
Using compression tester ⇒ Operating instructions.
– Operate starter until tester

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Compression pressures:
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New: 25 ... 31
ss bar, wear limit: 19 bar
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le
un
pt
Maximum permissible difference between all cylinders: 5 bar
an
d
itte
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erm
– Install glow plugs using 10 mm jointed wrench - 3220- , speci‐
ab
ility
fied torque: 15 Nm.
ot p
wit
is n
– Read fault memory ⇒ page 168 .
h re
ole,
spec
t to the co
Note
Disconnecting the central connector for unit injectors causes
rrectne
faults to be stored. Therefore, read fault memory and clear if nec‐
essary.
ss o
cial p
f inform
mer
atio
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n
c
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Prote AG.
1. Cylinder head 61
Sharan 1996 ➤
2 Valve gear
Note
Cylinder heads with cracks between the valve seats may be used
without reducing engine life, provided the cracks are small and
not more than 0.5 mm wide.
Assembly overview - valve gear ⇒ page 62 .

Checking valve guides ⇒ page 65 .
Renewing valve stem seals ⇒ page 65 .
Removing and installing camshaft ⇒ page 67 .
Removing and installing camshaft seal ⇒ page 71 .
2.1 Assembly overview - valve gear
1 - 20 Nm + 1/4 turn (90°) fur‐

ther
❑ Renew. olkswagen AG
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❑ Observe sequenceolkswag does
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tightening h⇒
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2 - Rocker arm
ss shaft
ce
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❑ Do not interchange.
un
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3 - Cylinder head bolt

rm
ab
pe
ility
❑ Observe sequence
ot
wit
when loosening and

, is n
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tightening ⇒ page 55 .
hole
spec
❑ Before installing, insert

es, in part or in w
washers
t to the co
( ⇒ Item 4 (page 62) )

in cylinder head.
rrectness of i
4 - Washer
l purpos
❑ For cylinder head bolts.

❑ Insert in cylinder head
before installing bearing
nform
ercia
caps
m
a
com
ti
5 - Bucket tappet
on in
r
❑ Do not interchange.
te o
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❑ With hydraulic valve

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clearance compensa‐
um
fo
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tion.
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❑ Set down with contact
C py
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surface facing down‐
ht
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wards.
c by lksw
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Prote AG.
❑ Before installing, check
camshaft axial clear‐
ance ⇒ page 64 .
❑ Oil contact surface.
❑ Before removing, remove camshaft bearing caps

Sharan 1996 ➤
6 - Valve cotter
7 - Valve spring plate
8 - Outer valve spring
❑ With valve spring compressor - 2037- , with cylinder head removed
9 - Inner valve spring
❑ With valve spring compressor - 2037- , with cylinder head removed
10 - Valve stem seal
❑ Renewing ⇒ page 65 .
11 - Valve guide
12 - Unit injector
13 - Cylinder head
❑ See note ⇒ page 62 .
14 - Seal
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Before installing, remove residual oil from camshaft journal using a clean cloth.
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❑ To install, mask off groove on kcamshaft using
does Sellotape)
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❑ Removing and installinged⇒bypage 71 . gu
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15 - Valves au
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❑ Valve dimensions ⇒ page 64 .
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16 - Bearing shell
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❑ Do not interchange used bearing shells (mark).

ab
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❑ Ensure that retaining lugs are correctly seated in bearing caps and cylinder head
wit
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17 - Camshaft
hole
spec
❑ Checking axial clearance ⇒ page 64 .

es, in part or in w
t to the co

❑ Check radial clearance with Plastigage, wear limit: 0.11 mm.
rrectness of i
❑ Runout: max. 0.01 mm.

❑ Identification ⇒ page 65 .
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18 - Bearing cap
nf
ercia
❑ Installation sequence ⇒ page 67 .

orm
❑ To install, seal parting surfaces of bearing caps 1 and 5 with sealant - AMV 174 004 01- ⇒ page 64
m
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19 - 8 Nm + 1/4 turn (90°) further

or
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❑ Renew.
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Prote AG.
2. Valve gear 63
Sharan 1996 ➤
Checking camshaft axial clearance

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge
Check with bucket tappets removed and with first, third and last
bearing caps fitted.
Wear limit: max. 0.15 mm
Seal parting surfaces of bearing caps 1 and 5 with sealant - AMV
174 004 01-
– Apply sealant - AMV 174 004 01- thinly and evenly on the sur‐
faces -1-. gen AG
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♦ Be careful that no sealant gets into grooves -arrows-.

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♦ The bearing caps must be installed within 5 minutes after ap‐

ility
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plying sealant.
wit
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spec
Valve dimensions
t to the co
Note
rrectne
Valves must not be reworked. Only lapping-in is permitted.

ss o
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Dimension Inlet valve Exhaust valve

inform
mer
∅a mm 35.95 31.45
atio
m
∅b mm 6.980 6.956
o
n
c
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c mm 89.95 89.95
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α ∠° 45 45
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Prote AG.

Sharan 1996 ➤
Camshaft identification
♦ Cam base diameter: a = 52.8 mm ∅
♦ Identification by stamped numbers and letters on front side of
No. 4 cylinder exhaust cam -arrow-: 038 R or 858 R
AG. Volkswagen AG d
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2.2 Checking valve guides
ed
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Special tools and
ss workshop equipment required c
ce
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pt
♦ Universal dial gauge bracket - VW 387-
du
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ility
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spec
es, in part or in w
t to the co
rrectness of i
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nf
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♦ Dial gauge
orm
m
atio
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Test procedure
o
n in
or c
– Insert new valve into guide. The end of the valve stem must
thi
te
sd
be flush with the guide. On account of differing stem diame‐

iva
o
r
ters, only use inlet valve in inlet guide and exhaust valve in
rp
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exhaust guide.
f
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– Determine rock. Wear limit: max. 1.3 mm
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– Cylinder head must be renewed if rock exceeds wear limit.
op Vo
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Prote AG.
2.3 Renewing valve stem seals
2. Valve gear 65
Sharan 1996 ➤

equipment required
♦ Valve assembly device -
2036-
♦ Puller - 3047A-
♦ Fitting tool - 3129-
♦ Valve lever - VW 541/1A-
♦ Thrust piece - VW 541/5-
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spec
t to the co
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2.3.1 Removing
iva
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pr
cum
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(With cylinder head installed)

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– Remove camshaft ⇒ page 67 .
C py
t. rig
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– Remove bucket tappets and place them with the contact sur‐
cop Vo
by lksw
cted
face downwards. When doing this, ensure that the tappets are
agen
Prote AG.
not interchanged.
– Set piston of respective cylinder to top dead centre (TDC).
– Fit valve assembly tool - 2036- and adjust mountings to height
of studs.
– Remove valve springs using valve lever - VW 541/1A- and
press tool - VW 541/5- .
Note
The valves are supported by the piston crown.

Sharan 1996 ➤
– Pull off valve stem seals using puller - 3047A- .
2.3.2 Installing
– Place the plastic sleeve -A- supplied on the respective valve
stem. This will prevent the new valve stem seal -B- being
damaged.
– Place new valve stem seal in fitting tool - 3129- .
– Oil valve stem seal sealing lip and press carefully onto the
valve guide.
AG. Volkswagen AG d
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2.4 Removing and installing camshaft
ce
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nl
pt
du
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itte
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erm
ab
ility
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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.
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Cop py
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co lksw
by
cted agen
Prote AG.
2. Valve gear 67
Sharan 1996 ➤

equipment required
♦ Counterhold tool - T10051-
♦ Puller - T10052-
- V.A.G 1331-
200 Nm) - V.A.G 1332-
♦ Sealant - AMV 174 004 01-
AG. Volkswagen AG d
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
2.4.1 Removing
orm
m
atio
m

o
n in
or c
– Remove securing bolts for camshaft toothed belt pulley -1-. thi
te
sd
iva
o
r
– Pull camshaft toothed belt pulley off hub.

rp
cu
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
– Loosen hub securing bolt -1-.

– To do this, use counterhold - T10051- .
– Loosen hub securing bolt about 2 turns.
– Apply puller - T10052- and screw securing bolts -1- into hub.
– Apply tension to hub by evenly tightening puller until hub sep‐
arates from taper of camshaft.
Note n AG. Volkswagen AG do

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When doing
horis this, hold puller with 30 mm spanner. tee
ut or
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– Remove hub from taper of camshaft.
ce
le
un
pt
an
d

itte
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erm
ab
ility
ot p
– Mark rocker arm shafts using a permanent felt tip marker to

wit
is n
prevent interchanging. This will prevent having to perform ba‐

h re
ole,
sic settings of unit injectors -arrows-.

spec
– Remove rocker arm shafts.

t to the co
Note
rrectne
First loosen both outer and then inner securing bolts respectively.
ss o
cial p
f i
– Remove tandem pump ⇒ page 136 .

nform
mer
atio
om
– First remove bearing caps 5, 1 and 3. Then loosen bearing

c
i
or
caps 2 and 4 alternately and diagonally.

thi
te
sd
iva
o
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– Remove camshaft.
p
cum
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fo
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t.
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Cop py
t. rig
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Prote AG.
2. Valve gear 69
Sharan 1996 ➤
2.4.2 Installing
Note
♦ When camshaft is installed, No. 1 cylinder cams must point

upwards.
♦ Do not interchange used bearing shells (mark).
♦ When installing the camshaft, ensure proper seating of retain‐
ing lugs in bearing caps and cylinder head.
♦ Before installing bearing caps, ensure that cylinder head bolt
washers are inserted in the cylinder head.
– Oil bearing shell running surfaces.

n AG. Volkswagen A
a oes ge Gd
ksw
– Install bearing caps
by Vol 2 and 4 using new bolts.
not
gu
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ise
– Tighten bearing
ho
r caps 2 and 4 diagonally and alternately
tee to 8
1 ut or
Nm + s/s4 turn (90°).
a ac
ce
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nl
– Install bearing caps 5, 1 and 3 using new bolts. pt

du
an
itte
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erm
ab
ility
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Note wit
, is n
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♦ Seal parting surfaces of bearing caps 1 and 5 with sealant -

hole
spec
AMV 174 004 01- ⇒ page 64 .

es, in part or in w
t to the co
♦ Bearing cap 5 must be flush with outer edge of cylinder head,

otherwise leaks can occur at the tandem pump.
rrectness of i
– Tighten bearing caps 5, 1 and 3 likewise to 8 Nm + 1/4 turn

l purpos
(90°).
– Install camshaft oil seal ⇒ page 71 .
nf
ercia
orm
m
atio
– Install rocker arm shafts and tighten securing bolts, first the
om
inner -2- and then the outer -1-, evenly and diagonally to 20 Nm
n in
or c
+ 1/4 turn (90°).

thi
te
sd
iva
o
r
rp
– Fit hub onto camshaft.

cu
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f
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Tighten hub securing bolt -1- to 100 Nm.

– To do this, use counterhold - T10051- .

Sharan 1996 ➤
– Push camshaft toothed belt pulley onto hub.
Note
The toothed segment -arrow- of the camshaft belt pulley must be

on top.
– Align camshaft toothed belt pulley at centre of elongated

holes.
– Hand tighten securing bolts -1- to camshaft toothed belt pulley
so that there is no play. n AG. Volkswagen A ge G do
swa es n
– Lock hub using locking
by pin - 3359- .
Vol
k ot g
ua
d ran
ise
– How to install tand
ho tension toothed belt ⇒
r page 42 . tee
or
au ac
ss pump ⇒ page 138 .
– Install tandem
ce
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nl
pt
du
an
itte
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Note
erm
ab
ility
ot p
wit
When new bucket tappets have been installed the engine must
, is n
h re
not be started for about 30 minutes. The hydraulic compensation
hole
spec
elements must settle (otherwise valves will strike pistons).
es, in part or in w
t to the co
2.5 Removing and installing camshaft oil seal
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Valve gear 71
Sharan 1996 ➤

equipment required
♦ Fitting tool - 10-203-
♦ Oil seal extractor - 3240-
- V.A.G 1331-
200 Nm) - V.A.G 1332-
♦ Bolt M12×65
AG. Volkswagen AG d
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olksw not
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
Removing
– Remove toothed belt ⇒ page 42 ⇒ page 42 .
rrectness of i
– Remove camshaft pulley and hub ⇒ page 67 .

l purpos
– Screw inner part of oil seal extractor - 3240- two turns (approx.
3 mm) out of outer part and lock using knurled screw.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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Vo
co lksw
by
cted agen
Prote AG.

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

tion and, 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
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gen AG does
The oil seal sealing lip must not be additionally oiled or Vgreased.
olks
wa not
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– Remove oil residue from camshaft journal using
ut
ho a clean cloth. eo
ra
s a c
s
– Tape over groove in taper of camshaft (e.g. with commercially
ce
le
available Sellotape). un
pt
an
d
itte
y li
– Fit oil seal carefully on camshaft.
rm
ab
pe
ility
ot
wit
– Press in oil seal with press piece of fitting tool - 10-203- and
, is n
h re
bolt M12×65 onto stop.
hole
spec
– Install camshaft pulley and hub ⇒ page 67 .
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.
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.
2. Valve gear 73
Sharan 1996 ➤
17 – Lubrication
1 Engine oil
Note
♦ The oil level must not be above the max. mark - danger of
damage to catalytic converter! Observe markings
⇒ page 74
♦ Observe rules for cleanliness ⇒ page 115 .
Engine oil specification ⇒ Maintenance ; Booklet 10.1

Oil capacities ⇒ page 74
Checking engine oil level ⇒ page 74
1.1 Oil capacities

Engine code ANU: without oil filter 4.0 l, with oil filter 4.5 l
Engine codes ASZ, AUY, BTB, BVK: without oil filter 3.8 l, with oil
filter 4.3 l
wage
1.2 Checking engine oil level byV
olks es n
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Test prerequisites tho tee
or
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• Engine oil temperature at least 60 °C. ss
ce
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nl
pt
du
• Vehicle must be level (horizontal).
an
itte
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erm
ab
• Wait a few minutes after switching engine off to allow oil to flow
ility
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back into sump.
wit
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h re
Test procedure
hole
spec
– Pull out dipstick, wipe off with a clean cloth and insert it again
es, in part or in w
to stop.
t to the co
– Pull out dipstick again and read oil level.
rrectness of i
Markings on oil dipstick
l purpos
1 - Max. mark
2 - Min. mark
nform
ercia
a - Area above hatched field up to max. mark: Do not top up with

m
at
engine oil!
om
ion
c
in t
b - Oil level within hatched field: Can be topped up with engine

or
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e
oil.
at
do
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cum
c - Area from min. mark up to hatched field: Must be topped up,

for
en
g
max. 0.5 l of engine oil!

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t.
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Prote AG.
74 Rep. gr.17 - Lubrication

Sharan 1996 ➤
2 Parts of lubrication system
Note
♦ Finding metal shavings or a large quantity of small metal par‐

ticles during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To prevent this
from causing further damage, perform the following repairs:
♦ Thoroughly clean oil channels.
♦ Renew oil spray jets
♦ Renew engine oil cooler
♦ Renew oil filter element
Assembly overview - oil pump, sump ⇒ page 75

Removing and installing sump ⇒ page 77
AG. Volkswagen AG d
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2.1 Assembly overview - oil pump, sump byV
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1 - 15 Nm ss a c
ce
le
un
2 - Sealing flange
pt
an
d
itte
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❑ With seal.
rm
ab
pe
ility
❑ Must seat on dowel
ot
sleeves.
wit
, is n
h re
hole
spec
⇒ page 23 .
es, in part or in w
t to the co
❑ Install with silicone seal‐
ant - D 176 404 A2-
⇒ page 23
rrectness of i
❑ Note differing versions
of seal.
l purpos
❑ PTFE seal with no inner

coil spring
nform
ercia
❑ Renewing crankshaft oil

m
seal - belt pulley end

a
com
tio
⇒ page 21 .
n in
r
te o
thi
3 - Chain tensioner with ten‐

s
iva
do
sioning rail, 15 Nm
r
rp
cum
fo
❑ Check for wear.

en
ng
t.
yi Co
❑ When installing, preten‐ . Cop py
sion spring and fit.
ht rig
rig ht
py by
co Vo
4 - Bracket
by lksw
cted agen
Prote AG.
❑ For oil level/tempera‐
ture sender wiring har‐
ness.
❑ Various versions: clip‐
ped or bolted
5 - Cylinder block
crankshaft ⇒ page 29 .
bling pistons and con‐
rods ⇒ page 32
2. Parts of lubrication system 75

Sharan 1996 ➤
6 - Oil dipstick
❑ The oil level must not be above the max. mark!
❑ Lugs on dipstick and funnel must align.
❑ Markings ⇒ page 74 .
7 - Piston fitting tool
❑ For oil dipstick.
❑ Pull out to extract oil.
❑ Lugs on dipstick and funnel must align.
8 - Guide tube
9 - Dowel sleeves
wage
es ks not
Vol gu
10 - O-ring ed
by ara
nte
ris
❑ Renew. uth o eo
ra
a c
ss
11 - Suction line
ce
e
nl
pt
du
❑ Clean strainer if soiled.
an
itte
y li
erm
ab
12 - Baffle plate
ility
ot p
13 - 15 Nm
wit
, is n
h re
❑ Loosen and tighten with T-bar and socket, 10 mm - 3185-
hole
spec
❑ Remove using hexagon key extension, 5 mm - 3249- .
es, in part or in w
14 - Oil sump t to the co

❑ Clean sealing surface before fitting.
rrectness of i
❑ Install with silicone sealant - D 176 404 A2- .

l purpos

15 - 20 Nm
nform
ercia
16 - Bracket
m
at
❑ Vehicles 06.00 ►
om
ion
c
in t
❑ For charge air pipe between exhaust turbocharger and charge air cooler
or
his
ate
do
riv
17 - Seal
p
cum
or
❑ Fitted firmly
f
en
ng
t.
yi Co
❑ If leaking, nip open and replace t. Cop py
rig
gh ht
18 - Oil drain plug, 30 Nm yri
p by
co Vo
by lksw
❑ Renew plug with attached seal. cted agen
Prote AG.
19 - 10 Nm
20 - Oil level and oil temperature sender - G266-
❑ Vehicles 06.00 ►
21 - Seal
❑ Renew.
❑ Lubricate before installing.
22 - Connector
❑ Black, 3-pin.
23 - 25 Nm
❑ Engine codes ASZ, BTB: 20 Nm + 1/4 turn (90°) further
24 - Timing chain
❑ Mark direction of rotation before removing.
❑ Check for wear.

