Service: Sharan 1996

Service
Sharan 1996 ➤
4-cyl. injection engine (5-valve), Mechanics
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
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Repair Group
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00 - Technical data
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10 - Removing and installing engine
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13 - Crankshaft group
15 - Cylinder head, Valve gear
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17 - Lubrication
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19 - Cooling system
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20 - Fuel supply system

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21 - Charging
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26 - Exhaust system
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Technical information should always be available to the foremen and mechanics, because their careful
and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In
addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course,
be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg 00056606920

Sharan 1996 ➤
4-cyl. injection engine (5-valve), Mechanics - Edition 02.2005
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.2 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.4 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.5 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.6 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.7 Additional information and removal instructions for vehicles with air conditioner . . . . . . . . . .16
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
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1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.2 Removing and installing ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
2 Removing and installing sealing flanges and flywheel/drive plate . . . . . . . . . . . . . . . . . . . .30
2.1 Removing and installing sealing flanges and flywheel/drive plate . . . . . . . . . . . . . . . . . . . .30
2.2 Renewing crankshaft oil seal -belt pulley end- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
2.3 Removing and installing sealing flange -belt pulley end- . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
2.4 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
3.1 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
3.2 Colour markings . . . . . . . . . . . . . . . . . . . . n. A.G. ..V.ol.ks.w.a.g.en. A. . . . . . . . . . . . . . . . . . . . . . . . . . .47
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3.3 Crankshaft dimensions . . . . . . . . .V.ol.ks. w.a. . . . . . . . . . . . . . . . .oe. s.n.ot. . . . . . . . . . . . . . . . . . . . .47
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and conrods . . . . . . . . . . . . . . .ra.n.te. . . . . . . . . . . . . . .48
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4.1 Dismantling and assembling au pistons and conrods . . . . . . . . . . . . . . . . . . .r a.c . . . . . . . . . . . .48
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4.2 Piston and cylinder dimensions
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15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

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1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

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1.1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

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1.2 Removing, installing and tensioning toothed belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

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1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

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1.4 Checking compression pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

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2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

2.1 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
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2.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

2.3 Renewing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
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2.4 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

2.5 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
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2.6 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

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2.7 Replacing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
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1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

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1.1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

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1.2 Dismantling and assembling oil filter bracket: engine code AJH . . . . . . . . . . . . . . . . . . . . . .113
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1.3 Dismantling and assembling oil filter bracket: engine code AWC . . . . . . . . . . . . . . . . . . . .118
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Contents i
Sharan 1996 ➤
1.4 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

1.5 Checking oil pressure and oil pressure switch: engine code AJH . . . . . . . . . . . . . . . . . . . .126
1.6 Checking oil pressure and oil pressure switch: engine code AWC . . . . . . . . . . . . . . . . . . . .128
19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130

1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
1.1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
1.2 Parts of cooling system body side: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
1.3 Parts of cooling system body side: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
1.4 Parts of cooling system engine side: engine code AJH .G.. V. o.lk.s.w.ag. e. . . . . . . . . . . . . . . . . . . .138
1.5 Parts of cooling system engine side: engine code gen A . . . . . . . . n. A. G. d. o.e. . . . . . . . . . . . . . .142
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1.6 Coolant hose connection diagram: engine ed code
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1.7 Coolant hose connection diagram: engine ho
r code AWC . . . . . . . . . . . . . . . . . . . . . . te. e.o. . . . . .150
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1.8 Draining and filling cooling systemss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.c . . . .152
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1.9 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
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1.10 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
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1.11 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
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1.12 Checking coolant circulation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
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1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
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1.1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
1.2 Removing and installing fuel tank with attachments and fuel filter: engine code AJH . . . . . .167
1.3 Removing and installing fuel tank with attachments and fuel filter: engine code AWC . . . .175
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1.4 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . .182
1.5 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
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1.6 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
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1.7 Removing and installing fuel gauge sender: engine code AWC . . . . . . . . . . . . . . . . . . . . . .185
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1.8 Crash fuel shut-off: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
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1.9 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187

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2 Accelerator mechanism: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
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2.1 Accelerator mechanism: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195

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2.2 Servicing accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
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2.3 Adjusting throttle cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197

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3 Electronic power control (EPC): engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199 ht. rig
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3.1 Electronic power control (EPC): engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199 copy Vo
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3.2 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
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3.3 Servicing parts of electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
3.4 Checking accelerator pedal position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
4 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
4.1 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
4.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
4.3 Servicing parts of the activated charcoal filter system: engine code AJH . . . . . . . . . . . . . .206
4.4 Servicing parts of the activated charcoal filter system: engine code AWC . . . . . . . . . . . . . .209
4.5 Checking activated charcoal filter solenoid valve 1: engine code AWC . . . . . . . . . . . . . . . .212
4.6 Checking fuel tank breather: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
4.7 Checking fuel tank breather: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
21 - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
1.1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
1.2 Removing and installing turbocharger and attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
1.3 Removing and installing parts of charge air cooling: Engine code AJH . . . . . . . . . . . . . . . .225
1.4 Removing and installing parts of charge air cooling: engine code AWC . . . . . . . . . . . . . . . .228
1.5 Overview of turbocharging: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233
1.6 Overview of turbocharging: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236
1.7 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
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1.8 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240

1.9 Removing and installing charge air cooler: engine code AWC . . . . . . . . . . . . . . . . . . . . . .240
2 Checking charge air system: engine code AJH . . . . . .e.n.A.G.. V. o.lk.sw . a. g.e.n.A.G. . . . . . . . . . . . . . .242
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2.1 Checking charge air system: engine code AJH V. o.lk.s.w. . . . . . . . . . . . . . . . o. e.s.no. t.g. . . . . . . . .242
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2.2 Checking charge pressure regulation . . . .is.e.d b. . . . . . . . . . . . . . . . . . . . . . . . . . . .a.ra.n . . . . . .242
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2.3 Checking charge pressure control solenoid ut
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2.4 Checking pressure unit for charge pressure ss regulating valve . . . . . . . . . . . . . . . . . . . . . .c . .244
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2.5 Checking overrun shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
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3 Checking charge pressure system: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
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3.1 Checking charge pressure system: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
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3.2 Checking charge pressure regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
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3.3 Checking charge pressure control solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
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3.4 Checking charge pressure sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
3.5 Checking pressure unit for charge pressure regulating valve . . . . . . . . . . . . . . . . . . . . . . . .253
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3.6 Checking overrun shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256
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1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256
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1.1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256
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1.2 Front exhaust pipe and catalyst with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
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1.3 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262
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2 Secondary air system: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
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2.1 Secondary air system: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
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2.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264

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2.3 Removing and installing parts of the secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . .264
pr
cum
r
fo
2.4 Checking combi-valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268
en
ng
t.
yi Co
op
3 Secondary air system: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269 C py
t. rig
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3.1 Secondary air system: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
ht
pyri by
Vo
o
by c
3.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
lksw
cted agen
Prote AG.
3.3 Removing and installing parts of the secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . .270
3.4 Checking secondary air pump motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
3.5 Checking combi-valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
4 Exhaust gas recirculation system: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
4.1 Exhaust gas recirculation system: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
4.2 Servicing parts of exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278
4.3 Checking potentiometer for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .281
Contents iii
Sharan 1996 ➤
AG. Volkswagen AG d
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iv Contents
Sharan 1996 ➤
00 - Technical datalkswagen AG. Volkswagen AG does no

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1 - Technical data
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1.1 - Technical data
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spec
es, in part or in w
1.2 - Engine number
t to the co
rrectness of i
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nform
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com
tion in
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-> The engine number ("Code letters" and "Serial number") can be found on the front by the joint between
p by
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engine/gearbox.
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Additionally there is a sticker on the toothed belt guard with "Engine code" and "Serial number".
The engine code is also included on the vehicle data plate.
The engine number consists of up to nine characters (alphanumeric). The first part (maximal 3 characters)
makes up the "engine code", and the second part (6 characters), the "serial number". If more than 999,999
engines with the same engine code are produced, the first of the six characters is replaced with a letter.
1.3 - Engine data
Engine code AJH AWC

Manufactured 11.97 ▸05.00 06.00 ▸
Capacity ltr. 1.8 1.8
Output kW at rpm 110/5500 110/5800
Torque Nm at rpm 210/1850...4500 210/1800...4300
Bore ø mm 81.0 81.0
Stroke mm 86.4 86.4
Compression ratio 9.5 9.5
RON 95 unleaded1 95 unleaded1
System designation Motronic ME3.8.5 Motronic ME7.5
Emissions fulfil D3 standard EU4 standard
Self-diagnosis yes OBD
Knock control 2 knock sensors 2 knock sensors
Lambda regulation 1 probe 2 probes
1.1 - Technical data 1

Sharan 1996 ➤
Catalyst yes yes

Exhaust gas recirculation no yes
1) In exceptional circumstances min. 95 RON, however with reduced performance
Engine code AJH AWC

Charging yes yes
Charge pressure control yes yes
Secondary air system yes yes
Electronic engine performance control no yes
Variable intake manifold no no
Variable valve timing no no
satelettronica
AG. Volkswagen AG d
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2 00 - Technical data
Sharan 1996 ➤

1.1 - Removing and installing engine
AG. Volkswagen AG d
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pe
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
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thi
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Special tools, workshop equipment, test and measuring appliances and auxiliary items required
◆ 2024 A Lifting tackle

◆ T10012 Engine bracket
◆ VW 313 Support clamp
◆ VW 540 Engine and gearbox support
◆ VW 540/1 B Supplementary set
◆ V.A.G 1202 A Workshop crane
1.1 - Removing and installing engine 3

Sharan 1996 ➤
AG. Volkswagen AG d
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nl
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du
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
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nf
ercia
orm
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◆ V.A.G 1306 Drip tray

◆ V.A.G 1331 Torque wrench (5...50 Nm)
◆ V.A.G 1383 A Engine/gearbox jack
◆ V.A.S 5024 Fitting tool for spring-type clips
◆ VAS 5085 Step ladder
◆ G 000 100 Grease (vehicles with manual gearbox)
◆ Cable tie
1.2 - Notes on removing

- The engine is removed downwards together with the gearbox.
- All cable ties which are opened or cut open when removing engine, must be replaced in the same position
when installing engine.
- Remove engine cover.
- First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.
- With ignition switched off disconnect battery earth strap.
- Remove battery.
4 10 - Removing and installing engine

Sharan 1996 ➤
- -> Remove air duct trim -1-.