Sharan 1996 ➤
25 - Chain sprocket
❑ For oil pump.
❑ Check for wear.
26 - Oil pump
❑ With 12 bar pressure relief valve.
❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
❑ Renew if running surfaces and gears are scored.
2.2 Removing and installing oil sump

equipment required
♦ 10 mm jointed spanner -
3185-
♦ Hexagon key extension, 5
mm - 3249- AG. Volkswagen AG d
agen oes
olksw not
yV gu
♦ Torque wrench (5... 50 Nm) ed b ara
nte
is
- V.A.G 1331- hor eo
aut ra
c
♦ Used oil collection and ex‐ ss
ce
e
traction unit - V.A.G 1782-

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.
Not illustrated
♦ Silicone sealant - D 176 404 A2-
♦ Hand drill with plastic brush attachment
♦ Eye protection
♦ Flat scraper

olkswagen AG
wag en AG. V
Sharan 1996 ➤ olks
does
not
yV gu
4-cylinder diesel engine (1.9 l engine) - Editionse04.2014
d b ara
nte
ri
ho eo
ut ra
2.2.1 Removing
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
engine)
ility
ot p
wit
– Drain engine oil.
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
rrectness of i
Vehicles 06.00 ►
l purpos
– Pull 3-pin connector off oil level and oil temperature sender -
G266- .
nform
ercia
– Remove securing bolts -arrows- from bracket on sump for

m
at
om
charge air pipe between turbocharger and charge air cooler.
ion
c
in t
or
his
ate
do
riv
– Loosen sump bolts using T-bar and socket, 10 mm - 3185- .

p
cum
or
(Remove using hexagon key extension, 5 mm - 3249- ).

f
en
ng
t.
yi Co
– Remove sump, it may be necessary to release sump by tap‐ Cop py
ht. rig
ping lightly with a rubber head hammer. opy
rig by
Vo
ht
c lksw
– Remove sealant residue from cylinder block with a flat scraper.
by
cted agen
Prote AG.
WARNING
Wear eye protection.
– Remove sealant residue on sump with a rotating brush, e.g. a

hand drill with a plastic brush.
2.2.2 Installing
Note

♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.

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

mm).
– Apply silicone sealing compound, as shown, to clean sealing
surface on sump. Sealant bead must be:
♦ 2 ... 3 mm thick.
♦ Run bead along inner side of bolt holes -arrows-.
Note
The sealant bead must not be thicker, otherwise excess sealing

compound will enter the oil sump and may block the oil suction
line strainer.
– Apply silicone sealing compound bead as shown to the clean

sealing surface of the sump. (The figure shows the position of
the sealant bead on the cylinder block.)
– Install sump immediately and tighten all sump bolts lightly.
Note
The sump must be flush with cylinder block.
– Tighten oil sump bolts to 15 Nm.

– Tighten bolts securingagsump
en AG. to
Volgearbox tod 40 Nm.
kswagen AG
oes
ksw not
Vol gu
d by ara
ise nte
Note thor eo
au ra
c
ss
Let sealing compound dry for approx. 30 minutes after installing
ce
le
un
pt
oil sump. Only then fill with engine oil.

an
d
itte
y li
rm
ab
pe

ility
ot
quence.
wit
, is n
h re
Vehicles 06.00 ►
hole
spec
es, in part or in w
t to the co
– Tighten bolts for sump/charge air pipe bracket -arrows- to 20

Nm.
rrectness of i

l purpos

gine) .
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 ➤
3 Oil filter bracket, oil pressure, engine

oil cooler and oil supply line
Assembly overview - oil filter bracket and engine oil cooler: En‐
gine codes ANU, AUY, BVK ⇒ page 80
Assembly overview - oil filter bracket and engine oil cooler: En‐
gine codes ASZ, BTB ⇒ page 82 . Volkswage n AG n AG d
wage oes
Assembly overview -oil supply line to turbochargery V⇒
olkpage
s 83 not
gu
b ara
ed
Removing and installing oil supply line to turbocharger
ho
ris nte
eo
⇒ page 83 s aut ra
c
s
Checking oil pressure and oil pressure switch ⇒ page 86 .
ce
e
nl
pt
du
an
itte
3.1 Assembly overview - oil filter bracket and engine oil cooler: Engine codes
y li
erm
ab
ANU, AUY, BVK
ility
ot p
wit
, is n
h re
hole
spec
1 - Plug, 25 Nm
es, in part or in w
t to the co
2 - Seal
❑ Renew.
rrectness of i
3 - Engine oil cooler
l purpos
jacent components.
nf
ercia
or
❑ Coolant hose schematic
m
m
atio
diagram:
om
n in
c
❑ Engine code ANU

or
thi
e
⇒ page 97
t
sd
iva
o
r
❑ Engine codes AUY,

rp
cu
o
BVK ⇒ page 98 m
f
en
ng
t.
yi Co
❑ Checking engine oil t. Cop py
cooler for leaks
rig
gh ht
yri by
⇒ page 111 op Vo
by c lksw
cted agen
Prote
4 - Seal
AG.
❑ Renew.
❑ Lubricate before instal‐
ling.
❑ Fit into lugs on engine oil
cooler.
5 - 0.3 bar oil pressure switch -
F22- , 22 Nm
❑ Vehicles ► 05.00
❑ Identification: blue
❑ If seal is leaking, nip
open and renew.
6 - Plug, 40 Nm
❑ Do not unscrew.
7 - Spring
❑ For pressure relief valve, approx. 5 bar.
8 - Piston
❑ For pressure relief valve, approx. 5 bar.

Sharan 1996 ➤
9 - Oil pressure switch - F1- , 22 Nm

❑ Vehicles ► 05.00: 0.9 bar, identification: grey
❑ Vehicles 06.00 ►: 0.7 bar; identification: brown
❑ If seal is leaking, nip open and renew.
10 - Gasket
❑ Renew.
11 - 15 Nm + 1/4 turn (90°) further
❑ Renew.
❑ First fit upper left and lower right bolts and then tighten all four bolts diagonally.
❑ Ensure clearance to adjacent components.
13 - Seal
❑ Renew.
14 - Oil supply line AG. Volkswagen AG d
agen oes
❑ To turbocharger. yV
olksw not
gu
b ara
❑ Removing and installing ⇒ page 83 . orised
nte
h eo
ut ra
15 - Banjo bolt ss a c
ce
e
❑ Specified torque ⇒ Item 4 (page 83)

nl
pt
du
an
itte
16 - Cap, 25 Nm
y li
erm
ab
❑ Loosen and tighten with oil filter spanner - 3417-
ility
ot p
wit
, is n
17 - O-ring
h re
hole
❑ Renew.
spec
es, in part or in w
18 - Oil filter element
t to the co
❑ Observe change intervals.
rrectness of i
❑ Ensure "Top" is uppermost when fitting
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.
3. Oil filter bracket, oil pressure, engine oil cooler and oil supply line 81
olkswagen AG
en AG. V
Sharan 1996 ➤ ksw
ag does
not
Vol
ed
by - Edition 04.2014 gu
ara
ris nte
utho eo
ra
3.2 Assembly overview - oil filter bracket and engine oil cooler: Engine codes ss
a c
ce
le
ASZ, BTB
un
pt
an
d
itte
y li
erm
ab
ility
1 - Gasket
ot p
wit
is n
❑ Renew.
h re
ole,
spec
2 - 15 Nm + 1/4 turn (90°) fur‐
ther
t to the co
❑ Renew.
❑ First fit upper left and
rrectne
lower right bolts and
then tighten all four bolts
s
diagonally.
s o
cial p
f i
nform
mer
atio
m
jacent components.
o
n
c
i
or
n
4 - Seal
thi
te
sd
va
❑ Renew.
i
o
pr
cum
r
fo
5 - Union, 30 Nm
en
ng
t.
yi Co
op py
6 - Oil supply line t. C rig
gh ht
yri by
❑ To turbocharger. cop Vo
by lksw
cted agen
❑ When loosening and Prote AG.
tightening, counterhold
union
⇒ page 83 .
7 - 0.7 bar oil pressure switch -
F1- , 22 Nm
❑ Identification: brown.
❑ If seal is leaking, nip
open and renew.
8 - Cap, 25 Nm
9 - O-ring
❑ Renew.
10 - Oil filter element
❑ Observe change intervals.
11 - Seal
❑ Renew.
❑ Lubricate before installing.
❑ Fit into lugs on engine oil cooler.
❑ Ensure clearance to adjacent components.
❑ Coolant hose schematic diagram: Engine codes ASZ, BTB ⇒ page 99
❑ Checking engine oil cooler for leaks ⇒ page 111
13 - Seal
❑ Renew.

Sharan 1996 ➤
14 - Plug, 25 Nm
15 - 10 Nm
16 - Bracket
❑ For wiring harness and connector for earth connection
3.3 Assembly overview - oil supply line to turbocharger
1 - Oil supply line

❑ To turbocharger.
wage
2 - Union nut, 22 Nm olks es n
ot g
byV ua
❑ When loosening and ir se
d ran
tee
tightening, counterhold autho
or
ac
union ss
ce
e
nl
3 - Seal
pt
du
an
itte
y li
❑ Renew.
erm
ab
ility
ot p
4 - Banjo bolt, 25 Nm
wit
, is n
h re
5 - Clip
hole
spec
6 - 10 Nm
es, in part or in w
t to the co
7 - Bracket
8 - 25 Nm
rrectness of i
❑ Renew.
l purpos
9 - 10 Nm
10 - 10 Nm
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.
3.4 Removing and installing oil supply line

to turbocharger
Removing
Sharan 1996 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 04.2014 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
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove noise insulation.

– Place drip tray - V.A.G 1306- underneath.
– Remove air filter housing.
– Remove union nut -2- or banjo bolt -4- from oil filter bracket.
– Remove bolt -6-.
– Remove union nut -2- from turbocharger.
– Remove bolt -9- from bracket -7-.
– Remove nut -8- and bracket -7-.
– Remove oil supply line -1-.
Installing

Sharan 1996 ➤
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
Cop py
Install in reverse order. In the process, note the following: ht. rig
rig ht
py by
co Vo
by lksw
cted agen
WARNING
Prote AG.
The following procedure for the installation of the oil supply line
must be strictly adhered to.
– Screw bracket -7- with nut -8- loosely to exhaust manifold.

– Screw union nut -2- or banjo bolt -4- to oil filter bracket hand-
tight.
– Screw union nut -2- to turbocharger hand-tight.
– Tighten union nut -2- or banjo bolt -4- on oil filter bracket to
specified torque.
– Tighten union nut -2- on exhaust turbocharger to specified tor‐
que.
– Position clamps -5- on oil supply line.
– Tighten bolts -6- and -9- to specified torque.
– Tighten nut -8- to prescribed torque.
Sharan 1996 ➤
3.5 Checking oil pressure and oil pressure switch

equipment required
♦ Oil pressure tester - V.A.G
1342-
♦ Voltage tester - V.A.G
1527/B-
♦ Auxiliary measuring set -
V.A.G 1594/A-
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
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
Test prerequisites
en
ng
t.
yi Co
op py
• Oil level OK, checking ⇒ page 74
. C rig
ht ht
rig by
py
• Engine oil temperature at least 80 °C (radiator fan must have
co Vo
by lksw
cted
run once)
agen
Prote AG.
Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
3.5.1 Test sequence: Vehicles ► 05.00

Test sequence: Vehicles 06.00 ► ⇒ page 87 .
Checking oil pressure switch
Checking 0.9-bar oil pressure switch

Sharan 1996 ➤
– Remove 0.9-bar oil pressure switch - F1- -grey insulation- and

screw into tester.
– Screw tester into oil filter bracket in place of oil pressure
switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester - V.A.G 1527 B- to battery positive (+)
and oil pressure switch using cable from auxiliary measuring
set - V.A.G 1594/A- . LED must not light up.
– Start engine and increase speed slowly. At 0.75 ... 1.05 bar,
the LED must light up; otherwise renew oil pressure switch.
Checking 0.3-bar oil pressure switch
– Remove 0.3-bar oil pressure switch - F22- -blue insulation-

and screw into tester.
– Screw tester into oil filter bracket in place of oil pressure
switch.
set - V.A.G 1594/A- . The LED must light up.
the LED must go out; otherwise renew oil pressure switch.
Checking oil pressure
– Increase engine speed further. At 2000 rpm and an oil tem‐
perature of 80 °C the oil pressure should be at least 2.0 bar.
. Volkswagen AG
At higher engine speeds, oil pressure must not exceed 7.0 gen AIfG
wabar. does
necessary renew oil filter bracket. Volks not
gu
by ara
ed nte
ris
tho eo
3.5.2 Test sequence: Vehicles
ss 06.00 ►
au ra
c
ce
e
nl
Checking oil pressure switch

pt
du
an
itte
– Remove 0.7-bar oil pressure switch - F1- -brown insulation- y li

erm
and screw into tester. ab

ility
ot p
wit
, is n
– Screw tester into oil filter bracket in place of oil pressure h re

switch.
hole
spec
es, in part or in w

t to the co

rrectness of i
set - V.A.G 1594/A- . LED must not light up.

l purpos
the LED must light up; otherwise renew oil pressure switch.
nf
ercia
Checking oil pressure

orm
m
– Increase engine speed further. At 2000 rpm and an oil tem‐

atio
m
perature of 80 °C the oil pressure should be at least 2.0 bar.

o
n in
or c
thi
e
At higher engine speeds, oil pressure must not exceed 7.0 bar. If
t
sd
iva
necessary renew oil filter bracket.

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 ➤
19 – Cooling
1 Removing and installing parts of cool‐
ing system
WARNING

tions:
♦ Route all the various lines and electrical wiring so that they
are in their original positions.
hot components.
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.
88 Rep. gr.19 - Cooling

Sharan 1996 ➤
Note
♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ Spring-type clip pliers - VAS 5024- are recommended for in‐
stallation of spring-type clips.
♦ 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).
Assembly overview - cooling system, body side: Engine codes

ANU, AUY, BVK ⇒ page 89
Assembly overview - cooling system, body side: Engine codes
ASZ, BTB ⇒ page 91
Assembly overview - cooling system, engine side: Engine codes
ANU, AUY, BVK ⇒ page 92
Assembly overview - cooling system, engine side: Engine codes
ASZ, BTB ⇒ page 94
Assembly overview - additional cooler ⇒ page 95 .
Coolant hose schematic diagram: Engine code ANU
⇒ page 97
Coolant hose schematic diagram: Engine codes AUY, BVK
⇒ page 98
Coolant hose schematic diagram: Engine codes ASZ, BTB
⇒ page 99
Draining and filling with coolant ⇒ page 100 .
. Volkswagen AG
gen AG does
Removing and installing radiator and fan V⇒olkpage
swa 103 not
by gu
d ara
Removing and installing coolant pumporis ⇒ page 105 .
e nte
th eo
u ra
Removing and installing thermostat
ss
a ⇒ page 107 . c
ce
le
Checking cooling system for leaks ⇒ page 109 .

un
pt
an
d
itte
y li
Checking engine oil cooler for leaks ⇒ page 111

erm
ab
ility
ot p
wit
1.1 Assembly overview - cooling system, body side: Engine codes ANU, AUY,
is n
h re
ole,
BVK
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
89
cted agen
Prote AG.
1. Removing and installing parts of cooling system
Sharan 1996 ➤
1 - Rubber bush
2 - Upper coolant hose
❑ Check for secure seat‐
ing.
diagram:
❑ Engine code ANU
⇒ page 97
BVK ⇒ page 98
3 - Radiator
⇒ page 103 .
❑ After renewing, renew lkswage es n
entire coolant. d byV
o ot g
ua
ran
ir se tee
4 - Rubber bush utho
or
a ac
ss
5 - 10 Nm
ce
le
un
pt
6 - Thermo-switch - F18- , 35
an
d
itte
y li
Nm
rm
ab
pe
ility
❑ For radiator fan.
ot
wit
, is n
❑ Switching tempera‐
h re
tures: speed 1 on: 92…
hole
spec
97 °C off: 84… 91 °C;
es, in part or in w
speed 2 on: 99… 105 °
t to the co
C off: 91… 98 °C
7 - Connector
rrectness of i
❑ Black, 3-pin.
l purpos
❑ For radiator fan thermal

switch
nform
ercia
8 - Reinforcement strut
m
a
9 - Connector
com
tion in
❑ For continued coolant circulation pump - V50- .
r
te o
thi
s
iva
❑ Black, 2-pin. do
r
rp
cum
fo
10 - Connector
en
ng
t.
yi Co
❑ For right radiator fan - V35- t. Cop py
rig
❑ Black, 2-pin.
gh ht
pyri by
Vo
co lksw
by
11 - Coolant circulation pump - V50- cted agen
Prote AG.
❑ For vehicles 06.00 ► fitted on plenum chamber
❑ Black 2-pin connector
12 - Retaining clip
13 - Securing clip
❑ For continued coolant circulation pump - V50- .
14 - 10 Nm
15 - Fan ring
16 - Right radiator fan - V35-
17 - Radiator fan - V7-

Sharan 1996 ➤
18 - Connector
❑ For radiator fan - V7- .
❑ Black, 2-pin.
19 - Cowling
20 - Lower coolant hose
❑ Coolant hose schematic diagram:
❑ Engine code ANU ⇒ page 97 agen
AG. Volkswagen AG d
oes
lksw not
❑ Engine codes AUY, dBVK
by ⇒ page 98
Vo gu
a
e ran
ris tee
21 - Charge air coolerutho or
a ac
ss
ce
le
un
pt
an
d
1.2 Assembly overview - cooling system, body side: Engine codes ASZ, BTB
itte
y li
rm
ab
pe
ility
ot
wit
, is n
1 - Radiator
h re
hole
spec
⇒ page 103 .
es, in part or in w
t to the co
❑ After renewing, renew
entire coolant.
rrectness of i
2 - O-ring
l purpos
3 - Connection
nform
ercia
❑ Secured to radiator with

retaining clip.
m
a
com
ti

on in
ing.
r
te o
thi
s
iva

do
r
rp
cum

fo
en
ng
ing.
t.
yi Co
Cop py
t. rig
gh ht
yri
diagram ⇒ page 99 . p by
o Vo
by c lksw
cted agen
5 - 9 Nm Prote AG.
6 - Radiator fan control unit -