- Unbolt battery trim -2- with coolant expansion tank and lay to side without opening cooling system.
satelettronica
AG. Volkswagen AG d
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- In preparation forrisfurther dismantling work, disconnect theranconnectors
ed
tee -arrows- behind the battery.
- Remove battery aut tray.
ho
or
a
- Pull off or disconnect
ss all other electrical connections as necessary c from engine and body and lay to one
side.
ce
e
nl
pt
du
- Remove air cleaner:

an
itte
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erm
ab
=> Repair group 24; Servicing injection system; Dismantling and assembling air cleaner. Servicing injection
ility
ot p
system Dismantling and assembling air cleaner.

wit
, is n
h re
hole
Vehicles with engine code AJH

spec
es, in part or in w
t to the co
- Remove intake hose:=> Page 225 , Removing and installing parts of charge air cooling: engine code AJH.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
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- -> Disconnect throttle cable at throttle valve control part cable disc and support bracket -arrows- (do not
yri
gh by
ht
remove locating clip on support bracket).
op Vo
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Prote AG.
Vehicles with engine code AWC
- Remove intake hose:=> Page 228 , Removing and installing parts of charge air cooling: engine code AWC.
1.2 - Notes on removing 5

Sharan 1996 ➤
Continuation for all vehicles
- -> Disconnect fuel supply and return pipes and the pipe from the activated charcoal filter solenoid valve 1 -
arrows- at fuel rail.
Warning!
Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connec‐
tion. Then release pressure by carefully pulling hose off connection.
satelettronica
- Unclip fuel hoses from bracket.
- Seal the pipes so that the fuel system is not contaminated by dirt etc.
- Observe rules for cleanliness =>gePage
n AG. Vo183
lkswa.gen AG
does
- Pull vacuum and breatherVhoses
olks
wa off engine as necessary. not
- Remove noise insulation
ed b tray.
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ara
ris nte
tho eo
Vehicles with engine
ss
a code
u
AJH ra
c
ce
e
nl
pt
- Remove pressure hose between secondary air pump motor and combi-valve
du
an
itte
=> Page 264 , Removing and installing parts of secondary air system.
y li
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ab
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Note:
wit
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Press buttons on hose couplings to do this.

hole
spec
es, in part or in w
t to the co
- Remove air pipes between turbocharger/charge air cooler, turbocharger/air cleaner and charge air cooler/
throttle valve control part => Page 225 , Removing and installing parts of charge air cooling system: engine
code AJH
rrectness of i

l purpos
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Note:
om
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thi
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- Remove air pipes between turbocharger/charge air cooler, turbocharger/air cleaner and charge air cooler/
o
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f
en
throttle valve control part=> Page 228 , Removing and installing parts of charge air cooling system: engine
ng
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code AWC t. Cop py
rig
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Vehicles with 5-speed manual gearbox 006 cop Vo
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- Pull pipe/hose off slave cylinder on gearbox:
=> 5-Speed manual gearbox 006; Repair group 30; Assembly overview; Hydraulics and clutch release mech‐
anism Assembly overview Hydraulics and clutch release mechanism
- Remove operating cable from gearbox:

Sharan 1996 ➤
=> 5-speed manual gearbox 006; Repair group 34; Servicing selector mechanism; Removing and installing
operating cables Servicing selector mechanism Removing and installing operating cables
- Remove drive shafts:
=> Running gear, Axles, Steering; Repair group 40; Removing and installing drive shaft Removing and installing
drive shaft
Vehicles with 6-speed manual gearbox 02N
- Pull pipe/hose off slave cylinder on gearbox and lay to one side.
=> 6-speed manual gearbox 02N; Repair group 30; Assembly overview - Hydraulics and clutch release mech‐
anism Assembly overview - Hydraulics and clutch release mechanism
- Remove operating cable from gearbox:
=> 6-speed manual gearbox 02N; Repair group 34; Servicing selector mechanism; Removing and installing
- Remove drive shafts:
drive shaft
satelettronica
Vehicles with automatic gearbox 099 - 4-speed
- Remove selector lever cable from gearbox:
=> Automatic gearbox 099 - 4-speed; Repair group 37; Servicing selector mechanism; Dismantling and as‐
sembling selector mechanism Servicing selector mechanism Dismantling and assembling selector mechanism
- Unbolt drive shafts from gearbox flange shaft

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and
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=> Running gear, Axles, Steering;
edb
y
Repair group 40; Removing anduainstalling
ran drive shaft Removing and installing
is
drive shaft thor tee
or
au ac
ss
Vehicles with automatic gearbox 09B - 5-speed
ce
e
nl
pt
du
an
- Remove selector lever cable from gearbox:

itte
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erm
ab
ility
ot p
=> Automatic gearbox 09B - 5-speed; Repair group 37; Servicing selector mechanism; Dismantling and as‐
wit
sembling selector mechanism Servicing selector mechanism Dismantling and assembling selector mechanism
, is n
h re
hole
spec
- Unbolt drive shafts at gearbox flanged shaft and tie up.

es, in part or in w
t to the co
drive shaft
rrectness of i
Vehicles with air conditioner

l purpos
- Observe additional information and removal instructions => Page 16 .

nform
ercia

m
at
om
- Remove ribbed belt => Page 28 .

ion
c
- Remove power assisted steering vane pump on compact bracket and lay to side; hoses remain connected.
in t
or
his
ate
do
riv
=> Running gear, Axles, Steering; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes
p
cum
or
Assembly overview: vane pump, reservoir, hydraulic pipes

f
en
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t.
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- Unbolt P.A.S. hydraulic pipe at right engine bracket.
C py
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- Remove front exhaust pipe => Page 257 , front exhaust pipe and catalyst with attachments.
ht
pyri by
Vo
- Drain coolant => Page 152 .
o
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- Pull connectors off thermo-switch and radiator fan. Prote AG.

Sharan 1996 ➤
- Pull radiator coolant hoses off engine using spring-type clip pliers V.A.G 1921 or VAS 5024.
- Removing front bumper:
=> General body repairs, exterior, Repair group 63; Front bumper, Removing and installing front bumper
AG. Volkswagen AG d
agen oes
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- Bring lock carrier into service position:
t to the co
=> General body repairs, exterior; Repair group 50; Body, front; Lock carrier service position Body, front Lock
carrier service position
rrectne
- Insert engine bracket T 10012 in engine/gearbox jack V.A.G 1383 A.
satelettronica
- -> Bolt engine support T10012 to cylinder block using securing bolt M10x25.
ss
Tightening torque 45 Nm
o
cial p
f
- Lift engine and gearbox lightly using engine/gearbox jack V.A.G 1383 A.
inform
mer
- Remove pendulum support.
atio
om
n
c
i
or
n
=> Running gear, Axles, Steering; Repair group 40; Servicing front wheel suspension; I - Assembly overview, thi
te
sd
a
subframe, anti-roll bar, wishbone Servicing front wheel suspension I - Assembly overview, subframe, anti-roll
iv
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pr
bar, wishbone
cum
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Prote AG.
- -> Unbolt assembly mounting, right securing bolts -1-.

Sharan 1996 ➤
- -> Unbolt assembly mounting, left securing bolts -A-.
Note:
To remove securing bolts use ladder VAS 5085.
- Carefully lower assembly slightly.
- -> Remove the securing bolts -A- and remove the bracket -B-.
satelettronica
AG. Volkswagen AG d
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- -> Unbolt securing bolts and nuts on left of subframe -arrows-.

an
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Note:
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To remove securing bolts use ladder VAS 5085.

h re
ole,
spec

t to the co
- Carefully lower engine with gearbox.

rrectne
Note:
Engine and gearbox must be guided carefully when lowering to prevent damage to the bodywork, hoses and
ss o
wiring.
cial p
f inform
mer
atio
om
1.3 - Securing engine to assembly stand

n
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When working on the engine, it should be secured to the assembly stand support clamp VW 313 using the
fo
en
ng
engine and gearbox bracket VW 540 and supplementary set VW 540/1B.

t.
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Prote AG.

Sharan 1996 ➤
Work sequence
- Remove gearbox.
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Vehicles with automatic gearbox d byV ua
ran
ir se tee
tho
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ss
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- Secure torque converter against "falling out" after separating engine from gearbox.
s
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- Bolt engine/gearbox bracket VW 540 with supplementary set VW 540/1 B onto cylinder block. C py
t. rig
gh
- -> Attach lifting device 2024 A as follows and lift engine out of engine/gearbox jack using workshop crane.
ht
pyri by
Vo
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cted agen
Pulley end: Prote AG.
4th hole in hook rail at position 1

Flywheel end:
3rd hole in hook rail at position 8
Warning!
The hooks and locating pins must be secured with locking pins.
Notes:
◆ The positions marked 1...4 on the bar must be towards the pulley end.
◆ The holes in the hook rails are counted up from the hook.
- Fit engine in support clamp VW 313 using workshop crane V.A.G 1202 A.
1.4 - Notes on installing
Installation is carried out in the reverse order, when doing this note the following:
Warning!
When doing any repair work, especially in the engine compartment, pay attention to the following due to the
cramped conditions:
◆ Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant, refrigerant,
brake fluid and vacuum pipes and hoses) and electrical wiring so that the original positions are restored.
◆ Ensure sufficient clearance to all moving or hot components.