J293-
⇒ page 103 .
7 - Retaining clip
ing.
8 - Connector
❑ For coolant temperature
sender - radiator outlet -
G83- .
❑ Black, 2-pin.
9 - Radiator outlet coolant tem‐
perature sender - G83-
❑ Before removing, release pressure in cooling system if necessary.
❑ Coolant hose schematic diagram ⇒ page 99 .
1. Removing and installing parts of cooling system 91

Sharan 1996 ➤
11 - Cowling
12 - Connector
❑ For radiator fan control unit - J293-
1.3 Assembly overview - cooling system, engine side: Engine codes ANU, AUY,
BVK

2 - Thermostat
⇒ page 107 .
AG. Volkswagen AG d
❑ Note installation posi‐ lksw
agen oes
not
tion ⇒ page 107 . d by Vo gu
ara
se nte
❑ Checking: heat thermo‐tho ri
eo
stat in water. s au ra
c
s
❑ Opening begins at ap‐
ce
e
nl
pt
prox. 87 °C.
du
an
itte
y li
erm
ab
ility
ot p
❑ Opening lift at least 7
wit
mm.
, is n
h re
hole
3 - O-ring
spec
es, in part or in w
❑ Renew.
t to the co
4 - Connection
❑ For thermostat. rrectness of i
5 - Coolant pipe
l purpos
6 - From heat exchanger

nf
ercia

or
diagram:
m
m
atio
m
❑ Engine code ANU

o
n in
c
⇒ page 97
or
thi
te

sd
iva
o
r
BVK ⇒ page 98
rp
cu
o
m
f
en
ng
7 - To heat exchanger
t.
yi Co
op py
t. C rig
gh ht
yri
diagram: p by
co Vo
by lksw
❑ Engine code ANU
cted agen
Prote AG.
⇒ page 97
BVK ⇒ page 98
8 - 10 Nm
9 - Cap
❑ Check using cooling system tester - V.A.G 1274- and adapter - V.A.G 1274/9- .
❑ Pressure relief valve must open at between 1.4 and 1.6 bar
10 - Expansion tank
❑ Check cooling system for leaks with cooling system tester - V.A.G 1274- and adapter - V.A.G 1274/8- .
❑ Observe markings ⇒ page 100
11 - Connector
❑ Black, 2-pin.

Sharan 1996 ➤
12 - Connection
13 - To auxiliary heater (if fitted)
14 - From auxiliary heater (if fitted)
15 - Coolant temperature sender - G62-
❑ For engine control unit. agen
AG. Volkswagen AG d
oes
lksw not
❑ Before removing, release pressure
db
y V in cooling system if necessary.
o gu
a
e ran
ris tee
16 - To cylinder head utho or
a ac
ss
17 - Retaining clip
ce
e
nl
pt
du
an
itte
y li
erm
18 - O-ring
ab
ility
ot p
wit
, is n
h re
19 - Thermal switch for air conditioning shut-off - F163- and Thermal switch for radiator fan third speed - F165-
hole
spec
❑ Brown, 4-pin
es, in part or in w
t to the co
❑ For vehicles with air conditioning: ⇒ Heating, air conditioning system; Rep. gr. 87
20 - To top of radiator
rrectness of i
❑ Coolant hose schematic diagram:
l purpos
❑ Engine code ANU ⇒ page 97

❑ Engine codes AUY, BVK ⇒ page 98
nf
ercia
21 - 15 Nm
orm
m
atio
22 - Connection
om
n in
c
❑ Secured with securing clip

or
thi
te
sd
iva
o
r
rp
cu
23 - Continued coolant circulation thermal switch - F95-
o
m
f
en
ng
t.
yi Co
24 - Coolant circulation pump - V50- Cop py
t. rig
gh
❑ For vehicles 06.00 ► fitted on plenum chamber
ht
pyri by
Vo
co lksw
by
❑ Black 2-pin connector Prote
cted AG.
agen
25 - Securing clip
26 - Connection
❑ Fitted at cylinder block
27 - To coolant pump.
28 - Coolant pump

Sharan 1996 ➤
1.4 Assembly overview - cooling system, engine side: Engine codes ASZ, BTB
1 - To exhaust gas recircula‐

tion cooler.
diagram ⇒ page 99 .
2 - To auxiliary heater (if fitted)
3 - From heat exchanger
4 - To heat exchanger
5 - From exhaust gas recircu‐
lation cooler
6 - Coolant circulation pump -
V50-
7 - From auxiliary heater (if fit‐
ted)
8 - 15 Nm
9 - Connection
❑ Fitted at cylinder block
10 - To cylinder head n AG. Volkswagen AG do
lkswage es n
o ot g
yV ua
11 - Expansion tank ir se
d b ran
o tee
❑ Check cooling system auth or
ac
for leaks with cooling
ss
system tester - V.A.G 1274- and adapter - V.A.G 1274/8- .
ce
le
un
pt
an
d
❑ Observe markings ⇒ page 100

itte
y li
rm
ab
12 - Seal
pe
ility
ot
wit
❑ Observe installation position on cap

, is n
h re
hole
spec
es, in part or in w
13 - Cap
t to the co
❑ Check using cooling system tester - V.A.G 1274- and adapter - V.A.G 1274/9- .
❑ Pressure relief valve must open at between 1.4 and 1.6 bar
rrectness of i
14 - 10 Nm
l purpos
15 - From additional cooler

nform
ercia
16 - Coolant pipe
m
a
com
tio
17 - O-ring
n in
r
te o
thi
s
iva
do
r
rp

um
fo
en
g

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
94
co Vo
by lksw
Rep. gr.19 - Cooling cted agen
Prote AG.
Sharan 1996 ➤
19 - Coolant hose
❑ To heat exchanger for fuel cooler, connection: WA
❑ Coolant hose schematic diagram ⇒ page 99 .Volkswa
AG. gen AG
agen does
21 - Connection olksw not
yV gu
db ara
❑ For thermostat. rise nte
tho eo
22 - O-ring au ra
c
ss
❑ Renew.
ce
e
nl
pt
du
an
itte
23 - Thermostat
y li
erm
ab
ility
ot p
wit
❑ Note installation position ⇒ page 107 .
, is n
h re
❑ Checking: heat thermostat in water.
hole
spec
❑ Opening begins at approx. 87 °C.
es, in part or in w
t to the co
❑ Opening lift at least 7 mm.
rrectness of i
l purpos
25 - Coolant pump
nform
ercia

m
at
om
ion
c
in t
or
his
ate
26 - Retaining clip
do
priv
cum
or

f
en
ng
t.
yi Co
27 - Coolant temperature sender - G62- Cop py
ht. rig
❑ Grey
rig ht
py by
co Vo
by lksw
❑ For engine control unit. Prote
cted AG.
agen
❑ Before removing, release pressure in cooling system if necessary.

1.5 Assembly overview - additional cooler
Note
♦ On vehicles with engine codes ASZ, BTB this additional cooler

is always installed.
♦ For vehicles with engine codes ANU, AUY, BVK this additional
cooler is only installed, when no fuel cooler is fitted on under‐
body of vehicle ⇒ page 122 .

Sharan 1996 ➤
1 - 7 Nm
2 - Coolant hose
❑ To junction piece
3 - Coolant hose
❑ From heat exchanger
for fuel cooler, connec‐
tion: WE
4 - Coolant pipe
❑ Secured at the air intake
elbow
AG. Volkswagen AG d
agen oes
5 - Retaining frame olksw not
byV gu
ara
ed
6 - Additional cooler horis nte
eo
ut
❑ Clipped into retaining ss a ra
c
frame
ce
le
un
pt
❑ For heat exchanger
an
d
itte
y li
⇒ page 120
rm
ab
pe
ility
❑ To remove, remove
ot
wit
front bumper: ⇒ Body
, is n
h re
Repairs; Rep. gr. 63 ;
hole
Exterior; Front bumper
spec
es, in part or in w
06.00 ►; Assembly over‐
t to the co
view
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 ➤
1.6 Coolantlkshose
wage
n AGschematic
. Volkswagen AG
diagram:
does
n
Engine code ANU
o ot g
yV ua
edb ran
ris tee
1 - Cylinder ublock/cylinder
tho or
head ss
a ac
ce
e
nl
2 - Coolant pipe
pt
du
an
itte
y li
3 - Heat exchanger for heater
erm
ab
unit
ility
ot p
wit
, is n
4 - Return hose with inside
h re
throttle
hole
spec
es, in part or in w
5 - Expansion tank
t to the co
6 - Connection for auxiliary
coolant heater (optional extra)
rrectness of i
l purpos
V50-
8 - Radiator
nform
ercia

m
at
om
i
10 - Coolant pump
on
c
in t
or
11 - Thermostat
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.

Sharan 1996 ➤
1.7 Coolant hose schematic diagram: Engine codes AUY, BVK
1 - Cylinder block/cylinder
head
2 - Radiator
❑ For exhaust gas recircu‐
lation.
3 - Shut-off valve for auxiliary
heater
❑ Vehicles with optional
equipment only.
heater
equipment only.
V50-
AG. Volkswagen AG d
agen oes
6 - Heat exchanger for heater olks
w not
yV gu
unit se
d b ara
nte
ri
ho eo
7 - Additional heat aexchanger
ut ra
c
ss
ce
e
nl
equipment only.
pt
du
an
itte
y li
8 - Expansion tank
erm
ab
ility
ot p

wit
, is n
throttle
h re
hole
spec
10 - Gearbox oil cooler

es, in part or in w
t to the co
❑ Only for automatic gear‐

box
11 - Coolant pipe
rrectness of i
12 - Radiator
l purpos

nf
ercia
14 - Coolant pump
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 ➤
1.8 Coolant hose schematic diagram: Engine codes ASZ, BTB
1 - Cylinder block/cylinder
head
2 - Radiator
lation.
heater
5 - Connection
V50-
7 - Heat exchanger for heater
unit
8 - Additional heat exchanger
equipment only.
9 - Expansion tank
throttle
11 - Heat exchanger for fuel
cooler
wage
es
ks not
Vol gu
13 - Additional
ed cooler for heat
by ara
nte
exchanger
thoris eo
au ra
14 - Radiator
ss c
ce
le
un
pt

an
d
itte
y li
erm
16 - Coolant pipe
ab
ility
ot p
17 - Coolant pump
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 ➤
1.9 Draining and filling coolant

equipment required
♦ Refractometer - T10007-
♦ Drip tray - VAS 6208-
VAS 5024 A-
♦ Cooling system charge unit
- VAS 6096-
♦ Adapter - V.A.G 1274/7-
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
1.9.1 Draining
l purpos
– Open filler cap on coolant expansion tank.

nf
ercia
orm
m
WARNING
atio
om
n in
or c
Hot steam may escape when expansion tank is opened. Place

thi
te
cloth over cap and open with caution.

sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
– Remove noise insulation ⇒ Body Repairs; Rep. gr. 50 ; Exte‐ Cop py
t. rig
gh ht
yri by
engine) cop Vo
by lksw
cted agen
Prote
Vehicles ► 05.00
AG.
– Pull lower coolant hose off radiator.

Sharan 1996 ➤
Vehicles 06.00 ►
– Pull out retaining clip -arrow- for lower coolant hose and re‐
move coolant hose from quick-release coupling of radiator.
– In addition to draining coolant from engine, pull coolant hose
off engine oil cooler.
Note
If the cooling system was filled with G11 anti-freeze, coloured

green:
– The cooling system must be flushed out as follows before re‐
fitting the coolant hoses and filling with new coolant G 12 Plus-
Plus, coloured lilac:
– Remove as much coolant from cooling system as possible.
Blow into coolant expansion tank with compressed air for this.
– Connect hoses, fill cooling system with plain water and refit
cap.
– Start engine and run for approx. 2 minutes.
– Drain coolant and blow out the cooling system again with com‐
pressed air.
Note

gen AG
. Volkswagen AG
d wa oes
olks not
byV gu
ara
ed nte
ris
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
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 ➤
1.9.2 Filling
Note
♦ In vehicles as of model year 2008, only G 12 plus-plus ac‐

cording to TL VW 774 G may be used as coolant additive.
♦ For vehicles up to and including model year 2007 coolant ad‐
ditive G 12 plus according to TL VW 774 F and G 12 plus-plus
according to TL VW 774 G can be used.
♦ The coolant additive G 12 plus-plus can be mixed with the
previous coolant additive G 12 plus. Identification: both are
coloured purple.
♦ Coolant additives marked “according to TL VW 774 G” or “ac‐
cording to TL VW 774 F” prevent frost and corrosion damage,
scaling and also raise boiling point of coolant. Therefore, the
cooling system must be filled all year round with coolant ad‐
ditive and corrosion protection additive.
♦
♦ Because of its higher boiling point, the coolant improves en‐
gine reliability under heavy loads, particularly in countries with
tropical climates.
♦ Frost protection is required down to about -25 °C (in countries
with arctic climates: down to about -35 °C).
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The
coolant additive concentration must be at least 40 %.
AG. Volkswagen AG d
♦ If for climatic reasons greater frost protection is required, the
lksw
agen oes
not
amount of coolant additive can be increased, but only dup by to 60
Vo gu
ara
% (frost protection to about -40 °C). Otherwise frostoriprotection
se nte
and cooling effectiveness are reduced again. auth eo
ra
ss c
♦ The refractometer -T10007- is recommended for determining
ce
le
un
pt
the current anti-freeze concentration.
an
d
itte
♦ If radiator, heat exchanger, cylinder head or cylinder head y li

erm
ab
gasket is renewed, do not reuse old coolant. ility
ot p
wit
is n
h re
ole,
Recommended mixture ratios:

spec
Vehicle equipment Frost pro‐ Anti- G 123) Water3)

t to the co
tection to freeze
quantity2)
rrectne
one -25 °C 40 % 2.7 l 4.1 l

heat exchanger -35 °C 50 % 3.4 l 3.4 l
s
two -25 °C 40 % 3.4 l 5.2 l

s o
cial p
heat exchangers -35 °C 50 % 4.3 l 4.3 l

f inform
two -25 °C 40 % 3.7 l 5.5 l

mer
heat exchangers and -35 °C 50 % 4.6 l 4.6 l

atio
m
additional water
o
n
c
i
or
heater
thi
te
sd
iva
2) The amount of anti-freeze must not exceed 60 %; frost protection and cooling
pr
cum
r
effectiveness will decrease if amount of anti-freeze is too high.

fo
en
ng
t.
yi
3) The quantity of coolant can vary depending upon vehicle equipment.
Co
Cop py
ht. rig
Procedure rig ht
py by
co Vo
by lksw
– Install lower coolant hose and secure. cted agen
Prote AG.
– Reconnect coolant hoses to engine oil cooler.

With cooling system charge unit - VAS 6096- :

Sharan 1996 ➤
– Screw adapter - V.A.G 1274/7- onto expansion tank.

– Fill coolant circuit using cooling system charge unit -
VAS 6096- ⇒ Operating instructions for cooling system charge
unit VAS 6096 .
– Install noise insulation ⇒ Body Repairs;
agen
AG.Rep.
Volkswgr.
agen50
AG; dBody
oes -
olksw insulation (diesel engine)
front; Assembly overview - ynoise not.
V gu b ara
ed nte
oris e
1.10 Removing and installing radiator and fan th or
au ac
ss
ce
le
un
pt
an
d

itte
y li
equipment required
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
VAS 5024 A-
rrectne
- VAS 6096-
s
s o
cial p
f in
form
mer
- V.A.G 1331-
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 ➤
1.10.1 Removing
– Drain coolant ⇒ page 100 .
Vehicles with engine codes ANU, AUY, BVK
– Pull upper coolant hose off radiator.
– Detach bottom coolant hose from the clips on the air ducting.
– Pull the connecting hoses off charge air cooler.
– Remove the air pipe inlet connection/charge air cooler.
n AG. Volkswagen A ge G do
swa es
– Pull connectors off thermal
by
Vol
k
switch and radiator fan. not gua
d ran
se
– Remove thermo
thoswitch.
ri tee
or
au ac
– Remove reinforcement
ss strut.
ce
e
nl
pt
du
– Unscrew fan ring securing bolts and remove fan ring with fan.
an
itte
y li
erm
ab
Vehicles with no air conditioner
ility
ot p
– Remove radiator securing bolts.
wit
, is n
h re
hole
– Remove radiator downwards.
spec
es, in part or in w
t to the co
WARNING
rrectness of i
l purpos
nform
mercia
Note
at
om
ion
c
in t
or
To prevent damage to condenser or to refrigerant lines/hoses,

his
te
ensure that the lines and hoses are not stretched, kinked or bent.
a
do
priv
cum
for
en
g

n
t.
yi Co
Cop py
Vehicles ► 05.00
t. rig
gh ht
pyri by
Vo
o
– Remove radiator grille with trim frame: ⇒ Body Repairs; Rep.
c by lksw
cted agen
gr. 66 ; Exterior; Trim; Removing and installing radiator grille
Prote AG.
with trim frame

Vehicles 06.00 ►
gr. 50 ; Exterior; Body - front; Lock carrier service position .
– Remove left headlight: ⇒ Electrical system; Rep. gr. 94 ;
Servicing headlights
– Remove condenser from radiator.
– Secure condenser to body so that the refrigerant lines/hoses
are not under tension.
Vehicles with engine codes ASZ, BTB
gr. 50 ; Exterior; Body - front; Lock carrier service position .