Sharan 1996 ➤
- Check whether the dowel sleeves for centring engine/gearbox are in the cylinder block and install if neces‐
sary.
AG. Volkswagen AG d
agen oes
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un
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ility
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ole,
spec
t to the co
- -> Fit intermediate plate onto sealing flange and slide onto dowel sleeves -arrows-.
rrectne
Vehicles with 5-speed manual gearbox 006
ss
- Clean input shaft splines and lightly grease with G 000 100.
o
cial p
f
- Check clutch and clutch operating mechanism, then install:
inform
satelettronica
mer
=> 5-Speed manual gearbox 006; Repair group 30; Assembly overview; hydraulics and clutch release mech‐
atio
m
anism Assembly overview hydraulics and clutch release mechanism

o
n
c
i
or
n thi
e
Vehicles with 6-speed manual gearbox 02N

t
sd
iva
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pr
cum
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fo
- Clean input shaft splines and lightly grease with G 000 100. en
ng
t.
yi
- Check clutch and clutch operating mechanism, then install:
Co
Cop py
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=> 6-speed manual gearbox 02N; Repair group 30; Assembly overview - Hydraulics and clutch release mech‐
p by
co Vo
by lksw
anism Assembly overview - Hydraulics and clutch release mechanism Prote
cted AG.
agen
- Screw in all bolts on assembly mountings by hand approx. 5...6 turns.
Note:
-> Before inserting the bolts for the assembly mounting the bracket -B- must be installed and tightened
Tightening torque for bracket => Page 14 .
1.4 - Notes on installing 11

Sharan 1996 ➤
- Align assembly mountings stress-free by rocking.
Note:
Assembly mounting tightening torques
=> Page 14 .
- Connect pipe/hose on slave cylinder and secure with clip:
=> 5-Speed manual gearbox 006; Repair group 30; Assembly overview; hydraulics and clutch release mech‐
anism Assembly overview hydraulics and clutch release mechanism
- Attach operating cable to gearbox, adjust if necessary:
=> 5-Speed manual gearbox 006; Repair group 34; Servicing selector mechanism; Removing and installing
Vehicles with 6-speed manual gearbox. V02N
satelettronica
olkswagen AG
gen AG
wa d oes
olks not
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- Connect pipe/hoseseon d slave cylinder and secure with clip:
b ara
nte
ri
ho eo
ut
=> 6-speed manual
ss a gearbox 02N; Repair group 30; Assembly overview
- Hydraulics and clutch release mech‐
ra
c
anism Assembly overview - Hydraulics and clutch release mechanism
ce
e
nl
pt
du
an
itte
- Attach operating cable to gearbox, adjust if necessary:

y li
erm
ab
ility
ot p
=> 6-speed manual gearbox 02N; Repair group 34; Servicing selector mechanism; Removing and installing
wit
, is n
h re
hole
spec

es, in part or in w
t to the co
- Install selector cable on gearbox, adjust if necessary:

rrectness of i
=> Automatic gearbox 099 - 4-speed; Repair group 37; Servicing selector mechanism; Servicing selector
mechanism
l purpos

nf
ercia
or
- Install selector cable on gearbox, adjust if necessary:

m
m
atio
om
n in
c
=> Automatic gearbox 09B - 5-speed; Repair group 37; Servicing selector mechanism Servicing selector
or
thi
mechanism
te
sd
iva
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rp
cu

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m
f
en
ng
t.
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op
- Remove front exhaust pipe => Page 257 , front exhaust pipe and catalyst with attachments. C py
ht. rig
- Install drive shafts: rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
drive shaft
- Install pendulum support:
=> Running gear, Axles, Steering; Repair group 40; Servicing front wheel suspension; I - Assembly overview,
bar, wishbone
- Installing P.A.S. vane pump:

Sharan 1996 ➤
=> Running gear, Axles, Steering; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes
Assembly overview: vane pump, reservoir, hydraulic pipes
- Bolt hydraulic pipe for P.A.S. to right engine bracket

Tightening torque: 20 Nm.
Vehicles with air conditioner
- Installing air conditioner compressor:
=> Heating, Air conditioning; Repair group 87; removing and installing compressor bracket removing and in‐
stalling compressor bracket
- Install ribbed belt => Page 28 .
- Install air pipes between turbocharger/charge air cooler, turbocharger/air cleaner and charge air cooler/
throttle valve control part: => Page 225 , Removing and installing parts of charge air cooling system: engine
code AJH
- Install intake hose: => Page 225 , Removing and installing parts of charge air cooling system: engine code
satelettronica
AJH
- Install pressure hose betweenasecondary
gen AG
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agepump
n AG d motor and combi-valve
oes
=> Page 264 , Removing yV
oand
lksw installing parts of secondary not
gu air system.
- Adjusting acceleratorisedcable
b =>Page 195 , Servicing accelerator
ara
n mechanism.
r tee
ho
ut or
Vehicles with engine
ss code
a AWC ac
ce
le
un
pt
- Install air pipes between turbocharger/charge air cooler, turbocharger/air cleaner and charge air cooler/
an
d
itte
throttle valve control part: => Page 228 , Removing and installing parts of charge air cooling: engine code
y li
rm
ab
AWC
pe
ility
- Install intake hose: => Page 228 , Removing and installing parts of charge air cooling: engine code AWC
ot
wit
, is n
- Install pressure hose between secondary air pump motor and combi-valve
h re
=> Page 270 , Removing and installing parts of secondary air system
hole
spec
es, in part or in w

t to the co
- Install air cleaner:

rrectness of i
l purpos
- Install battery tray and battery.

nform
mercia
- Electrical connections and routing:

com
tion in
r
te o
=> Current flow diagrams, Electrical fault finding and Fitting locations
thi
s
iva
do
r
rp
Filling with new coolant => Page 152 .

um
fo
en
ng
t.
yi Co
op
- Install noise insulation tray. C py
t. rig
gh ht
pyri by
o Vo
by c lksw
cted agen
Prote AG.
- Carry out a test drive and interrogate fault memory:
=> Repair group 01; Fault memory; Interrogating and erasing fault memory Fault memory Interrogating and
erasing fault memory
- Match engine electronics control unit to throttle valve control part:
1.4 - Notes on installing 13

Sharan 1996 ➤
=> Repair group 24; Engine control unit; Adapting engine control unit to the throttle valve control part Engine
control unit Adapting engine control unit to the throttle valve control part
Vehicles with engine code AWC AG. Volkswagen AG d
agen oes
lksw not
- Carry out a test drive and interrogate fault memory:
by Vo gu
ara
d
rise nte
o eo
=> Repair group 01; Fault memory; Interrogating
auth and erasing fault memory of engine control
r a unit Fault memory
Interrogating and erasing fault memory
s of engine control unit
s c
ce
e
nl
pt
- Adapt engine control unit to throttle valve control part and to EGR valve.
du
an
itte
y li
erm
ab
=> Repair group 24; Engine control unit; Adapting engine control unit to throttle valve control part and EGR
ility
ot p
valve Engine control unit Adapting engine control unit to throttle valve control part and EGR valve
wit
, is n
h re
hole
spec
- On vehicles with automatic gearbox the gearbox control unit must be matched additionally:
es, in part or in w
t to the co
=> Self-diagnosis for automatic gearbox 09B - 5-speed; Repair group 01; Performing self-diagnosis; Initiating
basic setting Performing self-diagnosis Initiating basic setting
rrectness of i
l purpos
1.5 - Tightening torques
nf
ercia
satelettronica
o
Bolted connections Tightening torque
rm
m
atio
m
Bolts, nuts M6 10 Nm
o
n in
c
M7 15 Nm
or
thi
te
sd
a
M8 20 Nm
iv
o
r
rp
cu
M10 40 Nm
o
m
f
en
ng
t.
yi
M 12 60 Nm
Co
Cop py
t. rig
Deviating from above opyri
gh by
Vo
ht
Hydraulic pipe to engine bracket 20 Nm

c by lksw
cted agen
Prote AG.
Starter to engine and gearbox 45 Nm
Front exhaust pipe to turbocharger 25 Nm
Note:
Assembly mounting tightening torques
=> Page 14 .
1.6 - Assembly mountings
Tightening torques
(Bolts oiled)

Sharan 1996 ➤
-> Assembly mounting, right:
A = 55 Nm
B = 60 Nm
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
-> Assembly mounting, left on vehicles with manual gearbox:
satelettronica
A = 55 Nm
ss
B = 110 Nm
o
cial p
f
C = 100 Nm
inform
D = 20 Nm
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.
-> Assembly mounting, left on vehicles with automatic gearbox:

A = 55 Nm
B = 110 Nm
C = 60 Nm
1.6 - Assembly mountings 15

Sharan 1996 ➤
-> Assembly mounting, left:
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
1) Replace bolts or nuts
Note:
All threaded holes into which self-locking bolts were screwed must be cleaned of residue from locking fluid
using a thread cutter.
1.7 - Additional information and removal instructions for vehicles with air conditioner
Warning!
The air conditioning system refrigerant circuit must not be opened.
satelettronica
Notes:
◆ The refrigerant circuit can only be opened in workshops having specially trained personnel and the neces‐
sary tools and workshop equipment.
◆ To avoid damage to condenser as well as to refrigerant pipes and hoses, ensure that the pipes and hoses
are not stretched, kinked or bent.
To facilitate removing and installing the engine without opening the refrigerant circuit:
- Remove retaining clamp(s) from refrigerant pipes. AG. Volkswagen AG d

agen
- Remove ribbed belt => Page 28 . Volksw
oes
not
- Remove alternator: d by gu
ara
rise nte
tho eo
=> Electrical system; Repair group 27; alternator with ribbed
ss a belt alternator with ribbed belt
u ra
c
ce
le
un
pt
- Removing air conditioner compressor:
an
d
itte
y li
rm
ab
=> Heating, Air conditioning; Repair group 87; removing and installing compressor bracket removing and in‐
pe
ility
stalling compressor bracket
ot
wit
, is n
h re
- Secure air conditioner compressor to body so that the refrigerant hoses/pipes are relieved.
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 ➤
13 - Crankshaft group
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
1 - Dismantling and assembling engine uthorise nte
eo
ra
s a c
s
1.1 - Dismantling and assembling engine
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
satelettronica
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.
Notes:
◆ When stripping and assembling the engine it should be secured to the engine frame with engine and gearbox
bracket VW 540 and supplementary set VW 540/1B.
◆ If large quantities of metal shavings or small metal particles are found in the engine oil during an engine
repair this can be due to partial seizure of crankshaft or conrod bearings. In this case it is not only necessary
to thoroughly clean the oil passages, but also to replace the oil cooler and oil filter to prevent subsequent
damage.
I =>Page 18
1.1 - Dismantling and assembling engine 17