Sharan 1996 ➤
– Pull out retaining clip for upper coolant hose and remove cool‐
ant hose from quick-release coupling of radiator.
– Pull connecting hose off charge air cooler left at connection.
– Remove charge air cooler connecting
gen AG flange. n AG d
. Volkswage
wa oes
olks no
– Separate connector todradiator
by
V fan control unit - J293- at cowl‐
t gu
ara
ing. orise nte
e h
ut or
– Unbolt coolantspipe
sa securing bolt from additional cooler out of ac
air intake elbow.
ce
e
nl
pt
du
an
– Unbolt air intake elbow from radiator and remove.
itte
y li
erm
ab
Vehicles with no air conditioner
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
WARNING
rrectness of i
l purpos
nform
mercia
at
om
Note
ion
c
in t
or
his
e
To prevent damage to condenser or to refrigerant lines/hoses,

at
do
riv
ensure that the lines and hoses are not stretched, kinked or bent.
p
cum
for
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
1.10.2 Installing pyri by
Vo
o
by c lksw
cted agen
Prote
AG.
note the following:

– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Replenish coolant ⇒ page 100 .
Vehicles with engine codes ANU, AUY, BVK
– Check headlight adjustment and correct if necessary ⇒ Main‐
tenance ; Booklet 10.1 .
1.11 Removing and installing coolant pump

Sharan 1996 ➤

equipment required
VAS 5024 A-
- VAS 6096-
- V.A.G 1331-
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 AG.
Removing
(with engine installed)
Note
♦ Always renew seals and gaskets.

♦ Cover toothed belt with a cloth to protect it from coolant before
removing coolant pump.

lkswage es n Sharan 1996 ➤
o ot g
byV 4-cylinder diesel engine (1.9 ua l engine) - Edition 04.2014
d ran
ir se tee
tho
u or
– Drain coolant ⇒ page 100
ss
a . ac
ce
e
nl
pt
du
an
itte
y li
– Remove coolant pump securing bolts -1- and carefully remove
erm
ab
coolant pump -2-.
ility
ot p
wit
Installing , is n
h re
hole
spec
es, in part or in w
note the following:
t to the co
rrectness of i
l purpos
nf
ercia
orm
– Moisten new O-ring -3- with coolant.
m
atio
om
– Insert coolant pump -2- into cylinder block and tighten securing
n in
or c
bolts -1-. Specified torque: 15 Nm.
thi
te
sd
iva
o
r
rp
cu
o
m
f
Note
en
ng
t.
yi Co
Cop py
. rig
The coolant pump plug faces downwards.
t
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.12 Removing and installing thermostat

Sharan 1996 ➤

equipment required
VAS 5024 A-
- VAS 6096-
- V.A.G 1331-
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
Prote AG.
Removing
Note
Always renew seals and gaskets.
– Drain coolant ⇒ page 100 .

Sharan 1996 ➤
– Pull coolant hose off connection -3-.

– Remove connecting flange -3- securing bolts -4- and remove
connecting flange -3- with thermostat -1-.
– Turn thermostat -1- 1/4 turn (90°) to left and remove from con‐
nection -3-. gen AG
. Volkswagen AG
d wa oes
olks not
Installing byV gu
ara
ed nte
ris
Installation is carried out in the reverse order. When tho installing, eo
note the following: au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
– Moisten new O-ring -2- with coolant.
ot p
wit
is n
– Insert thermostat -1- in union -3- and turn 1/4 turn (90°) to right.
h re
ole,
spec
t to the co
Note
The brace on the thermostat must be almost vertical.
rrectne
– Fit connection -3- with thermostat -1- into cylinder block.
ss o
cial p
– Tighten securing bolts -4-. Specified torque: 15 Nm
f inform
mer
atio
om
n
c
1.13 Checking cooling system for leaks
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 ➤
AG. Volkswagen AG d
Special tools and workshop agen oes
olksw not
equipment required d byV gu
ara
ise nte
r
♦ Cooling system tester - ut
ho eo
ra
V.A.G 1274- ss a c
ce
le
un
♦ Adapter for cooling system
pt
an
d
tester - V.A.G 1274/7-
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Test prerequisite
• Engine at operating temperature
Test sequence:
WARNING
Hot steam may escape when expansion tank is opened. Place

cloth over cap and open with caution.
– Open cap on coolant expansion tank.

Sharan 1996 ➤
– Fit cooling system tester - V.A.G 1274- with cooling system

tester adapter - V.A.G 1274/7- on expansion tank.
– Use hand pump on tester to create a pressure of about 1.0 bar.
If pressure drops:
– Find leaks and rectify.
Checking pressure relief valve in filler cap
– Attach cooling system tester - V.A.G 1274- or - V.A.G 1274 B-

with cooling system tester adapter - V.A.G 1274/9- to cap.
– Use hand pump on cooling system tester to create a pressure
of max. 1.4 bar.
The pressure relief valve must not open.
If the pressure relief valve opens prematurely:
– Renew sealing cap.
– Increase pressure to over 1.4 bar.
The pressure relief valve must open.
AG. Volkswagen AG d
If the pressure relief valve does not open: lksw
agen oes
not
o
yV gu
– Renew sealing cap. ised b ara
nte
or eo
h
aut ra
1.14 Checking engine oil cooler for leaks 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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤

equipment required
♦ Hose clips up to 25 mm Ø -
3094-
♦ Cooling system tester -
V.A.G 1274-
VAS 5024 A-
AG. Volkswagen AG d
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
♦ Torque wrench - V.A.G 1331-

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
riv
Not illustrated
p
cum
for
♦ Expansion tank - 1K0 121 407 A bzw. 6Q0 121 407 A bzw.
en
ng
t.
yi Co
1J0 121 407 B- t. Cop py
rig
gh ht
♦ Plug - 191 211 343- pyri by
Vo
o
by c lksw
cted
♦ Cap - 1J0 121 324-
agen
Prote AG.
♦ Coolant hose - 251 265 056-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
orise Sharan
nte 1996 ➤
h eo
aut 4-cylinder diesel engine (1.9 l engine) - Edition r a04.2014
ss c
ce
le
Prerequisites:
un
pt
an
d
itte
y li
• Engine cold
rm
ab
pe
ility
Test procedure
ot
wit
, is n
h re
– Remove noise insulation.
hole
spec
– Clamp supply line and return line off engine oil cooler using
es, in part or in w
t to the co
hose clips to ∅ 25 mm - VAS 3094- .
– Loosen hose clips -arrows- using spring-type clip pliers - VAS
5024- .
rrectness of i
l purpos
Note
nform
ercia
Collect escaping coolant with drip tray - V.A.G 1306- or drip tray
m
- VAS 6208- .
a
com
tion in
r
te o
– Pull coolant hoses off engine oil cooler.
thi
s
iva
do
r
rp
cum
– Slide filler cap -5- to rear connection of engine oil cooler -4-.
fo
en
ng
t.
yi Co
– Secure sealing plug -2- to breather connection of expansion Cop py
t. rig
tank -1-. opyri
gh by
Vo
ht
by c
– Secure coolant hose -3- to engine oil cooler and expansion
lksw
cted agen
Prote
tank.
AG.
– Fill expansion tank up to “Max” marking.

– Attach cooling system tester - V.A.G 1274B- with cooling sys‐
tem tester adapter - V.A.G 1274/7- to expansion tank.
– Use hand pump on tester to create a pressure of about 1.6 bar.
– Watch pressure drop on pressure gauge. A pressure drop
within 10 minutes is not permitted.
If pressure drops:
– Renew engine oil cooler ⇒ page 82 .
note the following:
– Check coolant level, replenish coolant if necessary
⇒ page 100 .

Sharan 1996 ➤
20 – Fuel supply system

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

clamp-type clips.
♦ Always replace clamp-type clips with screw or spring-type
swa
gen AG
. Volkswagen AG
does
clips. yV
olk not
gu
edb ara
♦ Fuel hoses on engine must be secured withtho spring-type clips
ris nte
eo
only. The use of clamp or screw-type clips
au is not permissible. ra
c
ss
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
Safety precautions when working on fuel supply system
ot p
wit
⇒ page 115 .
, is n
h re
hole
Rules for cleanliness ⇒ page 115 .
spec
es, in part or in w
Assembly overview - fuel tank ⇒ page 115 .
t to the co
Removing and installing fuel tank ⇒ page 125 .
rrectness of i
Assembly overview - fuel filter: Engine codes ANU, AUY, BVK
⇒ page 117
l purpos
Assembly overview - fuel filter: Engine codes ANU, ASZ, AUY,

BTB, BVK ⇒ page 119
nform
ercia
Assembly overview - heat exchanger for fuel cooler

m
at
⇒ page 120
om
ion
c
in t
r
Removing and installing fuel cooler: Engine codes ANU, AUY,

o
his
te
BVK ⇒ page 122

a
do
priv
cum
or
Emptying fuel tank ⇒ page 123 .

f
en
ng
t.
yi Co
Removing and installing fuel delivery unit ⇒ page 128 . ht. Cop py
rig
rig ht
Removing and installing fuel gauge sender ⇒ page 130 . py by
co Vo
by lksw
cted agen
Checking fuel pump ⇒ page 130 . Prote AG.
Checking tandem pump ⇒ page 132 .

Removing and installing tandem pump ⇒ page 136 .
Assembly overview - accelerator mechanism ⇒ page 138 .
114 Rep. gr.20 - Fuel supply system

Sharan 1996 ➤
1.1 Safety precautions when working on

fuel supply system
WARNING

tions:
sitions.
wage
♦ Ensure that there is sufficient clearance to all ymoving
Volks or es n
ot g
hot components. ir se
d b ua
ran
o tee
th or
au ac
ss
When removing and installing the fuel gauge sender from a full or
ce
e
nl
pt
partly full fuel tank the following must be observed:
du
an
itte
y li
erm
♦ Even before work commences, the extraction hose of an ac‐
ab
ility
tivated fume extraction system has to be placed in the vicinity
ot p
wit
of the assembly opening of the fuel tank to extract any escap‐
, is n
h re
ing fumes. If no exhaust gas extraction system is available, a
hole
spec
radial fan with a displacement greater than 15 m3/h can be
es, in part or in w
used providing that motor is not in air flow.
t to the co
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
1.2 Rules for cleanliness
rrectness of i
l purpos
When working on the fuel supply and injection system, pay careful
attention to the following “6 rules” for cleanliness:
nform
ercia
♦ Thoroughly clean all unions and surrounding areas before dis‐

connecting.
m
at
om
ion
♦ Place removed parts on a clean surface and cover. Use only
c
in t
or
lint-free cloths.
his
ate
do
riv
♦ Carefully cover opened components or seal if repairs cannot

p
cum
or
be carried out immediately.

f
en
ng
t.
yi Co
op
♦ Install clean components only. Do not remove replacement C py
t. rig
parts from packing until immediately before installing. Do not
gh ht
yri by
use parts that have not been stored in their packing (e.g. in
cop Vo
by lksw
cted
tool boxes etc.).
agen
Prote AG.
♦ When system is open: do not work with compressed air if this

can be avoided. Do not move vehicle unless absolutely nec‐
essary.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
1.3 Assembly overview - fuel tank
1. Removing and installing parts of fuel supply system 115

Sharan 1996 ➤
1 - Cap
2 - Seal
❑ If damaged only renew
together with cap.
3 - Clamping ring
4 - Rubber cup
5 - Gravity valve
❑ To remove valve unclip
upwards out of filler
neck
❑ Check valve for
through-flow valve verti‐
cal: open, valve tilted
45°: closed
6 - O-ring
7 - Breather valve
❑ Cannot be removed, re‐
new only together with
filler neck
❑ Check ⇒ page 117 . AG. Volkswagen AG d
agen oes
8 - Connector olksw not
V gu
d by ara
❑ 4-pin orise nte
eo
h
ut ra
9 - Union nut, 80 Nm ss a c
ce
le
❑ Remove and install us‐

un
pt
an
ing union nut tool -
d
itte
y li
3217- .
rm
ab
pe
ility
10 - Rubber bush
ot
wit
, is n
h re
hole
spec
11 - Non-return valve
es, in part or in w
t to the co
❑ Check for ease of movement
12 - 10 Nm
rrectness of i
13 - Filler neck
l purpos
❑ With expansion tank and breather valve

14 - Seal nform
ercia
m
a
com
15 - Clamping ring
ion in
r
te o
16 - Breather line
thi
s
iva
do
r
17 - 25 Nm
rp
cum
fo
en
g
18 - Fuel tank
n
t.
yi Co
op py
❑ When removing, support using engine and gearbox jack - V.A.G 1383 A- .
t. C rig
gh ht
yri by
❑ To remove, drain fuel tank ⇒ page 123 .
op Vo
by c lksw
cted agen
Prote
19 - Securing strap
AG.
❑ Note different lengths.

20 - Seal
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.

Sharan 1996 ➤
21 - Fuel delivery unit

❑ With fuel gauge sender (G).
❑ Clean strainer if soiled.
❑ Note installation position of flange on fuel tank ⇒ page agen
117
AG. V.olkswagen AG d
oes
lksw not
❑ Removing and installing ⇒ page 128 . byV
o gu
ara
ed
❑ To remove, drain fuel tank ⇒ page 123 h.o ris nte
eo
ut ra
❑ Removing and installing fuel gauge ssender
s a ⇒ page 130 . c
ce
le
❑ Checking fuel pump ⇒ page 130 .
un
pt
an
d
itte
22 - Supply line
y li
rm
ab
pe
❑ To fuel filter
ility
ot
wit
❑ Clipped onto fuel tank.
, is n
h re
hole
spec
es, in part or in w
❑ To pull off flange, press release button on connecting piece.
t to the co
23 - Return line
❑ From fuel cooler.
rrectness of i
❑ Clipped onto fuel tank.
l purpos

❑ To pull off flange, press release button on connecting piece.
nform
mercia
a
com
tio
Installation position of fuel gauge sender
n in
r
te o
thi
Marking on flange must align with marking on fuel tank -arrows-.
s
iva
do
r
rp
c
Marking on flange points opposite direction of travel.
um
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Checking breather valve

Valve in rest position: closed
Valve pushed in direction of arrow: open
1.4 Assembly overview - fuel filter: Engine

codes ANU, AUY, BVK
Only vehicles with fuel cooler at underbody

Sharan 1996 ➤
1 - Fuel line lkswage es n
o ot g
yV ua
2 - O-ring ir se
d b ran
tee
o
❑ Renew. auth or
ac
ss
3 - Regulating valve
ce
e
nl
pt
du
an
❑ Installation position: ar‐
itte
y li
row points towards fuel erm
ab
tank
ility
ot p
wit
❑ When changing filter,
, is n
h re
remove retaining clip
hole
spec
and take off regulating
es, in part or in w
valve with fuel pipes still
t to the co
attached.
❑ Below + 15 °C: passa‐
geway to filter open
rrectness of i
❑ Over + 31 °C: passage‐
l purpos
way to filter closed

4 - Retaining clip
nf
ercia
o
rm
m
atio
ing.
om
n in
c
5 - Return line
or
thi
te
sd
a
❑ To fuel cooler
iv
o
r
rp
cu
❑ Clipped into bulkhead
o
m
f
en
ng
t.
yi
❑ Blue or with blue mark‐
Co
op py
ing. t. C rig
gh ht
yri by
❑ Check for secure seat‐ cop Vo
by lksw
ing. cted agen
Prote AG.
6 - Supply line
❑ From fuel tank.
❑ White or with white
marking.
ing.
7 - Fuel filter
❑ Fill with diesel before installing.
❑ Direction of flow is marked with arrows.
❑ Do not interchange connections.
8 - Gasket
9 - Water drain screw
❑ To bleed remove regulating valve securing clip and remove regulating valve complete with connected
fuel lines.
❑ Loosen and allow approx. 100 cm3 fluid to drain
10 - Return line
❑ From tandem pump ⇒ Item 27 (page 39)

Sharan 1996 ➤
11 - Connection
12 - Fuel temperature sender - G81-
wage es n
13 - O-ring yV
olks ot g
ua
d b
❑ Renew if damaged. o
ir se
ran
tee
th or
u
14 - Supply line ss
a ac
ce
le
un
pt
an
d
❑ To tandem pump ⇒ Item 26 (page 39) .
itte
y li
rm
ab
❑ White or with white marking.
pe
ility
ot
wit
, is n
h re
hole
spec
1.5 Assembly overview - fuel filter: Engine
es, in part or in w
t to the co
codes ANU, ASZ, AUY, BTB, BVK
Vehicles without fuel cooler at underbody
rrectness of i
l purpos
1 - Supply line
ing.
nform
ercia
❑ To tandem pump
m
a
com
t
⇒ Item 26 (page 39) .
ion in
r
❑ White or with white

te o
thi
marking.
s
iva
do
r
rp
cum
2 - Return line
fo
en
ng
t.
yi
Co
op py
ing. t. C rig
gh ht
yri by
❑ From heat exchanger cop Vo
by lksw
for fuel cooler, connec‐ cted agen
Prote AG.
tion: radiator outlet
❑ Blue or with blue mark‐
ing.
3 - O-ring
❑ Renew.
4 - Regulating valve
❑ Installation position: ar‐
row points towards fuel
tank
❑ When changing filter,
remove retaining clip
and take off regulating
valve with fuel pipes still
attached.
❑ Below + 15 °C: passa‐
geway to filter open
❑ Over + 31 °C: passage‐
way to filter closed
5 - Retaining clip
ing.
6 - Return line
❑ To fuel tank.

Sharan 1996 ➤
7 - Supply line
❑ From fuel tank.
❑ Clipped into bulkhead of plenum chamber.
❑ White or with white marking.
❑ Check for secure seating. n AG. Volkswagen AG do
lkswage es n
8 - Fuel filter byV
o ot g
ua
d ran
❑ Fill with diesel before installing. ir se tee
tho
u or
❑ Direction of flow is marked with arrows.
ss
a ac
ce
e
❑ Do not interchange connections.
nl
pt
du
an
itte
y li
erm
ab
9 - Gasket
ility
ot p
wit
, is n
h re
hole
10 - Water drain screw
spec
es, in part or in w
❑ To bleed remove regulating valve securing clip and remove regulating valve complete with connected
t to the co
fuel lines.
❑ Loosen and allow approx. 100 cm3 fluid to drain
rrectness of i
l purpos
1.6 Assembly overview - heat exchanger for

fuel cooler
nf
ercia
orm
m
atio
om
n in
c
Note
or
thi
te
sd
iva
♦ The heat exchanger for the fuel cooler is located on the fuel
o
r
rp
cu
filter (on the left in engine compartment).
o
m
f
en
ng
t.
yi Co
♦ For vehicles with engine codes ASZ, BTB this heat exchanger Cop py
t. rig
is always installed. gh ht
pyri by
Vo
co lksw
♦ For vehicles with engine codes ANU, AUY, BVK this heat ex‐
by
cted agen
Prote
changer is only installed, when no fuel cooler is fitted at
AG.
underbody of vehicle ⇒ page 122 .

Sharan 1996 ➤
1 - 5 Nm
2 - Return line
❑ Secured to connection
“radiator outlet” of heat
exchanger.
ing.
❑ To fuel filter
⇒ Item 2 (page 119) . n AG. Volkswagen AG do
wage
❑ Blue or with blue mark‐ olks es n
ot g
yV
ing. d b ua
ran
ir se tee
ho
3 - Coolant hose aut or
ac
ss
ce
le
un
“WA” of heat exchanger.
pt
an
d
itte
y li
erm
ab
ing.
ility
ot p
wit
❑ To junction piece cool‐
is n
h re
ant hose, below
ole,
spec
t to the co
4 - Coolant hose
rrectne
“WE” of heat exchanger.
ss
ing.
o
cial p
f in
❑ From additional cooler
form
mer
atio
m
o
n
c
i
or
n thi
5 - Fuel line
te
sd
va
i
o
pr
cum
r
“KE” of heat exchanger.

fo
en
ng
t.
yi
Co
Cop py
ing.
t. rig
gh ht
yri by
❑ Blue or with blue marking. cop Vo
by lksw
cted agen
Prote AG.
6 - Connection
7 - Retaining clip
8 - O-ring
❑ Renew.
10 - Return line
❑ From tandem pump ⇒ Item 27 (page 39)
11 - 8 Nm
12 - Bracket
13 - Heat exchanger for fuel cooler

Sharan 1996 ➤
1.7 Removing and installing fuel cooler: En‐

gine codes ANU, AUY, BVK agen
AG. Volkswagen AG d
oes
ksw not
Special tools and workshop equipment required Vol gu
d by ara
e nte
ris
♦ Torque wrench (5... 50 Nm) - V.A.G 1331- tho eo
au ra
c
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
♦ Spring-type clip pliers - VAS 5024 A-
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.
Note
♦ The fuel cooler is located in the return line to fuel tank. It is

installed at the underbody of the vehicle.
♦ This fuel cooler is only installed when no heat exchanger is
fitted on fuel filter (in engine compartment left) ⇒ page 120 .
Removing
Observe safety precautions ⇒ page 115 .
Observe rules for cleanliness ⇒ page 115 .
– Separate fuel lines at fuel cooler.
WARNING
the system, place cloths around the connections. Then

Sharan 1996 ➤
– Remove securing nuts -arrows-.

Installing
♦ Tighten fuel cooler securing nuts to 15 Nm.
1.8 Emptying fuel tank

♦ Fuel extractor - VAS 5190-
AG. Volkswagen AG d
agen oes
olksw not
♦ Union nut tool - 3217- d by
V gu
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

Emptying fuel tank if it is more than 3/4 full ⇒ page 123 .
nform
ercia
Emptying fuel tank if it is less than 3/4 full ⇒ page 124

m
a
com
tion in
1.8.1 Emptying fuel tank if it is more than 3/4

r
te o
thi
s
iva
full
do
r
rp
cum
fo
en
ng
t.
yi Co
Caution Cop py
t. rig
gh ht
pyri by
Secure earth wire of fuel extractor - VAS 5190- to a bare metal
o Vo
by c lksw
cted agen
part of the body. Prote AG.

Sharan 1996 ➤
– Remove cotter -2- from shaft -1- of fuel extractor - VAS 5190- .
– At distance -a- = 1280 mm from end, mark extraction hose with
insulating tape -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
– Remove filler cap from fuel tank filler neck.
ce
e
nl
pt
du
an
– Screw shaft end -1- of fuel extractor unit - VAS 5190- onto fuel
itte
y li
filler neck.
erm
ab
ility
ot p
– Push extraction hose into fuel tank until marking on hose
wit
, is n
-arrow- coincides with shaft end.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
Note
orm
m
atio
m
A ball valve -2- is located at the bottom of the filler neck in the fuel
o
n in
c
tank -1-; it must not be damaged by the extraction hose -3-.

or
thi
e
Therefore push hose into filler neck only as far as marking

t
sd
iva
-arrow-.
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
– Empty fuel tank as far as possible. t. Cop py
rig
gh ht
– Carefully pull out extraction hose. yri
p by
o Vo
by c lksw
cted agen
Prote AG.
Note
♦ When no more fuel is extracted, the tank is emptied just

enough for the sender flange to be opened without danger.
♦ If the fuel tank has to be drained fully, proceed as follows:
⇒ page 124
1.8.2 Emptying fuel tank if it is less than 3/4 full

– Remove both centre seats ⇒ Rep. gr. 72 .
– Fold back floor carpet.
– Remove cover from fuel delivery unit.

Sharan 1996 ➤
WARNING
Fuel supply line is pressurised. Wear eye protection and pro‐

tective clothing to avoid possible injury and skin contact. Before
loosening hose connections, wrap a cloth around the connec‐
tion. Then release pressure by carefully pulling hose off con‐
nection.
– Pull return line -1-, supply line -2-, fuel line for auxiliary heater
(if fitted) -3- and 4-pin connector -4- off fuel delivery unit flange.
Note
Press buttons on hose couplings to do this.
– Loosen union nut using union nut tool - 3217- .

– Lift sender flange. AG. Volkswagen AG d
agen oes
olksw not
y V gu
– Insert extraction hose of fuel extractor - VASise
d b5190- as deeply ara
nte
as possible into fuel tank and extract fuel.
thor eo
au ra
s c
If fuel tank needed only to be emptied, sreinstall sender flange
ce
e
⇒ page 128 .
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
1.9 Removing and installing fuel tank

Special tools and workshop equipment required 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 ➤
♦ Engine and gearbox jack - V.A.G 1383/A-
1.9.1 Removing
♦ Observe safety precautions ⇒ page 115 .
♦ It is very difficult to remove the fuel filler neck from the fuel tank
or to install.
♦ Therefore the rear axle must be removed to remove the fuel
tank.
♦ Before disconnecting battery, open fuel tank flap and if nec‐
essary remove wheel bolt lock adapter from luggage compart‐
ment.
♦ Wear eye and hand protection when performing any type of
repair work on the fuel system!
– Make a note of the filling level of fuel tank.
4) Is required for procedure »Emptying fuel tank«.
– Disconnect battery ⇒ Electrical system; Repair group 27;

Starter, current supply; Battery; Disconnecting and reconnect‐
AG. Volkswagen AG d
ing battery . lksw
agen oes
n o ot g
yV ua
– Remove rear axle ⇒ Running gear,
ris
ed axles, steering; Rep. gr.
b ran
tee
42 . ut
ho
or
a ac
Filled fuel tank ss
ce
e
nl
pt
du
– Emptying fuel tank ⇒ page 123 .

an
itte
y li
erm
ab
Empty fuel tank

ility
ot p
wit
– Remove both centre seats. ⇒ Rep. gr. 72

, is n
h re
hole

spec
es, in part or in w

t to the co
WARNING
rrectness of i
Fuel supply line is pressurised. Wear eye protection and pro‐

l purpos
tective clothing to avoid possible injury and skin contact. Before

loosening hose connections, wrap a cloth around the connec‐
nf
ercia
tion. Then release pressure by carefully pulling hose off con‐

or
nection.
m
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 ➤
– Pull return line -1-, supply line -2-, fuel line for auxiliary heater
(if fitted) -3- and 4-pin connector -4- off fuel delivery unit flange.
Note
Press buttons on hose couplings to do this.
– Remove clamping ring and rubber cup ⇒ Item 3 (page 116) .

– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
housing liner .
– Remove filler neck securing bolts ⇒ Item 12 n(page
AG. Vo116)
lkswag.en A
ge G do
swa es n
– Then support fuel tank using engine by and gearbox jack - V.A.G
Vol
k ot g
ua
1383 A- . ris
ed ran
tee
tho or
– Remove securing bolts ofsssecuring
au straps. ac
ce
le
un
pt
an
– Slowly lower fuel tank approx. 15 cm.
d
itte
y li
erm
ab
ility
ot p
– Now unclip fuel lines -arrows- from fuel tank.
wit
is n
h re
– Carefully remove fuel tank together with fuel neck.
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
1.9.2 Installing
c
i
or
n thi
te
sd
a
All hoses and connectors which are separated when removing

iv
o
pr
the fuel tank must be reconnected in the original position when

um
r
fo
en
installing.
ng
t.
yi Co
op py
All clamps which have been loosened or separated while remov‐
. C rig
ht ht
rig
ing the fuel tank must be placed again in the same locations or py by
co Vo
renewed when installing. ⇒ Electronic parts catalogue
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
♦ Fuel lines are to be installed free of kinks.

♦ Clip fuel lines onto fuel tank -arrows-.
♦ Do not interchange supply line and return line (return line -1-
has a blue button and supply line -2- has a black button).
♦ Ensure that line connections are tight.
♦ Connections for fuel lines must engage audibly when joined.
♦ Check earth connection between body and filler neck for prop‐
er seating.
– Install rear axle ⇒ Running gear, axles, steering; Rep. gr. 42 .
– Perform road test.
1.10 Removing and installing fuel delivery

unit
AG. Volkswagen AG d
agen oes
Special tools and workshop equipment required olksw not
V gu
d by ara
e
♦ Union nut tool - 3217- horis nte
eo
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.
Removing
Observe rules for cleanliness ⇒ page 115 .
– First check whether a coded radio is fitted. If so, obtain anti-
theft coding.
– With the ignition switched off, disconnect battery earth strap.
– The fuel tank must not be more than 3/4 full when removing
the suction-jet pump. Empty fuel tank if necessary
⇒ page 123 .

Sharan 1996 ➤
WARNING
of repair work on the fuel system!wagen AG. Volkswagen AG doe
ks s no
Vol t gu
d by ara
ir se nte
– Pull return line -1-, supply utho line -2-, fuel line for auxiliary heater eo
ra
(if fitted) -3- and 4-pinssconnector
a
-4- off fuel delivery unit flange. c
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
Press in securing ring to release fuel lines.
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 ➤
– Loosen union nut using union nut tool - 3217- .

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

posal.
Installing
– Installing the fuel delivery unit is carried out in reverse order
of removal.
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. AG. Volkswagen AG d
agen oes
ksw
♦ Moisten seal with fuel only when installing flange or fuel de‐ ol not
byV gu
ara
livery unit. orised
nte
h eo
ut
♦ Fuel lines are to be installed free of kinks. ss a ra
c
ce
le
♦ Do not interchange supply line and return line (return line is

un
pt
an
d
green and supply line is black).

itte
y li
rm
ab
♦ Ensure that fuel hose connections are tight.
pe
ility
ot
wit
, is n
♦ Connections for fuel lines must engage audibly when joined.
h re
hole
♦ After installing fuel delivery unit, check that supply and return
spec
lines are still clipped onto fuel tank.
es, in part or in w
t to the co
♦ Observe installation position of fuel delivery unit ⇒ page 117 .
rrectness of i
1.11 Removing and installing fuel gauge
l purpos
sender
nform
ercia
Removing
m
– Remove fuel delivery unit ⇒ page 128 . a

com
tion in
r
– Release connector tabs of lines -3- and -4- and pull them off.
te o
thi
s
iva
do
– Raise retaining tabs -1- and -2- using a screwdriver and pull
r
rp
cum
fuel sender off downwards -arrow-.

fo
en
ng
t.
yi Co
Installing . Cop py
rig
ht ht
rig
– Insert fuel gauge sender into guides on fuel delivery unit and py by
co Vo
press upwards until it engages.
by lksw
cted agen
Prote AG.
– Install fuel delivery unit ⇒ page 128 .
1.12 Checking fuel pump


Sharan 1996 ➤
♦ Hand multimeter - V.A.G 1526 B- or multimeter - V.A.G 1715-
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
♦ Voltage tester - V.A.G 1527 B-
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
♦ Auxiliary measuring set - V.A.G 1594 C-
com
tion in
r
Test prerequisite
te o
thi
s
iva
do
• Fuses must be OK.
r
rp
cum
fo
• The battery voltage must be at least 11.5 V.

en
ng
t.
yi Co
op py
• All electrical consumers, e.g. lights and rear window heating, t. C rig
gh ht
must be switched off. yri
p by
co Vo
by lksw
cted
Checking function and voltage supply
agen
Prote AG.

– Switch on ignition. The fuel pump must be heard to run for
about 2 seconds.
– Switch off ignition.
If the fuel pump does not start:
– Pull 4-pin connector off fuel delivery unit flange.

Sharan 1996 ➤
– Connect voltage tester - V.A.G 1527 B- to outer contacts of

connector using auxiliary cables from auxiliary measuring set
- V.A.G 1594 C- .
– Switch on ignition. The LED must light up for about 2 seconds.
If LED does not light up
– Check actuation of fuel pump relay and wiring for open circuit
or short circuit. ⇒ Vehicle diagnostic tester Volkswa
AG. gen AG
agen does
LED lights up (voltage supply OK):
Vol
ksw not
gu
by ara
ed
– Remove fuel delivery unit
ho
ris ⇒ page 128 . nte
eo
t
au ra
– Check that electrical
ss wiring between flange and fuel pump is c
connected and has continuity.
ce
le
un
pt
an
d
itte
If no open circuit can be found:
y li
erm
ab
– Renew fuel delivery unit ⇒ page 128 .
ility
ot p
wit
is n
Checking current draw of fuel pump
h re
ole,
spec
– Pull 4-pin connector off fuel delivery unit flange.
t to the co
– Set multimeter to 20 A measuring range and connect in series
between contact -1- of connector and fuel pump using auxiliary
cables from adapter set - V.A.G 1594 C- .
rrectness
Note
o
cial p
The current pick-up clamp of multimeter - V.A.G 1715- can also f inform
mer
atio
be attached to an auxiliary cable between contacts -1- of con‐
om
nector and fuel pump.

n
c
i
or
n thi
te
sd
va
– Connect contacts -4- of connector and fuel pump using an

i
o
pr
cum
auxiliary cable from adapter set - V.A.G 1594 C- .

r
fo
en
ng
t.
yi
– Start engine and run at idling speed.
Co
Cop py
t. rig
gh
– Measure current draw of fuel pump: Specification: max. 7.5
ht
pyri by
Vo
o
Amperes. by c lksw
cted agen
Prote AG.
– If the measured value is not within specifications:
– Renew fuel delivery unit ⇒ page 128 .
1.13 Checking tandem pump

Checking delivery pressure ⇒ page 132
Checking for internal leaks ⇒ page 135
1.13.1 Checking delivery pressure


Sharan 1996 ➤
♦ Tandem pump tester - VAS 5187-
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
♦ Vehicle diagnostic, testing and information system - VAS
hole
spec
5051-
es, in part or in w
t to the co
♦ Diagnostic cable - VAS 5051/6A-
♦ Banjo bolt - 5187/1A-
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
yri
♦ Adapter - 5187/7- p by
co Vo
by lksw
cted agen
Test prerequisites Prote AG.
Coolant temperature must be at least 85 °C.

Unit injectors OK.
Fuel filter and fuel lines must not be blocked.
Intact fuel delivery unit
Procedure

Sharan 1996 ➤
– Remove screw plug -arrow-.
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
– Connect tandem pump tester - VAS 5187- as shown.
pt
an
d
itte
y li
rm
ab
pe
ility
– Connect vehicle diagnosis, testing and information system -
ot
wit
, is n
VAS 5052- and select operating mode “Vehicle self-diagno‐
h re
sis”.
hole
spec
es, in part or in w
– Press button “01 - Engine electronics” on display.
t to the co
– Press diagnosis function “08-Read measured value block”.
– Enter display group “1” using number block (key pad) and
rrectness of i
confirm entry with Q button.
l purpos
– Read engine idling speed in display zone “1”.
nform
– Increase engine speed to 4000 rpm.
mercia
– Observe pressure indicated on pressure gauge.

a
com
tion in
Specification: min. 7.5 bar

r
te o
thi
s
iva
If the specification is not attained:

do
r
rp
cum
fo
– Using a hose clip, clamp-off return line between fuel filter and
en
ng
t.
tandem pump.
yi Co
Cop py
t. rig
– Increase engine speed to 4000 rpm.
gh ht
pyri by
Vo
co lksw
by
– Observe pressure indicated on pressure gauge. cted agen
Prote AG.
Specification: min. 7.5 bar

If specification is now obtained:
Pressure loss at unit injectors.
– Renew unit injector O-rings.
If the specification is not attained:
– Renew tandem pump ⇒ page 136 .
Note
After removing pressure gauge, tighten plug to 25 Nm. Always

renew seal.

Sharan 1996 ➤
1.13.2 Checking for internal leaks
Note
The tandem pump must be checked for internal leaks between

fuel side and oil side after reinstalling a used tandem pump, e.g.
after renewing or repairing a cylinder head and/or when installing
a "short" engine. When leaking it is possible for the fuel to mix
with the oil which may cause the engine to fail.

AG. Volkswagen AG d
♦ Tester - V.A.G 1687- 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
Procedure
rrectne
– Pull fuel supply hose (white marking) ⇒ Item 26 (page 39) and
fuel return hose (blue marking) ⇒ Item 27 (page 39) off tandem
ss
pump.
o
cial p
f inform
– Seal fuel return union on tandem pump with a plug. Secure
mer
sealing plug with a spring-type clip.
atio
om
n
Prepare test unit - V.A.G 1687- as follows:
c
i
or
n thi
te
– Unscrew pressure regulating valve -2- and close valves -3-
sd
iva
o
r
and -4-.
p
cum
r
fo
en
ng
– Connect test connection -5- to fuel supply union of tandem

t.
yi Co
op
pump using a commercially available compressed air connec‐ C py
ht. rig
tion and a section of fuel hose. Use a spring-type clip to secure. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.