Sharan 1996 ➤
II =>Page 23
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
satelettronica
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
Part I
r
rp
cu
o
m
f
en
ng
t.
yi
1 Toothed belt guard - upper part
Co
Cop py
2 Toothed belt
t. rig
gh ht
pyri by
◆ Mark D.O.R. before removing
co Vo
by lksw
cted
◆ Check for wear
agen
Prote AG.
◆ Do not kink
◆ Removing, installing and tensioning
=> Page 60
3 Idler wheel
4 27 Nm
5 65 Nm
◆ Use counter-hold 3036 to loosen and tighten
6 Camshaft sprocket
◆ Note installation position:
The small web of the camshaft sprocket points outwards and the No. 1 Cyl. TDC marking is visible
◆ Note position when installing toothed belt
18 13 - Crankshaft group
Sharan 1996 ➤
=> Page 60 , Removing, installing and tensioning toothed belt
satelettronica
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
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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
7 Tensioning roller
l purpos
◆ Removing, installing and tensioningtoothed belt => Page 60

8 Washer
nform
ercia
9 Tensioning device for toothed belt

◆ Removing, installing and tensioningtoothed belt => Page 60
m
a
com
tio
10 O-ring
n in
r
te o
◆ Renew
thi
s
iva
11 Coolant pump
do
r
rp
cum
◆ Check for ease of movement

fo
en
ng
◆ If damaged or leaking renew complete

t.
yi Co
op
◆ Removing and installing C py
t. rig
=> Page 159
gh ht
pyri by
Vo
co
12 15 Nm
by lksw
cted agen
Prote AG.
13 Crankshaft toothed belt sprocket

Sharan 1996 ➤
satelettronica
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
14 90 Nm + 1/4 turn (90 °) further

t to the co
◆ Renew
◆ Counter-hold with 3415 to loosen and tighten
◆ Threads and shoulder must be free of oil and grease
rrectness of i
◆ The quarter turn further can be done in several stages.

l purpos
15 20 Nm
16 Toothed belt guard - centre section
nf
17 Toothed belt guard - lower part

ercia
orm
18 10 Nm
m
atio
m
◆ Insert with locking fluid "D 000 600 A2"

o
n in
or c
19 Ribbed belt
thi
te
sd
a
◆ Mark direction of rotation before removing

iv
o
r
rp
cu
◆ Check for wear

o
m
f
◆ Do not kink
en
ng
t.
yi Co
◆ Removing and installing Cop py
=> Page 28 ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
satelettronica
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
20 Pulley
◆ For power assisted steering pump
nf
ercia
21 25 Nm
rm
m
atio
22 Belt pulley/vibration damper

om
n in
c
◆ Can only be installed in one position.

or
thi
e

t
sd
iva

o
r
rp
cu
o
23 Tensioning device for ribbed belt

f
en
ng
t.
yi
◆ To slacken ribbed belt, turn with open-end spanner => Page 28 , Removing and installing ribbed belts
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Sharan 1996 ➤ auth or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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
. rig
satelettronica
t
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
24 45 Nm
25 Right engine bracket
◆ Removing and installing
Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Part II ut
ho eo
ra
s a c
s
1 Knock sensor 1 (G61)
ce
e
nl
pt
du
◆ Checking (engine code AJH):

an
itte
y li
erm
ab
=> Repair Group 01; Fault memory; Interrogating and erasing fault memory Fault memory Interrogating and
ility
ot p

wit
, is n
h re
hole
◆ Checking (engine code AWC):

spec
es, in part or in w
t to the co
=> Repair Group 01; Fault memory; Interrogating and erasing engine control unit fault memory Fault memory
Interrogating and erasing engine control unit fault memory
rrectness of i
2 20 Nm
◆ Tightening torque influences the function of the knock sensor
l purpos
3 Knock sensor 2 (G66)

nf
ercia
orm
m
atio
m

o
n in
or c
thi
e

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
23
py by
co Vo
1.1 - Dismantling and assembling engine
by lksw
cted agen
Prote AG.
Sharan 1996 ➤
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
satelettronica
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
4 Dipstick
cted agen
Prote AG.
◆ The oil level must not be above the max. mark!
◆ Markings => Page 112 , Fig. 1
5 Guide
◆ For dipstick
◆ Secured to intake manifold with bracket
6 O-ring
◆ Renew
7 Coolant pipe
◆ Coolant hose connection diagram: engine code AJH =>Page 148
◆ Coolant hose connection diagram: engine code AWC =>Page 150
8 20 Nm
9 Gasket
◆ Renew
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
satelettronica
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
10 Oil filter bracket

rm
m
atio
◆ Ensure clearance to adjacent components

om
◆ Dismantling and assembling: engine code AJH => Page 113

n in
or c
◆ Dismantling and assembling: engine code AWC => Page 118

thi
te
sd
a
11 15 Nm + 1/4 turn (90 °) further

iv
o
r
rp
cu
◆ Renew
o
m
f
en
ng

t.
yi Co
op py
12 10 Nm
. C rig
ht ht
rig
13 Engine speed sender (G28)
py by
co Vo
by lksw
cted
agen
Prote AG.

Sharan 1996 ➤
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
satelettronica
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.
14 Connection
15 15 Nm
16 Coolant thermostat
=> Page 161
◆ Observe installation position,
=> Page 161 Removing and installing thermostat
◆ Checking: heat-up thermostat in water
◆ Opening commences approx. 87 °C
◆ Ends approx. 102 °C
◆ Opening lift min. 7 mm
17 25 Nm
18 Support
◆ Between intake manifold and cylinder block
19 45 Nm
20 Compact bracket
◆ For alternator, air conditioner compressor and vane pump for power assisted steering
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
satelettronica
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
or
21 Bracket
m
m
atio
m
◆ Only vehicles with engine code AJH

o
n in
c
◆ For air pipe exhaust turbocharger/charge air cooler

or
thi
e
22 40 Nm
t
sd
iva
o
r
23 Cylinder block
rp
cu
o
m
f
en
ng
◆ Removing and installing crankshaft => Page 43

t.
yi Co
◆ Dismantling and assembling pistons and conrods Cop py
.
=> Page 48
ht rig
rig ht
py by
24 Spacer sleeve
co Vo
by lksw
cted agen
◆ Only vehicles with manual gearbox
Prote AG.
25 25 Nm
26 Support
◆ Between turbocharger and cylinder block

Sharan 1996 ➤
1.2 - Removing and installing ribbed belt
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b
Special tools, workshop equipment, testers, measuring instruments
rise
d and auxiliary items required arante
tho eo
◆ T10060 Mandrel s au ra
c
s
ce
e
nl
pt
du
Removing ribbed belt
an
itte
y li
erm
ab
satelettronica
Note:
ility
ot p
wit
, is n
Before removing the ribbed belt mark the direction of rotation. When installing the belt ensure it is correctly
h re
seated in the pulley.
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
- Mark direction of rotation of ribbed belt.
Prote AG.
- -> Using a 16 mm open jaw spanner swing tensioning element in direction of arrow until tensioning element
can be locked.
Sharan 1996 ➤
- -> Lock tensioning element using mandrel T10060 -arrow-.
- Remove noise insulation tray.
- Remove ribbed belt.
Installing ribbed belt
- Install in reverse order.
Notes:
◆ Ensure, before installing ribbed belt, that all ancillaries (alternator, air conditioner compressor, power as‐
sisted steering vane pump) are secured tightly.
◆ When fitting the ribbed belt observe belt direction of rotation and that the belt is seated correctly in the belt
. Volkswagen AG
pulleys. wagen AG does
ks
◆ For vehicles with air conditioning, put ribbed
by
Vol belt over air conditioning compressor
not
gu
a
last.
ed ran
ris tee
- Fit ribbed belt. tho or
au ac
ss
ce
e
After completing repairs always:

nl
pt
du
an
itte
y li
- Start engine and check belt running.
erm
ab
ility
ot p
wit
Ribbed belt routing
, is n
satelettronica
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
-> Belt drive without air conditioner compressor

o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
-> Belt drive with air conditioner compressor
Note:
Engines with an air conditioner compressor are fitted with a double ribbed belt.
1.2 - Removing and installing ribbed belt 29

Sharan 1996 ➤
2 - Removing and installing sealing flanges and flywheel/drive plate

2.1 - Removing and installing sealing flanges and flywheel/drive plate
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
Notes:
n in
r
te o
thi
s
iva
do
r
rp

um
fo
◆ Servicing clutch (engine code AJH):

en
ng
t.
yi Co
Cop py
t. rig
=> 5 Speed manual gearbox 006; Repair group 30; servicing clutch servicing clutch opyri
gh by
Vo
ht
by c lksw
cted
◆ Servicing clutch (engine code AWC):
agen
Prote AG.
=> 6-speed manual gearbox 02N; Repair group 30; Servicing clutch Servicing clutch
Sharan 1996 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
satelettronica
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1 90 Nm + 1/4 turn (90 °) further

◆ Renew
◆ Counter-hold with 3415 to loosen and tighten
◆ Threads and shoulder must be free of oil and grease
2 Crankshaft toothed belt sprocket
3 15 Nm
4 Oil seal
◆ Renewing => Page 34
5 Sealing flange
◆ Must be located on dowel sleeves
◆ Clean sealing surface before installing
◆ Insert with silicone sealant
D 176 404 A2
=> Page 38
2.1 - Removing and installing sealing flanges and flywheel/drive plate 31

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
satelettronica
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.
6 Cylinder block
◆ Dismantling and assembling pistons and conrods
=> Page 48
7 60 Nm + 1/4 turn (90 °) further
◆ Renew
8 Flywheel/drive plate
◆ To remove or install flywheel, hold with counter-hold tool 3067
◆ Removing and installing drive plate =>Page 41
9 Intermediate plate
◆ Do not damage/bend when assembling
Sharan 1996 ➤
satelettronica
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
10 Sealing flange with oil seal

es, in part or in w
t to the co
◆ Only renew complete

◆ To remove and install, remove sump
=> Page 123
rrectness of i
◆ Before installing, remove oil residue from crankshaft journal using a clean cloth
◆ Do not additionally oil or grease the oil seal sealing lip
l purpos
◆ Use protective sleeve supplied when installing

◆ Remove protective sleeve first after sealing flange has been slid onto crankshaft journal
nf
ercia
orm
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Prote AG.
2.1 - Removing and installing sealing flanges and flywheel/drive plate 33

Sharan 1996 ➤
2.2 - Renewing crankshaft oil seal -belt pulley end-
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satelettronica
ility
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spec
t to the co
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cial p
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mer
atio
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c
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pyri by
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cted agen
◆ 2080 A Fitting sleeve
Prote AG.
◆ 3203 Oil seal extractor

◆ 3265 Fitting sleeve
◆ 3415 Counter-hold tool
Not illustrated, for vehicles with PTFE oil seals:
◆ T10053 Assembly device
Removing
- Removing ribbed belt and tensioning element => Page 28 .