Sharan 1996 ➤
– Connect compressed air hose -1- (compressed air source) to

charge air system tester - V.A.G 1687- .
Note
If there is water in the sight glass, drain at water drain screw -6-.
– Open valve -3-.

– Adjust pressure to 1.0 bar with pressure regulating valve -2-.
Caution
The maximum test pressure is 1.3 bar and this must not be
exceeded.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 1.0 bar.
– Close valve -3- to retain pressure and observe the pressure
drop over a period of 1 minute.
If the pressure does not drop the tandem pump can be reused, if
the pressure drops the tandem pump must be renewed.
1.14 Removing and installing tandem pump

kswage es n
DANGER! byV
ol ot g
ua
d ran
ir se tee
o
The tandem pump may, under no circumstances,
auth
be disman‐ or
ac
tled as the vacuum part could otherwise malfunction. This ss
ce
le
would result in the failure of the brake servo.

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 ➤

equipment required
- V.A.G 1331-
♦ Hand vacuum pump -
V.A.G 1390-
♦ Water drainage container -
V.A.G 1390/1-
VAS 5024 A-
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
1.14.1 Removing
h re
hole
– Pull supply hose -1- (white marking) and return hose -2- (blue spec
es, in part or in w
t to the co
marking) off fuel filter.
WARNING
rrectness of i
l purpos
nf
ercia

orm

m
atio
m

o
n in
or c

thi
te
sd

iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
– Connect hand vacuum pump - V.A.G 1390- with fluid recep‐ . Cop py
tacle - V.A.G 1390/1- to return hose.
t rig
gh ht
pyri by
Vo
co
– Operate hand vacuum pump until no more fuel comes out of
by lksw
cted agen
Prote
return hose. Be careful that no fuel is sucked into hand vacuum
AG.
pump.

Sharan 1996 ➤
– Pull vacuum line -1- from brake servo off tandem pump -4-.
– Pull supply hose -2- (white marking) off tandem pump -4-.
– Remove securing bolts -arrows-.
– Remove tandem pump -4- from cylinder head.
– Pull tandem pump -4- slightly upwards, pull off return hose
-3- (blue marking) and remove tandem pump -4-.
1.14.2 Installing
note the following:
Note
♦ Ensure that tandem pump coupling seats properly in cam‐

shaft.
♦ Always replace tandem pump seals.
– Connect return hose -3- (blue marking) to return connection of

tandem pump.
– Install tandem pump and tighten upper securing bolts to
20 Nm.
– Tighten lower securing bolts to 10 Nm.
– Connect supply hose -2- (white marking) to supply connection
and vacuum line -1- from brake servo to tandem pump -4-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
– Attach supply hose -1- (white
ss marking) to fuel filter. c
ce
e
nl
– Connect hand vacuum pump - V.A.G 1390- and bleed con‐

pt
du
an
itte
tainer - V.A.G 1390/1- to return hose -2- (blue marking) of fuel

y li
erm
ab
filter.
ility
ot p
– Operate hand vacuum pump until fuel comes out of return

wit
, is n
h re
hose. Be careful that no fuel is sucked into hand vacuum

hole
pump.
spec
es, in part or in w
– Connect return hose -2- (blue marking) to fuel filter.

t to the co
rrectness of i
l purpos
1.15 Assembly overview - accelerator mechanism

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
138
by lksw
cted agen
Rep. gr.20 - Fuel supply system Prote AG.
Sharan 1996 ➤
4-cylinder diesel engine
olksw
(1.9 l engine) - Edition 04.2014
AG. V agen AG
agen does
lksw not
1 - Bearing bracket db
yV
o gu
ara
rise nte
2 - Connector tho eo
au ra
❑ Black, 6-pin. ss c
ce
le
un
pt
3 - 10 Nm
an
d
itte
y li
erm
4 - Accelerator position sender
ab
ility
- G79-
ot p
wit
is n
❑ Not adjustable.
h re
ole,
❑ The accelerator position
spec
sender passes the posi‐ urposes, in part or in wh
t to the co
tion of the accelerator
on to the engine control
unit.
rrectne
❑ Remove footwell cover
to remove sender.
ss
❑ If renewed adapt control
o
cial p
f
unit for automatic gear‐
inform
box: ⇒ Self-diagnosis
mer
for 5-speed automatic
atio
m
gearbox 09B; Repair

o
n
c
group 01; Performing
i
or
n thi
e
self-diagnosis
t
sd
iva
o
pr
c
5 - Bracket
um
r
fo
en
ng
❑ For footwell cover

t.
yi Co
Cop py
❑ Clipped securely onto
t. rig
gh ht
yri
accelerator position p by
o Vo
by c lksw
sender Prote
cted AG.
agen

Sharan 1996 ➤
21 – Turbocharging/supercharging
1 Charge air system with turbocharger
Note
♦ All hose connections are secured with clamps and/or securing

clips.
Volkswagen AG
♦ Do not install hose connections with lubricant containing oil.swagen AG. does
k not
Vol gu
♦ Charge air system must be free of leaks. ed by ara
nte
ris
tho eo
♦ Before screwing on oil supply line, fill turbocharger
a at connec‐
u ra
tion with engine oil. ss c
ce
e
nl
pt
du
♦ After installing turbocharger run engine for approx. 1 minute
an
itte
at idling speed, do not rev engine. This ensures that the tur‐
y li
erm
ab
bocharger/compressor is adequately lubricated.
ility
ot p
wit
♦ Renew self-locking nuts.
, is n
h re
hole
spec
Safety precautions ⇒ page 141 .
es, in part or in w
t to the co
Hose connections with push-on connectors ⇒ page 141
rrectness of i
Assembly overview - turbocharger: Engine code ANU
l purpos
⇒ page 142
Assembly overview - turbocharger: Engine codes ASZ, BTB
nf
ercia
⇒ page 145
orm
m
atio
Assembly overview - turbocharger: Engine codes AUY, BVK
om
⇒ page 147
n in
or c
thi
e
Assembly overview - charge air cooling: Engine codes ANU, AUY,

t
sd
iva
BVK ⇒ page 149 o

r
rp
cu
o
m
f
en
ng
Assembly overview - charge air cooler: Engine codes ASZ, BTB

t.
yi Co
⇒ page 151 Cop py
t. rig
gh ht
yri
Checking charge air system for leaks ⇒ page 152 p by
co Vo
by lksw
cted agen
Charge pressure control hose routing diagram: Engine code ANU Prote AG.
⇒ page 153
Charge pressure control hose routing diagram: Engine codes
ASZ, AUY, BTB ⇒ page 155
140 Rep. gr.21 - Turbocharging/supercharging

Sharan 1996 ➤
1.1 Safety precautions
WARNING
. Volkswagen AG
gen AG d
When doing any Vrepair
olks work, especially in thesengine
wa oe
not compart‐
ment, pay attention
ed by to the following due to the cramped
gu
ara condi‐
tions: thoris nte
e o
au ra
♦ Route
ss all the various lines (e.g. for fuel, hydraulics, acti‐
c
ce
le
un
pt
an
d
itte
y li
sitions.
rm
ab
pe
ility
ot
wit
, is n
hot components.
h re
hole
spec
es, in part or in w
Note the following if testers and measuring instruments have to
t to the co
be used during a road test:
♦ Test and measuring instruments must always be secured to
rrectness of i
rear seat and operated by a second person from this location.
l purpos
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
nform
ercia
injuries when the airbag is triggered.

m
a
com
ti
on in
r
te o
thi
When working on the turbocharger, pay careful attention to the

s
iva
do
following rules for cleanliness:

r
rp
cum
fo
en
g

n
t.
yi Co
op
connecting. C py
ht. rig
rig ht
py by
co Vo
by lksw
lint-free cloths. Prote
cted AG.
agen
♦ Carefully cover opened components or seal if repairs cannot

♦ Install clean components only. Do not remove replacement
tool boxes etc.).
♦ Existing transport and protective packaging and sealing caps
must only be removed immediately prior to installation.
♦ When making repairs, remove oil from connection and hose
ends.
essary.
1.3 Hose connections with push-on connec‐

tors
Note
All hose connections of charge air system are secured by spring-

type clips or by connector couplings. Always check the following
points with push-on connectors:
1. Charge air system with turbocharger 141

Sharan 1996 ➤
– Release plug-in connector by pulling out retaining clip

-arrow-. Separate hose/pipe without tools.
– When installing, ensure that locking lugs -A- engage securely.
Checking charge air system for leaks ⇒ page 152
1.4 Assembly overview - turbocharger: En‐

gine code ANU
AG. Volkswagen AG d
Caution lksw
agen oes
not
o
byV gu
ara
ed
When a mechanical fault is found onthothe turbocharger, e.g. a
ris nte
eo
destroyed compressor impeller, it iss aunot only sufficient to renew ra
c
the turbocharger. To prevent this from
s causing further damage,
ce
e
perform the following repairs:

nl
pt
du
an
itte
y li
♦ Check air filter housing, air filter element and intake hoses
erm
ab
for soiling.
ility
ot p
wit
, is n
♦ Check complete charged air routing and charge air cooler
h re
for foreign objects.
hole
spec
es, in part or in w
If foreign objects are found in the charge air system, the charg‐
t to the co
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.
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 - Exhaust manifold
❑ With exhaust turbo‐
charger
❑ Only renew complete
2 - From charge air cooler
3 - Intake manifold
4 - Gasket
❑ Renew.
❑ Coating (beading) to‐
wards intake manifold
5 - 25 Nm
❑ Renew.
6 - Gasket
❑ Renew.
❑ Note installation posi‐
tion.
7 - Bracket
❑ For heat shield
8 - Washer
9 - Heat shield
❑ Engage in bracket
10 - From air filter.
11 - Bolt
❑ Specified torque: 10 Nm
12 - O-ring
AG. Volkswagen AG d
❑ Ensure it seats correctly agen oes
olksw not
in the groove d by V gu
ara
ise nte
❑ Renew if damaged. uthor eo
a ra
s c
13 - Turbocharger s
ce
le
un
pt
❑ Can only be renewed with exhaust manifold.

an
d
itte
y li
❑ Remove front exhaust pipe to remove turbocharger ⇒ page 170 .

erm
ab
ility
ot p
14 - Vacuum unit
wit
is n
❑ For charge pressure control.

h re
ole,
spec

t to the co
15 - Seal
❑ Renew.
rrectne
16 - Union, 40 Nm
17 - 17 Nm
ss o
18 - Oil return line with union nut

cial p
f inform
❑ Tighten to cylinder block to 25 Nm

mer
atio
m
19 - Oil return pipe gasket

o
n
c
i
or
❑ Renew.
thi
te
sd
va
20 - Gasket
i
o
pr
cum
r
fo
❑ Renew.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
143
Prote AG.
1. Charge air system with turbocharger
Sharan 1996 ➤
21 - Front exhaust pipe

22 - Union, 30 Nm
❑ Renew.
❑ Coat threads and bolt head contact surface with -G 052 112 A3- .
❑ Fill connection with engine oil before attaching oil supply line.
23 - Oil supply line
❑ From oil filter bracket ⇒ Item 6 (page 82) .
1.4.1 Removing and installing vacuum unit for

charge pressure regulating valve
Only engine code ANU
♦ Torque wrench - V.A.G 1331-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut ra
Removing ss a c
ce
e
nl
– Remove turbocharger ⇒ page 142 .

pt
du
an
itte
y li
– Unclip fuse -4-.

erm
ab
ility
ot p
– Remove securing bolts -2-.

wit
, is n
h re
– Remove vacuum unit -6-.

hole
spec
Installing
es, in part or in w
t to the co
– Install vacuum unit -6- on turbocharger (position securing bolts

with D 6); specified torque: 10 Nm.
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.

Sharan 1996 ➤
– Loosen lock nut -1- of operating rod -3-.

– Swing charge pressure valve lever -5- in direction of vacuum
unit onto stop and hold in place.
– Adjust length of operating rod -3- so that eye of rod can be
placed over pin of lever -5- with ease. (Lever on stop without
play)
– Screw in operating rod 8 turns (rod will be shortened).
– Tighten lock nuts.
– Connect operating rod onto lever and fit fuse -4-.
– Install turbocharger.

gine codes ASZ, BTB
Caution
When a mechanical fault is found on the turbocharger, e.g. a

destroyed compressor impeller, it is not only sufficient to renew
the turbocharger. To prevent this from causing further damage,
for soiling.
be renewed, if necessary. en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
b ara
ed nte
oris eo
th
au ra
c
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
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
charger
❑ Only renew complete
3 - Intake manifold
4 - Gasket
❑ Renew.
5 - 25 Nm
❑ Renew.
6 - Gasket
❑ Renew.
tion.
7 - Heat shield
8 - Washer
9 - Connection
❑ From air filter.
ing.
10 - Connecting hose
❑ From charge air cooler wage
es n
lks ot g
Vo
11 - Turbocharger d by ua
ran
ir se tee
❑ Can only be renewed uth o
or
with exhaust manifold.
ss
a ac
ce
le
❑ Remove front exhaust

un
pt
an
pipe to remove turbo‐

d
itte
y li
charger ⇒ page 170 .

rm
ab
pe
ility
12 - Seal
ot
wit
, is n
h re
❑ Renew.
hole
spec
13 - Union, 40 Nm
es, in part or in w
t to the co
14 - 17 Nm
rrectness of i

l purpos

❑ Renew.
nform
ercia
17 - Vacuum unit
m
a
com

ion in
r
❑ Integral part of turbocharger and cannot be replaced.

te o
thi
s
iva
do
18 - Gasket
r
rp
cum
fo
❑ Renew.
en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
20 - Union, 30 Nm cop Vo
by lksw
cted agen
❑ Renew. Prote AG.

Sharan 1996 ➤
21 - Bolt AG. Volkswagen AG d

agen oes
ksw
❑ Specified torque: 10 Nmby Vol not
gu
a
e an d r
22 - Oil supply line ris tee
tho or
au ac
❑ From oil filter bracket
ss ⇒ Item 14 (page 81) .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
gine codes AUY, BVK
es, in part or in w
t to the co
Caution
rrectness of i
When a mechanical fault is found on the turbocharger, e.g. a
l purpos
destroyed compressor impeller, it is not only sufficient to renew

the turbocharger. To prevent this from causing further damage,
nf
ercia
orm
m
atio
m
for soiling.
o
n in
or c
thi
te
sd
a

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
be renewed, if necessary.
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
charger
❑ Only renew complete agen AG. Volkswagen AG do
w es n
❑ Vehicles with four- olks ot g
byV ua
wheel drive ris ed ran
tee
ho
❑ Remove the s au bevel box:
t or
ac
⇒ four-wheel drive;
s
ce
e
Rep. gr. 34 ; Removing

nl
pt
du
an
and installing bevel box .
itte
y li
erm
ab
ility
ot p
wit
, is n
3 - Intake manifold
h re
hole
4 - Gasket
spec
es, in part or in w
❑ Renew.
t to the co
rrectness of i
5 - 25 Nm
l purpos
❑ Renew.
6 - Gasket
nform
ercia
❑ Renew.
m
at
om
tion. ion
c
in t
or
his
te
7 - Bracket
a
do
priv
❑ For heat shield

um
for
en
g

n
t.
yi Co
Cop py
8 - Washer ht. rig
rig ht
py by
o Vo
9 - 40 Nm by c lksw
cted agen
Prote AG.
❑ Tighten securing bolts
of support hand-tight.
10 - Support
❑ Between turbocharger and cylinder block.
11 - Heat shield
❑ Engage in bracket ⇒ Item 7 (page 148)
12 - From air filter.
13 - Bolt, 10 Nm
14 - Turbocharger
❑ Can only be renewed with exhaust manifold.
❑ Remove front exhaust pipe to remove turbocharger ⇒ page 170 .
15 - Vacuum unit
❑ Integral part of turbocharger and cannot be replaced.
16 - Seal
❑ Renew.
17 - Union, 40 Nm
18 - 17 Nm

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
orise nte
eo
Sharan 1996 ➤
h
s aut
4-cylinder r a diesel
c engine (1.9 l engine) - Edition 04.2014
s
ce
le
un
pt
an
d
itte
y li
❑ Renew.
erm
ab
ility
ot p
21 - 20 Nm
wit
is n
❑ Tighten securing bolts of support hand-tight.
h re
ole,
spec
22 - Gasket
t to the co
❑ Renew.
rrectne
24 - Union, 30 Nm
❑ Renew.
ss
o
cial p
f in
form
mer
25 - Oil supply line
atio
om
n
❑ From oil filter bracket ⇒ Item 14 (page 81) .
c
i
or
n thi
e
t
sd
iva
o
pr
c
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh
1.7 Assembly overview - charge air cooling:
ht
pyri by
Vo
co lksw
by
Engine codes ANU, AUY, BVK
cted agen
Prote AG.
Note

Sharan 1996 ➤
1 - Charge air pipe

❑ Adjust longitudinally in
bracket
( ⇒ Item 15
(page 150) ) so that air
pipe is not installed un‐
der tension.
2 - Connecting hose
❑ Charge air pipe/turbo‐
charger
3 - Connecting hose
. Volkswagen AG
❑ Connecting pipe/intake kswagen AG does
not
l
connection by Vo gu
a d ran
ise
4 - Connecting pipe uthor tee
or
sa ac
5 - Intake manifold spressure
ce
e
sender - G71- with intake

nl
pt
du
an
manifold temperature sender -
itte
y li
G72-
erm
ab
ility
ot p
6 - Connecting hose
wit
, is n
h re
7 - Air pipe
hole
spec
es, in part or in w
8 - O-ring
t to the co
9 - Connecting hose
rrectness of i
10 - Bracket
l purpos
11 - 10 Nm
nf
ercia
12 - Charge air cooler

orm
m
atio
om
n in
❑ Charge air cooler/

or c
charge air pipe

thi
te
sd
iva
o
r
14 - Bracket
rp
cu
o
m
f
en
ng
❑ Vehicles 06.00 ► yi
t.
Co
op
❑ Screwed to sump.
C py
t. rig
gh ht
yri by
15 - Bracket cop Vo
by lksw
cted agen
❑ Vehicles 06.00 ► Prote AG.
16 - 20 Nm
17 - Bracket
18 - Securing clip
19 - 20 Nm
20 - 20 Nm

AG. Volkswagen AG d
lksw
agen oes
not Sharan 1996 ➤
o
4-cylinder
d by
V
diesel engine (1.9 l engine) gu - Edition 04.2014
ara
e nte
ris
tho eo
1.8 Assembly overview - charge air cooler: au ra
ss c
Engine codes ASZ, BTB
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
Note
ot p
wit
is n
h re
ole,
spec
t to the co
1 - Charge air cooler
2 - 8 Nm
rrectne
3 - Rubber bush
ss
o
cial p
f
tion.
inform
mer
❑ Secured to lock carrier.
atio
m
4 - 10 Nm
o
n
c
i
or
n thi
e
5 - 10 Nm
t
sd
iva
o
r
❑ With bearing sleeve

p
cum
r
fo
en
ng
6 - Rubber bush
t.
yi Co
Cop py
t.
7 - O-ring
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
8 - Connecting hose
9 - Charge air pipe
❑ Adjust longitudinally in
bracket
( ⇒ Item 11
(page 151) ) so that air
pipe is not installed un‐
der tension.
10 - 20 Nm
11 - Bracket
12 - Bracket
❑ Screwed to sump.
ing.
14 - Intake hose
❑ From air filter.
15 - Intake manifold
16 - Connection
17 - Crankcase breather hose
❑ From pressure regulating valve on cylinder head cover
❑ To intake connecting pipe.