- Remove toothed belt => Page 60 .
lk swage es n
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byV ua
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ran
tee 1996 ➤
o
4-cyl. injectionauthengine (5-valve), Mechanics - Edition o02.2005
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un
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spec
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rrectness
- -> Remove crankshaft toothed belt sprocket. To do this counter-hold sprocket with 3415.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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satelettronica
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> To guide seal extractor, screw centre bolt into crankshaft onto stop by hand.
- Unscrew inner part of the oil seal extractor 3203 two turns (approx. 3 mm) out of the outer part and lock with
knurled screw.
- -> Lubricate threaded head of oil seal extractor 3203, place it in position and exerting firm pressure screw
it as far as possible into oil seal.
- Loosen knurled screw and turn inner part against crankshaft until the oil seal is pulled out.
Installing
Note:
Gradual introduction of PTFE oil seals (Poly-Tetra-Fluor-Ethylen). Identifying characteristics: no annular spring,
sealing lip wider. The sealing lip of this oil ring must not be oiled or lubricated. A plain encased seal of older
construction (with annular spring) may be replaced with a PTFE oil seal, but not vice versa.
2.2 - Renewing crankshaft oil seal -belt pulley end- 35

Sharan 1996 ➤
AG. Volkswagen AG d
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spec
- Before installing, remove oil remains from crankshaft journal with a clean cloth.
t to the co
Installing seal with annular spring
rrectne
- Lightly oil sealing lip of oil seal.
- -> Fit guide sleeve from 2080 A onto crankshaft journal.
- Slide oil seal over guide sleeve onto crankshaft stub.
ss o
cial p
f inform
mer
satelettronica
atio
om
n
c
i
or
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te
sd
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pr
cum
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fo
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
- -> Press in seal with press sleeve from 3265. To do this use old central bolt -1- for crankshaft toothed belt
sprocket:
- Press in oil seal 2...3 mm.
Installing PTFE seal
- -> Fit guide sleeve T10053/1 onto crankshaft journal.

- Slide oil seal over guide sleeve onto crankshaft stub.
Sharan 1996 ➤
4-cyl. injection engine (5-valve), Mechanics - Edition
olkswagen AG
02.2005
en AG. V ag does
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b ara
ed nte
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spec
es, in part or in w
t to the co
- -> Press in oil seal onto stop using press sleeve T10053 and bolt T10053/2 (M16 x 1.5 x 60).
rrectness of i
Continuation for all seals l purpos
nform
mercia
at
om
ion
c
in t
r
satelettronica
o
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.
- -> Install crankshaft toothed belt sprocket and hold with counter-hold tool 3415.
- Tighten central bolt to 60 Nm and turn
90° (1/4 turn)
further (turning further can be done in several stages).
Note:
Thread and shoulder must be free of oil and grease.
- Install toothed belt and adjust timing => Page 60 .

- Installing ribbed belt and tensioning element =>
Page 28 .
2.2 - Renewing crankshaft oil seal -belt pulley end- 37

Sharan 1996 ➤
2.3 - Removing and installing sealing flange -belt pulley end-
AG. Volkswagen AG d
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satelettronica
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c
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◆ 2080 A Fitting sleeve cop Vo
by lksw
◆ 3415 Counter-hold tool cted agen
Prote AG.
◆ D176 404 A2 Silicone sealant
◆ Hand drilling machine with plastic brush insert
◆ Protective glasses
◆ Flat scraper
Sharan 1996 ➤
Removing

- Remove toothed belt => Page 60 .
- -> Remove crankshaft toothed belt sprocket. To do this counter-hold sprocket with 3415.
- Remove sump => Page 123 .
- Unbolt sealing flange.
- Take off sealing flange, release using
en AG. V
olkslight
wageblows
n AG with a rubber headed hammer if necessary.
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- Remove sealant residue on cylinder block with a flat scraper.

rrectness of i
- Cover seal with a clean rag.

- -> Remove sealant remains on sealing flange with a rotating plastic brush (wear protective goggles).
l purpos
- Clean sealing surface, must be free of oil and grease.

nform
ercia
Installing
m
Notes:
a
com
tion in
◆ Note the use by date of the sealant.

r
te o
thi
◆ The sealing flange must be installed within 5 minutes of applying the silicone sealant.
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Prote AG.
- -> Cut off tube nozzle at forward marking (nozzle approx. 3 mm ø).
- Apply silicone sealing compound, as shown, to clean sealing surface of the sealing flange. Sealing com‐
pound bead must be:
- 2...3 mm thick.
2.3 - Removing and installing sealing flange -belt pulley end- 39

AG. Volkswagen AG d
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V gu
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Sharan 1996 ➤ ut
ho eo
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a
4-cyl. injection engine (5-valve),s Mechanics - Edition 02.2005
s c
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nl
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du
- and run on inside of bolt holes -arrows-.
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Notes:
ility
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◆ The sealing bead must not be thicker, otherwise excessive sealant may drip into the oil sump, the intake
, is n
h re
pipe oil strainer may be blocked and it could also drip onto the sealing surface of crankshaft seal.
hole
spec
◆ Cover the sealing surface of the oil seal with a clean cloth before applying the sealant.
es, in part or in w
t to the co
- Fit sealing flange immediately and lightly tighten all bolts.
Note:
rrectness of i
Use guide sleeve from 2080A to fit sealing flange with the oil seal already installed.
l purpos
- Tighten sealing flange securing bolts diagonally.
Tightening torque:15 Nm
nf
ercia
- Remove excess sealant
or
- Install sump => Page 123 .
m
m
atio
om
n in
Note:
or c
thi
e
After installing, the sealant must be allowed to dry for approx. 30 minutes before engine oil is replenished.
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Prote AG.
- -> Install crankshaft toothed belt sprocket and hold with counter-hold tool 3415.
- Tighten new central bolt to 90 Nm and turn
90° (1/4 turn)
Note:
Thread and shoulder must be free of oil and grease.

Page 28 .
2.4 - Removing and installing drive plate
Sharan 1996 ➤
Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
◆ VW 558 Retainer
◆ Hexagon bolt M8x45 and two M10 hexagon nuts
◆ Depth gauge
Loosening and tightening drive plate
satelettronica
AG. Volkswagen AG d
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- -> sSecure counter-hold tool VW 558 to the drive plate with
s c a hexagon bolt M8x45. Place two M10 hexagon
nuts between counter-hold tool and drive plate.
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nl
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Position of counter-hold tool:

erm
ab
A - To loosen
ility
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B - To tighten
wit
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- Loosen drive plate bolts.

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
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ate
do
priv
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Installing drive plate
Co
Cop py
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- -> Locate drive plate and packing plate with recesses -1-.
yri
p by
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- Fit new bolts -3- and tighten to
lksw
cted agen
Prote AG.
2.4 - Removing and installing drive plate 41

Sharan 1996 ➤
30 Nm.
- -> Check dimension -a- at three points and calculate average.

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

en AG. V
olblock.
kswagen AG
wag does
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satelettronica
If the specification is not attained: byV gu
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- -> Remove drive plate again and fit shim -2-. Tighten bolts again to
l purpos
30 Nm.
- Tighten bolts to 60 Nm and turn
nform
ercia
90° (1/4 turn)

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Sharan 1996 ➤
3 - Removing and installing crankshaft

3.1 - Removing and installing crankshaft
satelettronica
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nf
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Notes:
or
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◆ Before removing the crankshaft, ensure that a suitable surface is prepared to ensure that the sender wheel
r
rp
cu
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(item 8 ) is not damaged or lies against any other item.

f
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C py
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1 Oil pump with sprocket
by lksw
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Prote AG.
◆ With pressure relief valve of 12 bar
◆ Before installing, check that both dowel sleeves for centralizing oil pump/cylinder head are fitted
=> Page 106
3.1 - Removing and installing crankshaft 43

Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
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2 15 Nm rise nte
tho eo
3 Chain sprocket
ss au ra
c
◆ For oil pump drive
ce
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un
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◆ Check for wear

an
d
itte
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4 Bearing caps 1, 2, 4 and 5

erm
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ility
◆ For bearing cap without oil groove

ot p
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◆ For cylinder block with oil groove

is n
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◆ Do not interchange used bearing shells (mark)

ole,
Vehicles 06.00 ▸
spec
◆ Classification for ordering spare parts =>Page 47 , Fig. 1

t to the co
5 65 Nm + 1/4turn (90 °) further

◆ Renew
◆ Threaded along complete length (screw)
rrectne
◆ Tighten to 65 Nm when measuring radial clearance

ss o
cial p
f inform
mer
atio
om
n
c
i
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n thi
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sd
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pr
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fo
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t.
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Cop py
t. rig
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c by lksw
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Prote AG.
Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
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tho eo
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6 Bearing cap
y li
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ab
◆ Bearing cap 1: Pulley end

ility
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◆ Bearing cap 3 with recesses for thrust washers

wit
, is n
◆ Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side
h re
hole
7 Bearing shell 3
spec
es, in part or in w
◆ For bearing cap without oil groove

t to the co
◆ For cylinder block with oil groove

◆ Do not interchange used bearing shells (mark)
Vehicles 06.00 ▸
rrectness of i
◆ Classification for ordering spare parts =>Page 47 , Fig. 1

8 Sender wheel
l purpos
◆ Renew
◆ For engine speed sender (G28)
nform
ercia
◆ Can only be installed in one position. Holes are off-set

m
at
om
ion
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for
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t.
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Cop py
t. rig
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Vo
co lksw
by
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Prote AG.

Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
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rise nte
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es, in part or in w
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9 10 Nm + 1/4 turn (90 °) further
◆ Renew
rrectness of i
10 Thrust washer
l purpos
◆ For bearing 3 bearing cap

◆ Note fixing arrangement
nform
ercia
11 Crankshaft
◆ Axial clearance new: 0.07...0.23 mm
m
a
com
ti
Wear limit: 0.30 mm

on in
◆ Check radial clearance with Plastigage

r
te o
thi
New: 0.01...0.04 mm
s
iva
do
Wear limit: 0.15 mm

r
rp
cum
◆ Do not rotate the crankshaft when checking the radial clearance

fo
en
g
◆ Crankshaft dimensions
n
t.
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=> Page 47 C py
t. rig
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pyri by
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by
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Prote AG.
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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rise nte
tho eo
au ra
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ce
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un
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an
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ility
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spec
t to the co
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mer
atio
-> Fig. 1 Upper crankshaft bearing identification
m
satelettronica
o
n
c
i
or
n thi
te
sd
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Upper bearing shells of the proper thickness are allocated to the cylinder block at the factory. Colour markings
i
o
pr
cum
are used to identify the bearing shell thickness
r
fo
en
ng
t.
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op
Note: C py
t. rig
gh ht
pyri by
Vo
Arrow points in direction of travel.
co lksw
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cted agen
Prote AG.
Letters on the lower sealing surface of the cylinder block identify which bearing thickness must be inserted at
which position
3.2 - Colour markings
Letter on Colour of bearing

cylinder block
S = black
R = red
G = yellow
- The lower crankshaft bearing shells are always supplied as a spare part with the colour marking "yellow".
3.3 - Crankshaft dimensions
Note:
Dimensions given in mm.
Honing Main journal - ø Conrod journal- ø

dimension
Engine code Engine code AWC
AJH

Sharan 1996 ➤
Basic -0.022 -0.017 -0.022

dimension 54.00 54.00 47.80
-0.042 -0.037 -0.042
1st undersize -0.022 -0.017 -0.022
53.75 53.75 47.55
-0.042 -0.037 -0.042
2nd undersize -0.022 -0.017 -0.022
53.50 53.50 47.30
-0.042 -0.037 -0.042
3rd undersize -0.022 -0.017 -0.022
53.25 53.25 olkswagen AG 47.05
-0.042 w en AG. V
ag-0.037 does -0.042
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4 - Dismantling and assembling
ss pistons and conrods
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4.1 - Dismantling and assembling pistons and conrods

itte
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ility
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satelettronica
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
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s
iva
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fo
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t.
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Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.
Note:
Sharan 1996 ➤
When stripping and assembling the engine it should be secured to the engine frame with engine and gearbox
1 Piston ring
◆ Offset gaps by 120 °
◆ Remove and install with piston ring pliers
◆ "TOP" faces towards piston crown
◆ Checking ring gap=> Fig. 1
◆ Checking ring to groove clearance
=> Fig. 2
◆ 2 or 3 part oil scraper ring, mixed installations permissible
AG. Volkswagen AG d
agen oes
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ility
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satelettronica
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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
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by c lksw
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Prote AG.
2 Piston
◆ Checking => Fig. 3
◆ Mark installation position and cylinder number
◆ Arrow on piston crown points to pulley end
◆ Install using piston ring clamp
3 Conrod
◆ Only renew as a set
◆ Installation position:
Marking -A- faces towards pulley end
◆ Mark cylinder number -B-
4 Conrod bearing cap
◆ Installation position:
4.1 - Dismantling and assembling pistons and conrods 49

Sharan 1996 ➤
Marking -A- faces towards pulley end
◆ Mark cylinder number -B-
AG. Volkswagen AG d
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satelettronica
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nl
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du
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ab
ility
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, is n
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spec
es, in part or in w
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rrectness of i
l purpos
nform
mercia
at
om
ion
5 30 Nm + 1/4 turn (90 °) further

c
in t
or
◆ Renew
his
ate
do
riv
◆ Oil threads and contact surface

p
cum
◆ To measure radial clearance tighten to 30 Nm but not further

for
en
ng
6 Pressure relief valve, 27 Nm

t.
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◆ Opening pressure: 1.3...1.6 bar
. C rig
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rig by
7 Oil spray jet copy Vo
by lksw
cted
◆ For piston cooling
agen
Prote AG.
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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d b ara
rise nte
tho eo
au ra
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un
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an
d
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ab
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ility
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satelettronica
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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
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s
iva
do
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fo
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8 Bearing shell
n
t.
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◆ Note installation position C py
t. rig
gh
◆ Do not interchange used bearing shells
ht
pyri by
◆ Ensure retaining lugs fit tightly in recesses
co Vo
by lksw
cted agen
◆ Axial clearance Prote AG.
New: 0.10...0.31 mm
Wear limit: 0.40 mm
◆ Check radial clearance with Plastigage:
New: 0.01...0.05 mm
Wear limit: 0.12 mm
Do not rotate crankshaft when checking radial clearance
9 Cylinder block
◆ Checking cylinder bores
=>Fig. 4
◆ Piston and cylinder dimensions
=>Page 55
10 Conrod bolt
◆ Renew

Sharan 1996 ➤
satelettronica
lkswage es n
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spec
t to the co
rrectne
11 Circlip
s
12 Piston pin
s o
cial p
f
◆ If difficult to remove, heat piston to 60 °C
inform
◆ Remove and install with drift VW 222a
mer
atio
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Sharan 1996 ➤
-> Fig. 1 Checking piston ring gap
◆ Feeler gauges
Test sequence
- Push ring squarely from above down to approx. 15 mm from bottom end of cylinder.
Piston ring Gap

New Wear
limit
Compression rings mm 0.15...0.40 0.80
Oil scraper ring mm 0.25...0.50 1.0
satelettronica
AG. Volkswagen AG d
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-> Fig. 2 Checking ring to groove clearance

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is n
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spec
t to the co
◆ Feeler gauges
Test sequence
rrectne
- Clean ring groove before checking.

ss o
cial p
f in
Piston ring Clearance

form
mer
New Wear
atio
m
limit
o
n
c
i
or
Compression rings mm 0.02...0.07 0.12

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Prote
cted 4.1 - Dismantling and assembling pistons and conrods
AG.
agen
Sharan 1996 ➤
Piston ring Clearance

Oil scraper ring mm 0.02...0.06 0.12
-> Fig. 3 Checking piston
satelettronica
◆ Micrometer 75...100 mm
Test sequence
AG. Volkswagen AG d
agen oes
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- Take measurement about 10 mm from lower edge of pistonby
Vol
skirt and offset 90 °to piston
not
gupin axis.
ara
ed
ris nte
o
Deviation from specification aut
h eo
ra
max. 0.04 mm. ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
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, is n
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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
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Cop py
-> Fig. 4 Checking cylinder bores
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
◆ Internal dial gauge 50...100 mm
Sharan 1996 ➤
AG. Volksw-
a gEdition
e nA 02.2005
n G do
wage es n
olks
Test sequence by
V ot g
ua
ed ran
oris tee
- Take measurements at right angles -A- and -B- ata3
ut positions.
h or
ac
ss
ce
le
Deviation from specification
un
pt
an
d
max. 0.10 mm.
itte
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erm
ab
ility
Note:
ot p
wit
is n
h re
Measuring the cylinder bores must not be done when the cylinder block is mounted on a repair stand with
ole,
spec
adapter bracket VW 540, as incorrect measurements would then be possible.
t to the co
4.2 - Piston and cylinder dimensions
rrectne
Honing dimension Piston - ø Cylinder bore - ø
ss
Basic dimen. mm 80.9651) 81.010
o
cial p
f in
1st oversize mm 81.4651) 81.510
form
mer
atio
m
1) Dimension without graphite coating (thickness 0.02 mm).

o
n
c
i
The graphite coating wears away.
or
n thi
satelettronica
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.

Sharan 1996 ➤
15 - Cylinder head, Valve gear
1 - Removing and installing cylinder head

1.1 - Removing and installing cylinder head
Notes:
◆ When you install an exchange cylinder head with fitted camshaft, you must oil the contact surfaces between
the bucket tappets and the running surfaces of the cams before installing the cylinder head cover.
◆ The plastic packing pieces for protecting the open valves must not be removed until immediately before
fitting cylinder head.
◆ If the cylinder head is replaced, all the coolant in the system must also be renewed.
Removing and installing intake manifold:

=> Repair group 24; Servicing injection system; Removing and installing parts of injection system Servicing
injection system Removing and installing parts of injection system
Checking compression pressures => Page 75
satelettronica
AG. Volkswagen AG d
agen oes
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V gu
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or eo
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un
pt
an
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erm
ab
ility
ot p
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is n
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spec
t to the co
rrectness o
cial p
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mer
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n
c
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te
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Cop py
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Vo
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by c lksw
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Prote AG.
56 15 - Cylinder head, Valve gear

Sharan 1996 ➤
1 Cap
◆ Renew seal if damaged
2 Gasket
◆ Renew if damaged
3 Connecting hose
◆ To crankcase breather pipe
4 Cylinder head cover
5 Cylinder head cover gasket
◆ Before installing, seal transition points between bearing cap and cylinder head as well as between chain
tensioner and cylinder head => Page 86 , fig. 4 and
6 Oil deflector
Above inlet camshaft
lkswage es n
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byV ua
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a ac
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satelettronica
ce
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un
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an
d
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rm
ab
pe
ility
ot
wit
, is n
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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
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7 Cylinder head
◆ Check for distortion => Fig. 1
=> Page 68
◆ Reworking sealing surface
=> Page 85 , Fig. 1
◆ After replacing renew the complete coolant
8 Intake manifold gasket
1.1 - Removing and installing cylinder head 57

Sharan 1996 ➤
◆ Renew
◆ Note installation position AG. Volkswagen AG d
agen oes
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9 Cylinder head gasket d by V gu
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◆ Metal gasket thori
eo
◆ Renew s au ra
c
◆ If replaced renew the complete s
ce
e
nl
coolant
pt
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Identification: Part No. must be readable from inlet side
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
satelettronica
om
ion
c
in t
or
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ate
do
priv
cum
for
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Cop py
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pyri by
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Prote AG.
10 Toothed belt
◆ Check for wear
◆ Do not kink
=> Page 60
11 Exhaust manifold gasket
◆ Renew
◆ Note fitting position
12 Cylinder head bolt
◆ Renew
◆ Sequence when loosening and tightening => Page 68 , Removing and installing cylinder head
13 10 Nm
14 Gasket

Sharan 1996 ➤
. Volkswagen AG
gen AG does
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◆ Renew if damaged y V olk not
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15 Breather housing ris ed
nte
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◆ To remove turnaut breather housing to left ra
c
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ce
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nl
pt
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itte
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erm
ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
-> Fig. 1 Checking cylinder head for distortion

m
at
om
ion
c
in t
r
satelettronica
o
his
ate
do
riv
◆ Straight edge
p
cum
or
◆ Feeler gauges
f
en
ng
t.
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op py
Max. permissible distortion: 0.1 mm
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
1.2 - Removing, installing and tensioning toothed belts
satelettronica
lkswage es n
o ot g
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tho
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du
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ab
ility
◆ 10-222 A Support bracket
ot p
wit
◆ 10-222 A/5 Legs

, is n
h re
(Engine code AJH)

hole
spec
◆ 10-222 A/12 Shackle

es, in part or in w
(Engine code AWC)

t to the co
◆ 10-222 A/14 and 10-222 A/15 Legs

(Engine code AWC)
◆ T10092 Tensioning bolt
rrectness of i
◆ T40011 Locking pin

l purpos

nform
ercia
◆ D 000 600 A2 Locking fluid

◆ Bolts M8x35 Qty. 2 (engine code AWC)
m
at
om
ion
Removing
c
in t
or
his
ate
do
riv
- Note safety precautions before starting work => Page 182 .

p
cum
for
en
ng
t.
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Cop py
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Prote AG.
Sharan 1996 ➤
- Observe rules for cleanliness => Page 183 .
AG. Volkswagen AG d
Vehicles with engine code AWC lksw
agen oes
not
V o gu
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- First check whether a coded radio is fitted.
rised If this is the case obtain the anti-theft ntecoding.
- Remove battery. tho eo
s au ra
c
s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
- Remove air pipe between turbocharger and charge air cooler => Page 225 , Removing and installing parts
of charge air cooling: engine code AJH
rrectness of i
l purpos
nf
ercia
or
satelettronica
m
m
atio
om
n in
or c
thi
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sd
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f
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pyri by
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by c lksw
cted agen
Prote AG.
- -> Remove the securing screws -arrows- for bracket for charge air system air pipe from the sump.

- Remove toothed belt guard - upper part.
- Mark D.O.R. of toothed belt.
1.2 - Removing, installing and tensioning toothed belts 61

Sharan 1996 ➤
- -> Set camshaft sprocket to TDC No. 1 cylinder by turning
agen
AG.the
Volkcrankshaft.
swagen AG Mark on camshaft sprocket must
does
align with mark on cylinder head cover. Volksw not
g by ua
ed ran
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th or
au ac
ss
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
- -> Remove vibration damper/belt pulley.
ss
o
cial p
f inform
mer
atio
m
satelettronica
o
n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
- -> Fit engine support bracket 10-222 A with legs 10-222 A/5.
- Secure legs 10-222 A/5 using body bolts -arrows-.

- Insert securing hook of support bracket 10-222 A in lifting eye on right of cylinder head and take up weight
of engine.
- Remove both outer bolts of battery tray.

Sharan 1996 ➤
- -> Assemble engine support bracket 10-222 A with legs 10-222 A/14 and 10-222 A/15 as shown.
satelettronica
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
- -> Bolt leg 10-222 A/14 to battery tray with bolts M8x35 -arrows-.
an
d
itte
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Tightening torque: 25 Nm
rm
ab
pe
ility
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, 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
- -> Insert shackle 10-222 A/12 in lifting eye on right of cylinder head.
r
te o
- Hook securing hook of engine support 10-222 A in shackle 10-222 A/12 and take up weight of engine.
thi
s
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rp

um
fo
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t.
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op
- Remove pendulum support. C py
t. rig
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pyri by
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by c lksw
cted
agen
Prote AG.
bar, wishbone

Sharan 1996 ➤
- -> Remove right assembly mounting securing bolts -1-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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satelettronica
or eo
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aut ra
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pt
du
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ility
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, is n
- -> Remove bolts and nuts from engine mounting -arrows- and remove mounting complete.
h re
- Lift the engine as far as is possible with the support bracket.

hole
spec
- Remove engine mounting from cylinder block and lift out upwards.
es, in part or in w
- Remove toothed belt guard centre and lower parts.

t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
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f
en
ng
t.
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op
- -> Screw tensioning bolt T10092 into toothed belt tensioning element.
C py
t. rig
gh
- Align pressure piston using pointed pliers or thin wire before tensioning. (Hole in pressure piston must align
ht
pyri by
Vo
o
with hole in housing.) by c lksw
cted agen
- Tension piston of tensioning element just enough that the piston can be locked with locking pin T40011.
Prote AG.
- Remove toothed belt.
- Turn crankshaft back slightly.
Installing
Note:
When turning the camshaft the crankshaft must not be at TDC. Danger of damage to valves/piston crown.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
nte Sharan 1996 ➤
d b ara
rise
4-cyl.auinjection
tho
engine (5-valve), Mechanics -e oEdition ra 02.2005
ss c
A - Toothed belt completely removed
ce
le
un
pt
If toothed belt has only been removed from camshaft => Page 66 .
an
d
itte
y li
Conditions
rm
ab
pe
ility
• The pistons must not be positioned at TDC.
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
satelettronica
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Work sequence
- -> Bring mark on camshaft in line with the mark on cylinder head cover.
- Place toothed belt on crankshaft pulley and coolant pump (observe DOR).
- Install centre and lower parts of toothed belt guard. (Insert securing bolts with locking fluid "D 000 600 A2".)
- Install vibration damper/belt pulley (fits in one position only).


Sharan 1996 ➤
- -> Turn crankshaft to TDC No. 1 cylinder.
- Install pendulum support:
subframe, anti-roll bar, wishbone Servicing front wheelAsuspension
G. VolkswagenIA-GAssembly overview, subframe, anti-roll
bar, wishbone lksw
agen does
no
Vo t gu
by ara
ed
Vehicles with engine code AJH ho
ris nte
eo
aut ra
ss c
- Install air pipe between turbocharger and charge air cooler => Page 225 , Removing and installing parts
ce
e
nl
of charge air cooling: engine code AJH.
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
satelettronica
nf
ercia
orm
m
atio
m

o
n in
or c
thi
e
- -> Install air pipe bracket on sump.

t
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
yri
- Place toothed belt on the camshaft sprocket and tension => Page 67 . p by
co Vo
by lksw
cted agen
Prote AG.
B - Toothed belt only taken off camshaft sprocket
- -> Bring mark on camshaft in line with the mark on cylinder head cover.
- Turn crankshaft to TDC No. 1 cylinder.
- Place toothed belt on the camshaft sprocket and tension => Page 67 .

n AG. Volkswagen AG do Sharan 1996 ➤
lkswage es n
4-cyl. injection by V engine (5-valve), Mechanics
o ot g
uara - Edition 02.2005
ed nte
oris
Tensioning toothed belt au
th eo
ra
ss c
ce
le
un
pt
an
Conditions
d
itte
y li
erm
ab
ility
• The engine must not be more than warm to the touch.
ot p
• Engine is at TDC No. 1 cylinder.
wit
is n
h re
ole,
spec
Work sequence
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
satelettronica
um
r
fo
en
ng
- -> Tension toothed belt by pulling out locking pin T40011 and removing tensioning bolt T10092.
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- Turn crankshaft two full turns and check whether camshaft and crankshaft marks align with their reference
points.
Continuation, installing toothed belt
- Install upper toothed belt guard.
AJH
- Install battery.

Sharan 1996 ➤
- Fit engine mounting to cylinder block.
- Install engine assembly mounting.
Tightening torque => Page 14 .
Page 28 .
1.3 - Removing and installing cylinder head
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
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
op
◆ 3070 Fitting tool with guide pins C py
t. rig
◆ 3452 Tool or T10070 socket insert
gh ht
pyri by
◆ T10092 Tensioning bolt
co Vo
by lksw
cted
◆ T40011 Locking pin
agen
Prote AG.

Sharan 1996 ➤
olkswagen AG
en AG. V
◆ V.A.G 1331 Torque wrench (5...50 Nm) olkswag does
not
yV gu
db ara
rise nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
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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
satelettronica
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.
◆ VAS 5024 Spring-type hose clip pliers
Prerequisite
• The engine must be no more than warm to touch.
Work sequence
- Observe rules for cleanliness => Page 183 .
- With the ignition switched off disconnect battery earth strap.

Sharan 1996 ➤
- -> Disconnect fuel supply and return pipes and the pipe from the activated charcoal filter solenoid valve 1 -
arrows- at fuel rail.
Warning!

- Seal the pipes so that the fuel system is not contaminated by dirt etc.
satelettronica
- -> Disconnect throttle cable at throttle valve control part cable disc and support bracket -arrows- (do not
remove locating clip on support bracket).
Note:
- Pull vacuum hose off combi-valve. agen

AG. Volkswagen AG d
oes
olksw not
byV gu
Vehicles with engine code AWC rised ara
nte
ho eo
aut ra
- Remove intake hose:=> Page 228 , Removing
s and installing parts of charge air cooling: engine code
s c AWC.
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
- -> Pull off 6-pin connector (grey) off EGR valve (N18) -arrow-.
nform
ercia
m
a
com
tion in
r
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thi
s
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cum
fo
en
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t.
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Cop py
ht. rig
rig ht
py by

co Vo
by lksw
cted agen
Prote AG.
Sharan 1996 ➤
Note:
- Pull vacuum hose off EGR valve.
- Remove intake manifold.
satelettronica
injection system Removing andaginstalling
en AG. V parts
olkswagenof
AGinjection
doe system
ksw s no
Vol t gu
Note: e d by ara
nte
ris
ho eo
Seal the intake sports
au
t
in cylinder head with a clean cloth. ra
c
s
ce
e
- -> Remove air guide trim -1- and battery trim -2-.
nl
pt
du
- Remove the pipe for the crankcase breather.

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
- -> Remove the securing bolts from heat shield (exhaust side) -arrows-.
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.
- -> Remove the three exhaust gas turbocharger/exhaust manifold securing bolts -1-.
- Now remove the lateral coolant hose connection on the cylinder head.