Sharan 1996 ➤
19 - Air pipe
20 - 6 Nm AG. Volkswagen AG d
agen oes
olksw not
yV gu
21 - Intake manifold pressure sender - G71- with intake manifoldsedtemperature sender - G72-
b ara
nte
ri
ho eo
22 - Connecting hose aut ra
c
ss
ce
e
nl
pt
du
an
23 - Connection
itte
y li
erm
ab
ility
ot p
wit
, is n
1.9 Checking charge air system for leaks
h re
hole
spec
es, in part or in w
t to the co
♦ Charge air system tester - V.A.G 1687-
♦ Adapter - V.A.G 1687/10-
rrectness of i
– Remove intake hose -1- from air filter.
l purpos
– Connect adapter - 1687/10- in intake hose -1- and secure with

clip.
nform
ercia
Prepare charge air system tester - V.A.G 1687- as follows:

m
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.
– Turn pressure regulating valve -2- anti-clockwise onto stop.

– Close valves -3- and -4-.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.

Sharan 1996 ➤
– Connect charge air system tester - V.A.G 1687- to adapter -

1687/10- as shown.
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
– Connect compressed
auth
air hose -1- (compressed air source)orto ac
charge air
ss system tester - V.A.G 1687- .
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
If there is water in the sight glass, drain at water drain screw -6-. wit
, is n
h re
hole
spec
– Open valve -3-.
es, in part or in w
t to the co
– Adjust pressure to 0.5 bar with pressure regulating valve -2-.

rrectness of i
Caution
l purpos
The pressure must not exceed 0.5 bar! If the pressure is too
high this can cause damage to the engine.
nform
mercia
– Open valve -4- and wait until the test circuit is filled. If neces‐
com
tion in
sary readjust pressure to 0.5 bar.

r
te o
thi
s
– Check the charge air system for leaks by hearing, touching,

iva
do
r
with commercially available leak detector spray or using ultra‐

rp
cum
fo
sonic tester - V.A.G 1842- .

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note p by
co Vo
by lksw
cted agen
Prote AG.
♦ How to use the ultrasonic tester - V.A.G 1842- ⇒ operating
instructions
♦ If leaks occur, when doing any repair work observe notes for
charge air system ⇒ page 141 .
♦ Before removing the adapter, depressurise the test circuit by
pulling coupling off adapter - 1687/10- .
1.10 Charge pressure control hose routing diagram: Engine code ANU

Sharan 1996 ➤
1 - Vacuum actuator
2 - Air filter
3 - Variable intake manifold
flap changeover valve - N239-
4 - Exhaust gas recirculation
valve - N18- (electro-pneumat‐
ic)
5 - Charge pressure control
solenoid valve - N75-
AG. Volkswagen AG d
agen oes
6 - To turbocharger. olksw not
byV gu
ara
ed
7 - Connection to air pipe/air horis nte
eo
filter s aut ra
c
s
8 - Non-return valve
ce
e
nl
pt
du
an
❑ White connection to var‐ itte
y li
iable intake manifold
erm
ab
ility
flap changeover valve
ot p
wit
⇒ Item 3 (page 154) and
, is n
h re
to vacuum reservoir
hole
spec
es, in part or in w
t to the co
9 - Vacuum unit
❑ For charge pressure
control.
rrectness of i
10 - Connection at turbocharg‐
l purpos
er
11 - Intake connecting pipe
nf
ercia
o
❑ With exhaust gas recir‐
rm
m
culation valve (mechan‐
atio
m
ical) and intake manifold

o
n in
or c
flap
thi
te
sd
iva
12 - Vacuum connection
o
r
rp
cu
o
m
❑ Between tandem pump
f
en
ng
t.
yi
and brake servo
Co
Cop py
ht. rig
13 - Vacuum reservoir rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
1.11 Charge pressure control hose routing diagram: Engine codes ASZ, AUY,
BTB, BVK
1 - Vacuum actuator
2 - Air filter
valve - N18- (electro-pneumat‐ agen
AG. Volkswagen AG d
oes
ic) olksw not
V gu
d by ara
e nte
6 - To turbocharger. horis
eo
aut ra
7 - Non-return valve ss c
ce
e
nl
❑ White connection to
pt
du
an
charge pressure control
itte
y li
erm
solenoid valve.
ab
ility
⇒ Item 3 (page 155) , to
ot p
wit
variable intake manifold
, is n
h re
flap changeover valve
hole
spec
⇒ Item 4 (page 155) and
es, in part or in w
to vacuum reservoir
t to the co
8 - Vacuum unit
rrectness of i
❑ For charge pressure
control.
l purpos
❑ Integral part of turbo‐

charger and cannot be
nform
ercia
replaced.
m
at
om
ion
c

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or
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e

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do
riv

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or
flap
f
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t.
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10 - Vacuum connection t. Cop py
rig
gh
❑ Between tandem pump
ht
pyri by
Vo
and brake servo
o
by c lksw
cted agen
Prote AG.
11 - Vacuum reservoir

Sharan 1996 ➤
23 – Mixture preparation - injection

1 Repairing diesel direct injection sys‐
tem
AG. Volkswagen AG d
agen
Note olksw
oes
not
byV gu
ara
ed
is nte
The diesel direct injection system
ut
hor
control unit is equipped with a eo
fault memory. Read faultssmemory before and after performing re‐
a ra
c
pairs or adjustments ⇒ page 168 .
ce
e
nl
pt
du
an
itte
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Safety precautions ⇒ page 156 .
erm
ab
ility
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, is n
h re
General notes on injection ⇒ page 157 .
hole
spec
Overview - fitting locations ⇒ page 157
es, in part or in w
t to the co
Assembly overview - intake manifold flap ⇒ page 158
Assembly overview - air filter ⇒ page 160 .
rrectness of i
Assembly overview - unit injector ⇒ page 160
l purpos
Removing and installing O-rings for unit injector ⇒ page 161
nform
ercia
Removing and installing unit injector ⇒ page 163

m
1.1 Safety precautions

at
om
ion
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WARNING
a
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for

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ment, pay attention to the following due to the cramped condi‐ Cop py
tions: ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

sitions.
hot components.
To prevent injuries to persons and/or destruction of the injection

and glow plug system, the following must be noted:
♦ The ignition must be switched off before connecting or dis‐
connecting injection or glow plug system wiring or tester ca‐
bles.
♦ If the engine is to be turned at starter speed, without starting,
e.g. when checking compressions, disconnect unit injector
connector on cylinder head.
♦ Before disconnecting battery, obtain radio code for radios with
anti-theft coding.
♦ Disconnecting and connecting the battery must only be done
with the ignition switched off, as otherwise the control unit for
diesel direction injection system could become damaged.
Note the following if testers and measuring instruments have to
be used during a road test:
156 Rep. gr.23 - Mixture preparation - injection

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
autho eo
ra Sharan 1996 ➤
ss 4-cylinder diesel engine (1.9 l engine) - Edition 04.2014
c
ce
e
nl
pt
du
an
♦ Test and measuring instruments must always be secured to
itte
y li
rear seat and operated by a second person from this location.
erm
ab
ility
ot p
If test and measuring instruments are operated from front pas‐
wit
, is n
senger seat and the vehicle is involved in an accident, there is a
h re
hole
possibility that the person sitting in this seat may receive serious
spec
injuries when the airbag is triggered. es, in part or in w
t to the co
WARNING
rrectness of i
Secure fault reader to rear seat and operate from this position.
l purpos
nform
mercia
When working on the fuel supply and injection system, pay careful
at
om
io
attention to the following “6 rules” for cleanliness:
n
c
in t
or
his
e

at
do
riv
connecting.
p
cum
for
en
ng
t.
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lint-free cloths. t. Cop py
rig
gh ht
♦ Carefully cover opened components or seal if repairs cannot pyri by
Vo
co
by lksw
cted agen
Prote AG.
♦ Install clean components only. Do not remove replacement
tool boxes etc.).
essary.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
1.3 General notes on injection
Note
♦ Rules for cleanliness ⇒ page 157 .

♦ Safety precautions ⇒ page 156 .
♦ Fuel hoses on engine must be secured with spring-type clips
only. The use of clamp or screw-type clips is not permissible.
♦ Spring-type clip pliers - VAS 5024 A- are recommended for
installation of spring-type clips.
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
1.4 Overview of fitting locations

Components A to D are not shown in the illustration.
A - Brake pedal switch - F47- , in footwell on brake pedal
B - Brake light switch - F- , in footwell on brake pedal
C - Accelerator position sender - G79- , in footwell on accelerator
D - Clutch pedal switch - F36- , in footwell on accelerator pedal
1. Repairing diesel direct injection system 157

Sharan 1996 ➤
1 - Air mass meter - G70-

valve - N18- (electro-pneu‐
matic)
flap agen
AG. Volkswagen AG d
oes
lksw not
❑ Check mechanical ex‐ by
Vo gu
ara
haust gas recirculation rised
nte
valve ⇒ page 176 aut
ho eo
ra
ss c
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nl
pt
du
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itte
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6 - Coolant temperature send‐
erm
ab
er - G62-
ility
ot p
wit
, is n
7 - Diesel direct injection sys‐
h re
hole
tem control unit - J248-
spec
es, in part or in w
❑ With elevation sender -
t to the co
F96- .
rrectness of i
8 - Engine speed sender -
G28-
l purpos
9 - Intake manifold pressure

sender - G71- and intake
nf
ercia
o
manifold temperature sender -
rm
m
G72-
atio
om
n in
c
10 - Central connector
or
thi
e
❑ For unit injectors - N240

t
sd
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- … -N243-
r
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Cop py
12 - Connector
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pyri by
❑ For engine speed sender - G28- .
o Vo
by c lksw
cted agen
Prote AG.
13 - Connector
❑ For Hall sender - G40- , for camshaft position
14 - Hall sender - G40-
❑ For camshaft position.
1.5 Assembly overview - intake manifold

flap
The intake manifold flap is closed for approx. 3 seconds when
stopping engine and then opens again. This reduces the stop jolt.

Sharan 1996 ➤

2 - 10 Nm
flap
valve (mechanical)
5 - O-ring
❑ Renew.
6 - Intake manifold
7 - Gasket
❑ Renew.
8 - Connecting pipe
❑ To exhaust manifold
9 - 25 Nm
10 - Vacuum supply
❑ From vacuum reservoir
11 - Variable intake manifold gen AG. Volkswagen AG
does
Vol
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12 - Vacuum actuator
or
ise nte
th eo
13 - Bracket s au ra
c
s
ce
le
14 - 10 Nm
un
pt
an
d
itte
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erm
ab
ility
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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.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
1.6 Assembly overview - air filter

. Volkswagen AG
gen AG does
swa
1 - 6 Nm yV
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2 - Seal horis
eo
ut ra
❑ Renews if damaged.
s a c
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nl
3 - 2 Nm
pt
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an
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4 - O-ring
erm
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ility
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5 - 3 Nm
hole
spec
6 - Air mass meter - G70-
es, in part or in w
t to the co
7 - Air filter upper part
8 - Filter element
rrectness of i
9 - Line retainer
l purpos
10 - Air filter lower part

11 - Rubber bush
nf
ercia
orm
m
12 - Rubber insert
atio
om
n in
c
13 - Spacer sleeve
or
thi
te
sd
a
14 - 10 Nm
iv
o
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f
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
1.7 Assembly overview - unit injector

♦ Always renew seals and O-rings

Sharan 1996 ➤
1 - 20 Nm + 1/4 turn (90°) fur‐

ther
❑ Renew.
❑ Observe sequence
when loosening and
tightening ⇒ page 163 .
2 - Rocker arm shaft
❑ With rocker arms
⇒ page 163 . AG. Volkswagen Agen G do
swa es n
3 - Lock nut, b30
y V Nm
olk ot g
ua
d ran
se
4 - Adjuster
ho
ri screw tee
ut or
❑ss Renew.
a ac
ce
le
❑ Adjusting ⇒ page 163 .

un
pt
an
d
itte
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5 - Unit injector
erm
ab
ility
❑ Renew ball stud.
ot p
wit
is n
h re
⇒ page 163 .
ole,
spec
6 - O-ring
t to the co
7 - O-ring rrectne

s
8 - O-ring
s o
cial p

inform
mer
9 - Heat shield seal

atio
m
❑ Renew.
o
n
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i
or
n thi
10 - Circlip
te
sd
iva
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11 - Cylinder head
p
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fo
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t.
12 - Tensioning block
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Cop py
t. rig
13 - 12 Nm + 3/4 turn (270°) further
gh ht
pyri by
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by c lksw
❑ Renew.
Prote
cted AG.
agen
1.8 Removing and installing O-rings for unit

injector
♦ Assembly sleeves - T10056-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Sharan 1996 ➤ thor eo
u ra
4-cylinder diesel engine (1.9 l engine) - sEdition
sa 04.2014 c
ce
le
un
pt
1.8.1 Removing
an
d
itte
y li
rm
ab
– Remove unit injector ⇒ page 163 .
pe
ility
ot
wit
, is n
– Lever old O-rings very carefully out of unit injector.
h re
hole
spec
– Pay particular attention to ensure that seat of O-ring is not
es, in part or in w
damaged by burrs.
t to the co
1.8.2 Installing
rrectness of i
Note l purpos
♦ Always use the assembly sleeves to fit the O-rings. There is a
nform
ercia
danger of damaging the O-rings if the sleeves are not used.

m
a
♦ Gradual introduction of O-rings without different coloured
com
tion in
markings. Note the correct allocation of O-rings to grooves:
r
te o
thi
the thickness of the rings reduces towards injector nozzle.
s
iva
do
r
♦ Prevent O-rings from rolling when sliding them on. The O-rings
rp
cum
fo
must not be twisted in their seats in unit injector.
en
ng
t.
yi Co
Cop py
t. rig
– Pull heat shield seal off together with securing clip. opyri
gh by
Vo
ht
c lksw
– Clean seating surfaces for O-rings on unit injector very care‐
by
cted agen
Prote
fully.
AG.
– Place assembly sleeve - T10056/1- onto stop on unit injector.

– Push the upper, thicker O-ring carefully onto assembly sleeve
and into seat on unit injector.
– Remove assembly sleeve.

– Slide the middle, thinner O-ring carefully onto assembly sleeve
and into seat on unit injector.

Sharan 1996 ➤

– Push the lower O-ring carefully onto the assembly sleeve and
into the seat of the unit injector.
– Fit new heat shield seal together with securing clip.
– Install unit injector ⇒ page 163o.lkswagen AG
en AG. V ag does
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b ara
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un
pt
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d
1.9 Removing and installing unit injector

itte
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rm
ab
pe
ility
ot
wit
, is n
h re
equipment required
hole
spec
es, in part or in w
♦ Universal dial gauge brack‐
t to the co
et - VW 387-
♦ Special wrench, long reach
- 3410-
rrectness of i
♦ Special wrench, long reach
l purpos
- T10054-
♦ Puller - T10055- nform
ercia

m
a
com
ti
- V.A.G 1331-
on in
r
te o
thi
♦ Dial gauge
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
– Remove toothed belt guard upper part.
– Turn crankshaft until the cam pair point evenly upwards for the
unit injector which is to be removed.

Sharan 1996 ➤
– Loosen lock nuts of adjustment screws -1- and remove ad‐

justment screws.
– Remove rocker arm securing bolts -2- (from outwards to in‐
wards) with socket XZN 10 - 3410- and remove rocker arm
shaft.
– Remove tensioning block securing bolt -3- withnspecial
AG. Volkswagen AG d
wrench, long reach - T10054- and remove
olks
wthe
ageblock. oes
no
V t gu
by ara
– Lever connector off unit injector using
ris
ed a screwdriver. Support nte
opposite side of connector withulight
tho finger pressure to prevent eo
ra
canting. ss
a c
ce
e
nl
Observe unit injector cylinder allocation.
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.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
– Seat the puller into the slot on the side of the unit injector in‐
stead of the tensioning block.
– Pull unit injector out of cylinder head seat by gently tapping
upwards.
Installing
Note
♦ Each time work is performed which requires adjustment of the

unit injector, the adjustment screw in the rocker arm and also
the unit injector ball stud must be renewed.
♦ New unit injectors are supplied with O-rings and heat shield
seal.
– Heat insulating seal and O-rings must be renewed if old unit

injector is reused ⇒ page 161 .
– Before installing the unit injector, check that the three O-rings,
the heat shield seal and securing clip are seated correctly.
Note
. Volkswagen AG
gen AG does
swa
The O-rings must by V not be twisted.
olk not
gu
d ara
ise nte
or eo
– Oil athe
ut O-rings and fit the unit injector into the cylinder
h
ra head
extremely carefully.
ss c
ce
le
un
pt
– Push the unit injector evenly into the cylinder head onto its limit
an
d
itte
stop.
y li
rm
ab
pe
ility
– Insert tensioning block in slot on side of unit injector.

ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
If the unit injector is not at right angles to the tensioning block the
securing bolt may loosen and this can damage the unit injector or
the cylinder head.
rrectness of i
l purpos
– Therefore align the unit injector as follows.

– Screw new securing bolt into clamping block, but do not tighten
nform
ercia
(it must still be possible to turn the unit injector slightly).

m
– Now align unit injector at right angles to camshaft mounting

com
tion in
brackets.
r
te o
thi
s
iva
do
r
rp
Note
um
fo
en
ng
t.
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op
Gradual introduction of unit injector with new solenoid valve nut.
C py
ht. rig
A mixed installation is permissible providing measurement “a” is
rig ht
py by
adhered to.
co Vo
by lksw
cted agen
Prote AG.
Unit injector with old solenoid valve nut

Sharan 1996 ➤
– Check dimension “a” from outer edge of cylinder head to roun‐

ded edge of unit injector with a vernier gauge (measuring
range at least 400 mm).
Cylinder Dimension “a”
1 332.2 ± 0.8 mm
2 244.2 ± 0.8 mm
3 152.8 ± 0.8 mm
4 64.8 ± 0.8 mm
Unit injector with new solenoid valve nut
– Check dimension “a” from outer edge of cylinder head to roun‐

ded edge of unit injector with a vernier gauge (measuring
range at least 400 mm).
Cylinder Dimension “a”
1 333.0 ± 0.8 mm
2 245.0 ± 0.8 mm
3 153.6 ± 0.8 mm
4 65.6 ± 0.8 mm
Continuation for all unit injectors
– If necessary, adjust the unit injector and tighten the securing
bolt as follows:
– Tighten securing bolt to 12 Nm and turn 270° (3/4 turn) further
(turning further can be done in several stages).
– Fit rocker arm shaft and tighten new securing bolts as follows:
– First tighten inner bolts -2- then outer bolts -1- by hand. Then
using same sequence, tighten ato ge20 Nm
n AG. Voland
kswaturn
gen A90°
G do (1/4 turn)
further. yV
olksw es n
ot g
b ua
ed ran
– Adjust non-contact
ho
rgap
is of unit injectors ⇒ page 166 . tee
t or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
1.9.1 Adjusting non-contact gap of unit injec‐

es, in part or in w
t to the co
tors
– Fit dial gauge onto adjustment screw of unit injector as shown.
rrectness of i
– Turn crankshaft in direction of engine rotation until roller of

l purpos
rocker arm is located at tip of drive cam. Roller side

-arrow A- positioned at highest point, dial gauge -arrow B-
positioned at lowest point.
nf
ercia
or
– Remove dial gauge.

m
m
atio
om
– Now turn the adjuster screw into rocker arm until significant
n in
or c
resistance can be felt (unit injector is at limit stop).

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 ➤
– Turn adjustment screw 180° back off stop.

– Hold adjuster screw in this position and tighten lock nut to 30
Nm.
– Connect unit injector connector.
– Install cylinder head cover.
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
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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 ➤
2 Engine control unit

Reading and clearing engine Acontrol unit fault memory
G. Volkswagen AG d
⇒ page 168 . lksw
agen oes
n o ot g
yV u
Removing andriinstalling
se
db engine control unit ⇒ page 169
ara
n.t ee
ho
ut or
2.1 ss
a Reading and erasing engine control unit ac
fault memory
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
♦ Vehicle diagnosis, testing and information system - VAS 5051-
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
♦ Diagnosis cable - VAS 5051/1- or diagnosis cable -

or
his
e
VAS 5051/3-
at
do
priv
Procedure
um
for
en
ng
t.
yi
– Connect vehicle diagnosis, testing and information system -
Co
op py
VAS 5051- as follows:
t. C rig
gh ht
pyri by
Vo
o
Vehicles ► 05.00
c by lksw
cted agen
Prote AG.
– Open ashtray -3-.
– Press ashtray cover -1- on both sides in direction of arrows.
The ashtray -2- springs out slightly and can be removed.
– Pull open ashtray housing out of centre console.
– Push diagnosis cable - VAS 5051/1- connector onto diagnosis
connector.
Vehicles 06.00 ►

Sharan 1996 ➤
– Connect diagnosis cable - VAS 5051/1- or diagnosis cable -

VAS 5051/3- to diagnosis connector.
Only when engine does not start:
– Switch on ignition.
Select operating mode:
– Press button on display for “Vehicle self-diagnosis”.
Select vehicle system:
– Press button “01 - Engine electronics” on display.
The control unit identification and coding are indicated on display.
Select diagnostic function:
– Press button “02 - Read fault memory” on display.
– If no fault is stored in engine control unit “0 fault detected” is
displayed.
– If faults are stored in the engine control unit, these are shown
AG. Volkswagen AG d
one below the other on the display.lkswagen oes
n o ot g
yV ua
– Press ← button. ris
edb ran
tee
tho or
– Press button “05 - Clear
ss
fault memory” on display. au ac
ce
e
– Press function “06-End output”.

nl
pt
du
an
itte
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erm
ab
2.2 Removing and installing engine control
ility
ot p
unit
wit
, is n
h re
hole
– Before removing engine control unit, read control unit identifi‐ spec
cation and, with it, coding of current control unit as well
es, in part or in w
t to the co
⇒ page 168 .
Removing
rrectness of i

l purpos
– Remove battery.
– Release connector on engine control unit and pull connector
nform
ercia
off.
m
at
om
– Remove old control unit.

ion
c
in t
or
Installing
his
ate
do
riv
– Insert new control unit.

p
cum
for
en
g
– Fit connectors and lock in position.

n
t.
yi Co
Cop py
– Install battery. ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Engine control unit 169

Sharan 1996 ➤
26 – Exhaust system
1 Removing and installing parts of ex‐
haust system
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b
Note rise
d ara
nte
tho eo
au ra
♦ Removing and installing
ss exhaust manifold, engine code: ANU c
⇒ page 142 .
ce
le
un
pt
an
d
itte
♦ Removing and installing exhaust manifold, engine codes:
y li
erm
ab
ASZ, BTB ⇒ page 145 .
ility
ot p
♦ Removing and installing exhaust manifold, engine codes:
wit
is n
h re
AUY, BVK ⇒ page 147 .
ole,
spec
♦ After working on the exhaust system, ensure that the system
t to the co
is not under tension and that there is sufficient clearance to
the bodywork. If necessary, loosen double and single clamps
and align silencer and exhaust pipe so that sufficient clearance
is maintained to the bodywork and the support rings are evenly
rrectne
loaded.
s
♦ Renew self-locking nuts.
s o
cial p
f inform
Assembly overview - front exhaust pipe with catalytic converter
mer
⇒ page 170 .
atio
om
n
c
Assembly overview - silencers ⇒ page 171 . i

or
n thi
te
sd
a
1.1 Assembly overview - front exhaust pipe with catalytic converter

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.
170 Rep. gr.26 - Exhaust system

Sharan 1996 ➤
1 - Heat shield
2 - Panel nut
❑ Must be screwed on/off
3 - 25 Nm
4 - Bracket
5 - Retaining ring
6 - Gasket
❑ Renew. n AG. Volkswagen AG do
lkswage es n
o ot g
yV ua
7 - 25 Nm ir se
d b ran
o tee
h
8 - Catalytic converter aut or
ac
ss
9 - To front silencer
ce
le
un
pt
an
d
❑ ⇒ Item 7 (page 172)

itte
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rm
ab
pe
ility
ot
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11 - From turbocharger
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.
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Cop py
t. rig
1.2 Assembly overview - silencers
gh ht
pyri by
Vo
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by
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Prote AG.
Note
Longitudinally, the exhaust system must be aligned so that the

dimensions -a- -b- and -c- are adhered.
1. Removing and installing parts of exhaust system 171

Sharan 1996 ➤
1 - From catalytic converter n AG. Volkswagen AG do

wage es n
❑ ⇒ Item 8 (page 171) yV
olks ot g
ua
d b ran
2 - Clip ir se tee
tho
u or
a ac
3 - 40 Nm ss
ce
e
nl
❑ Renew.
pt
du
an
itte
y li
4 - Retaining ring
erm
ab
ility
ot p
wit
, is n
h re
tion
hole
spec
es, in part or in w
and
t to the co
5 - Panel nut
rrectness of i
❑ Must be screwed on/off
l purpos
6 - Heat shield
7 - Front silencer
nf
ercia
orm
8 - Rear silencer
m
atio
om
n in
9 - Dimension -a- = approx.
or c
thi
50 mm
te
sd
iva
o
r
10 - Dimension -b- = approx.

rp
cu
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m
15 mm
f
en
ng
t.
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op
11 - Dimension-c- = approx. 10
C py
t. rig
gh
mm
ht
pyri by
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by
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Prote AG.

Sharan 1996 ➤
2 Exhaust gas recirculation system
Note
♦ The exhaust gas recirculation system is activated by the diesel

direct injection system control unit - J248- via exhaust gas re‐
circulation valve - N18- (electric-pneumatic) to the exhaust gas
recirculation valve (mechanical).
♦ The tapered plunger in the mechanical exhaust gas recircula‐
tion valve varies the opening cross section according to valve
travel. wage
e ks s no
Vol t gu
♦ Pulsed control enables every conceivable
ed
by valve position. ara
ris nte
♦ Renew self-locking nuts. ho eo
aut ra
ss c
ce
e
nl
Assembly overview - exhaust gas recirculation: Engine code ANU
pt
du
an
⇒ page 173
itte
y li
erm
ab
Assembly overview - exhaust gas recirculation: Engine codes
ility
ot p
ASZ, AUY, BTB, BVK ⇒ page 175
wit
, is n
h re
Checking exhaust gas recirculation valve ⇒ page 176
hole
spec
es, in part or in w
2.1 Assembly overview - exhaust gas recirculation: Engine code ANU
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
o
by c lksw
cted agen
Prote AG.
2. Exhaust gas recirculation system 173

Sharan 1996 ➤
1 - O-ring
❑ Renew.
2 - Intake manifold
3 - Bracket
4 - Vacuum hose
❑ To exhaust gas recircu‐
lation valve (mechani‐
cal)
5 - Vacuum hose
❑ To vacuum pipe collec‐
tive connection brake
servo
6 - 10 Nm
valve - N18- (electro-pneumat‐
ic)
8 - Vacuum hose
❑ To air filter
AG. Volkswagen AG d
9 - Rubber bush agen oes
olksw not
y V gu
b ara
10 - Connector rise
d
nte
ho eo
❑ 2-pin aut ra
c
ss
ce
e
nl
pt
du
an
itte
12 - Gasket
y li
erm
ab
❑ Renew.
ility
ot p
wit
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13 - 25 Nm
h re
hole
14 - Connecting pipe
spec
es, in part or in w
❑ When installing, tighten t to the co

all bolts lightly (parts
must still just be able to
move against one another). Then tighten so parts are free of stress.
rrectness of i
15 - 25 Nm
l purpos

nform
ercia
❑ With mechanical exhaust gas recirculation valve and intake manifold flap
❑ Check mechanical exhaust gas recirculation valve ⇒ page 176
m
at
om
ion
17 - 25 Nm
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 ➤
2.2 Assembly overview - exhaust gas recirculation: Engine codes ASZ, AUY,
BTB, BVK
1 - Intake connecting pipe . Volkswagen AG

gen AG does
❑ With mechanical ol swa
kex‐ not
V gu
haust gas recirculation
ed by ara
nte
valve and thoris
intake mani‐ eo
fold flap
s au ra
c
s
❑ Check mechanical ex‐
ce
e
nl
pt
haust gas recirculation
du
an
itte
valve ⇒ page 176
y li
erm
ab
ility
2 - O-ring
ot p
wit
, is n
❑ Renew.
h re
hole
spec
3 - Intake manifold
es, in part or in w
t to the co
4 - 25 Nm
5 - Connecting pipe
rrectness of i
❑ When installing, tighten
all bolts lightly (parts
l purpos
must still just be able to

move against one an‐
other). Then tighten so
nf
ercia
o
parts are free of stress.
rm
m
atio
m
6 - To coolant circulation pump

o
n in
c
- V50- .
or
thi
te
sd
a
7 - Gasket
iv
o
r
rp
cu
❑ Renew.
o
m
f
en
ng
t.
yi Co
8 - Radiator Cop py
ht. rig
rig ht
py by
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lation. by c lksw
cted agen
Prote AG.
9 - 10 Nm
10 - 25 Nm
11 - Gasket
❑ Renew.
13 - Gasket
❑ Renew.
14 - Connecting pipe
❑ When installing, tighten all bolts lightly (parts must still just be able to move against one another). Then
tighten so parts are free of stress.
15 - 25 Nm
16 - From connecting flange on cylinder head
17 - 10 Nm
18 - 25 Nm
19 - Gasket
❑ Renew.
20 - 10 Nm
2. Exhaust gas recirculation system 175

Sharan 1996 ➤
2.3 Checking mechanical exhaust gas recir‐

culation valve
♦ Hand vacuum pump - V.A.G 1390-
Test procedure
– Remove connecting hose to charge air cooler at intake con‐
necting pipe.
– Disconnect vacuum hose from mechanical exhaust gas recir‐
culation valve.
– Connect hand vacuum pump - V.A.G 1390- to valve.
– Operate pump and observe diaphragm rod.
The diaphragm rod must move in direction of arrow.
– Pull hand vacuum pump hose off mechanical exhaust gas re‐
circulation valve. AG. Volkswagen A gen G do
swa es
The diaphragm rod must move back by
Vol to its original position counter
k not
gu
to the direction of the arrowrised ara
nt ee
tho or
s au ac
s
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 ➤
28 – Glow plug system

1 Checking glow plug system
Checking glow plugs ⇒ page 178
♦ Hand-held multimeter - V.A.G 1526 C-
♦ Auxiliary measuring set - V.A.G 1594 C-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
Test prerequisites horis nte
eo
aut ra
• The battery voltage must be at least 11.5 V. ss c ce
e
nl
• All electrical consumers, e.g. lights and rear window heating,

pt
du
an
itte
must be switched off.

y li
erm
ab
• Diesel direct injection system control unit - J248- OK.

ility
ot p
wit
, is n
• Fuse for glow plugs OK ⇒ Current flow diagrams, Electrical

h re
hole
fault finding and Fitting locations

spec
es, in part or in w
Test procedure
t to the co

– Disconnect connector on coolant temperature sender - G62-
rrectness of i
⇒ Item 6 (page 158) .

l purpos
Note
nf
ercia
orm
m
atio
Pulling the connector off sender, simulates engine condition

om
“cold” and when switching the ignition on the relevant glow period
n in
or c
is carried out.
thi
te
sd
iva
o
r
rp
cu
– Pull glow plug connectors off glow plugs.

o
m
f
en
ng
t.
yi
– Connect multimeter to measure voltage between glow plug
Co
Cop py
connector and earth.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
177
AG.
1. Checking glow plug system
Sharan 1996 ➤
– Switch on ignition. Approx. battery voltage must be displayed

for approx. 20 seconds.
If no voltage is present:
– Repair the fault in the wiring referring to current flow diagram:
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations
1.1 Checking glow plugs

♦ Vehicle diagnostic tester with measuring unit
AG. Volkswagen AG d
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
♦ 10 mm jointed spanner - 3220-
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
e
Test procedure
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
– Pull glow plug connectors off glow plugs. t. Cop py
rig
gh ht
– Place measuring tips of vehicle diagnostic tester with meas‐ yri
p by
o Vo
uring unit on each glow plug and vehicle earth one after the
by c lksw
cted agen
other.
Prote AG.
– Perform resistance measurement on glow plugs.

♦ Specification: max. 1 Ω
– If the specification is exceeded, renew the defective glow plug.
– Remove and install glow plugs with U/J extension and socket,
10 mm - 3220- . Specified torque: 15 Nm
178 Rep. gr.28 - Glow plug system

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Service

Service Department. Technical Information

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Copyright © 2015 Volkswagen AG, Wolfsburg K0056763920

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 - Crankshaft group . . . . . . . . . . . . a.ge. n.A.G.. V.o.lks.w.ag. e.n .AG. d.o. . . . . . . . . . . . . . . . . . . . . . . . 12

1.4 Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2 Sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.1 Assembly overview - sealing flanges and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.2 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.3 Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.4 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.3 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2.1 Assembly overview - oil pump, sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

1.12 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

1.14 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 115

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

1.1 Engine number

The engine number (“code letters” and “serial number”) can be

The engine number consists of up to nine characters (alphanu‐

“engine code”, and the second part (6 characters), the “serial

number”. If more than 999,999 engines with the same engine

In addition, there is a sticker on the toothed belt guard with “engine

1.2 Engine data

♦ Lifting tackle - 2024A-

♦ Support clamp - VW 313-

♦ Engine and gearbox sup‐

2 Rep. gr.10 - Removing and installing engine

♦ Torque wrench (5... 50 Nm)

♦ Engine bung set - VAS 6122-

♦ Grease - G 000 100- (vehicles with manual gearbox)

1.1 Notes on removing

The engine is removed from below with the gearbox

– Read fault memories of all control units before removing

1. Removing and installing engine 3

♦ Before carrying out further work, disconnect battery earth

– Remove engine cover. spec

– Remove battery and battery carrier.

– Remove noise insulation ⇒ Body Repairs; Rep. gr. 50 ; Exte‐

– Remove air filter housing together with intake manifold.

very hot (danger of scalding)!

♦ The fuel system is also under pressure! Before opening

– Seal lines so that fuel system is not contaminated by dirt.

4 Rep. gr.10 - Removing and installing engine

Vehicles with automatic gearbox

tomatic gearbox 09B; Rep. gr. 37 ; Repairing selector mech‐

1. Removing and installing engine 5

– Fit engine bracket - T10012- onto cylinder block with securing

– Unscrew right assembly mounting securing bolts -1-.

To remove securing bolts, use stepladder - VAS 5085- .

– Unscrew left assembly mounting securing bolts -A-.

To remove securing bolts, use stepladder - VAS 5085- .

Engine with gearbox must be guided carefully when lowered to

1.2 Securing engine to assembly stand