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
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erm
ab
satelettronica
ility
ot p
- -> Set camshaft sprocket to TDC No. 1 cylinder by turning the crankshaft. Mark on camshaft sprocket must
wit
, is n
align with mark on cylinder head cover.
h re
- Take toothed belt off camshaft toothed belt sprocket
hole
spec
=> Page 60 .
es, in part or in w
t to the co
- Remove ignition coils with output stages:
=> Repair group 28; Servicing ignition; Removing and installing parts of ignition Servicing ignition Removing
rrectness of i
and installing parts of ignition
l purpos
- Remove cylinder head cover.

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.
- -> Loosen cylinder head bolts using key 3452 or socket T10070 in the sequence given and then remove
completely.
Note:
Use tool 3452 or socket insert T10070 for Polydrive cylinder head bolts.
- Carefully lift cylinder head off.
Note:
To prevent dirt getting into the charge air system, cover the exhaust gas turbocharger with a clean cloth.

Sharan 1996 ➤
Installing
Notes:
◆ There must be no oil or coolant in the cylinder head bolt pockets in the cylinder block.
◆ Only remove the new cylinder head gasket from its packing immediately before installing.
◆ Handle the new gasket with extreme care. Damaging will lead to leaks.
- Place a clean cloth in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and
piston.
- Also prevent dirt and emery cloth particles from getting into the coolant.
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
satelettronica
ility
ot p
- Carefully clean cylinder head and cylinder block sealing surfaces. Thereby ensuring that no scoring or
wit
, is n
h re
scratches are formed (when using abrasive paper the grade must not be less than 100).
hole
- Carefully remove metal particles, emery remains and cloths.
spec
- -> Turn crankshaft to TDC No. 1 cylinder.
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
. rig
- -> To centralize screw guide pins from 3070 into holes for cylinder head bolts 8 and 10.
t
gh ht
yri by
- Fit new cylinder head gasket. Lettering (Part No.) must be readable.
cop Vo
by lksw
- Fit cylinder head, screw in 8 remaining cylinder head bolts and tighten by hand.
cted agen
Prote AG.
- Remove guide pins with removal tool from 3070. To do this turn removal tool anti-clockwise, until the pins
are free.
- Fit remaining cylinder head bolts and tighten hand-tight.

Sharan 1996 ➤
- -> Tighten cylinder head in tightening sequence as follows:
- Pretighten all bolts to 40 Nm.
- Then tighten all bolts a 1/4 turn (90 °) further using a rigid wrench.
- Then tighten all bolts again a 1/4 turn (90 °) further.
The rest of the assembly is basically a reverse of the dismantling sequence.
- Install cylinder head cover.

- Install ignition coils and tighten to
10 Nm. n AG. Volkswagen AG do
- Install toothed belt and adjust timing => Pagel wag. e
ks60 es n
Vo ot gu
y
db ara
ise nte
Filling with new coolant => Page 152 .thor eo
au ra
c
ss
ce
le
un
pt
an
d
itte
- Adjusting accelerator cable =>Page 195 , Servicing accelerator mechanism.
y li
erm
ab
- Interrogating and erasing fault memory:
ility
ot p
wit
is n
h re
ole,
spec
t to the co
satelettronica
rrectne
=> Repair group 01; Fault memory; Interrogating and erasing fault memory of engine control unit Fault memory
Interrogating and erasing fault memory of engine control unit
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
1.4 - Checking compression pressures
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
satelettronica
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.
◆ 3122 B Spark plug spanner

◆ V.A.G 1763 Compression tester with adapter V.A.G 1763/6
Check conditions
• Engine oil temperature must be at least 30 °C.

• The battery voltage must be at least 11.5 V.
• All electrical consumers, e.g. lights and rear window heating must be switched off.
• If the vehicle is equipped with an air conditioning system, this must be switched off.
Test sequence
- Remove fuse No. 14 from fuse holder.
1.4 - Checking compression pressures 75

Sharan 1996 ➤
-> Fuse holder for vehicles with engine code AJH.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
-> Fuse holder for vehicles with engine code
thor
AWC. eo
au ra
ss c
Note:
ce
e
nl
pt
du
an
itte
Removing fuse No. 14 interrupts the voltage supply to the injectors.
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
and installing parts of ignition spec
es, in part or in w
t to the co
- Remove spark plugs with spark plug socket and extension 3122B.
- Have a second mechanic operate the starter. (Also fully depress accelerator pedal in vehicles with engine
rrectness of i
code AJH.)
- Check compressions with compression tester V.A.G 1763 and adapter V.A.G 1763/6.
l purpos
Note:
nform
ercia
Using the compression tester => Operating instructions.

m
at
om
ion
- Operate starter until tester shows no further pressure increase.

c
in t
or
his
ate
do
riv
Compression pressure:
p
cum
for
en
g
New: 10...13 bar

n
t.
yi Co
op
Wear limit: 7.0 bar C py
t. rig
gh ht
pyri by
Vo
o
Permissible difference between all cylinders:
c by lksw
cted agen
max. 3 bar Prote AG.
- Install spark plugs with spark plug socket and extension 3122B and tighten to
30 Nm.
10 Nm.

Sharan 1996 ➤
Interrogating and erasing fault memory of engine control unit . Volkswag
n AG en AG
wage does
Volks not
gu
by ara
ed nte
ris
2 - Servicing valve gear au
tho eo
ra
c
ss
ce
le
2.1 - Servicing valve gear

un
pt
an
d
itte
y li
erm
ab
ility
ot p
Notes:
wit
is n
satelettronica
h re
ole,
◆ Cylinder heads which have cracks between the valve seats or between valve seat inserts and the spark
spec
plug thread can be used further without reducing service life, provided the cracks do not exceed a maximum
of 0.3 mm in width, or when no more than the first four spark plug threads are cracked.
t to the co
◆ After installing new bucket tappets the engine must not be started for approx. 30 minutes (otherwise valves
will strike pistons), then turn crankshaft two rotations.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.4 - Checking compression pressures 77

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
by
satelettronica
d ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
1 10 Nm
nf
ercia
2 Inlet camshaft
rm
m
atio
◆ Checking axial clearance => Fig. 2

om
n in

or c
thi
=> Page 96
te
sd
a
◆ Checking radial clearance with plastigage

iv
o
r
rp
cu
Wear limit: 0.1 mm

o
m
f
en
◆ Run-out: max. 0.01 mm

ng
t.
yi Co
op
3 Drive chain C py
t. rig
gh
◆ Before removing mark D.O.R. (installation position)
ht
pyri by
Vo
o
=> Page 96 Removing and installing camshafts by c lksw
cted agen
Prote
4 10 Nm
AG.

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
satelettronica
, 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
5 Chain tensioner
t.
yi Co
op py
. C rig
ht ht
◆ Only rotate engine with chain tensioner installed
rig by
opy Vo
◆ Secure with chain tensioner retainer 3366 before removing => Page 96 ; Removing and installing by c lksw
cted agen
camshafts
Prote AG.
◆ Seal transition points between chain tensioner and cylinder head

=> Fig. 5
6 Bonded rubber mounting
◆ Renew=> Page 96 , Removing and installing camshafts
7 Cylinder head
=> Page 68
◆ Reworking valve seats
=> Page 87
◆ Reworking sealing surface
=> Fig. 1
◆ Sealing transition points
=> Fig. 4 and Fig. 5
2.1 - Servicing valve gear 79

Sharan 1996 ➤
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
satelettronica
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
8 Valves
t.
yi Co
op py
◆ Do not rework only grinding-in is permitted t. C rig
gh ht
◆ Valve dimensions => Fig. 3 pyri by
Vo
o
by c
◆ Sodium-filled exhaust valves: Observe disposal instructions => Page 86
lksw
cted agen
Prote AG.
9 Oil seal
◆ Renewing=> Page 89
10 Hood
◆ For Hall sender
◆ When installing note fixing arrangement
11 Washer
◆ Conical
12 25 Nm

Sharan 1996 ➤
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
satelettronica
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
13 Hall sender (G40) housing

um
for
en
g
◆ Checking Hall sender:

n
t.
yi Co
Cop py
t. rig
gh
=> Repair group 28; Servicing ignition; Checking Hall sender Servicing ignition Checking Hall sender
ht
pyri by
Vo
co lksw
by
cted agen
14 10 Nm
Prote AG.
15 65 Nm
◆ Use counter-hold 3036 to loosen and tighten
16 Camshaft sprocket
The small web of the camshaft sprocket points outwards and the No. 1 Cyl. TDC marking is visible
17 Oil seal

Sharan 1996 ➤
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
satelettronica
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
18 Valve guide Prote AG.
◆ Checking => Page 102

19 Valve stem seal
20 Valve spring
◆ Removing and installing:
Cylinder head removed:
with valve spring depressor 3362 and thrust piece 3362/1
Cylinder head installed: => Page 103 , Renewing valve stem seals
21 Upper valve spring plate
22 Cotters
23 Bucket tappet
◆ Do not interchange
◆ With hydraulic valve clearance compensation
◆ Store with cam lobe contact surface downwards
◆ Before installing check camshaft axial clearance => Fig. 2
◆ Oil contact surface

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
satelettronica
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
ercia
24 Inlet camshaft bearing cap

m
◆ Observe installation position and installation sequence => Page 96 , Removing and installing cam‐
com
tion in
shafts
r
te o
thi
25 Double bearing cap

s
iva
do

r
rp
cum
fo
◆ Lightly coat contact surfaces with sealant "AMV 174 004 01" and observe installation position and in‐
en
ng
t.
stallation sequence => Page 96 , Removing and installing camshafts op
yi Co
◆ Seal transition points between double bearing cap and cylinder head
C py
t. rig
gh
=> Fig. 4
ht
pyri by
Vo
o
by c
26 Exhaust camshaft bearing cap
lksw
cted agen
Prote AG.
◆ Observe installation position and installation sequence => Page 96 , Removing and installing cam‐
shafts

Sharan 1996 ➤ AG. Volkswagen AG d
agen
Volks-w Edition 02.2005
oes
not
y gu
db ara
rise nte
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
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
satelettronica
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.
27 Exhaust camshaft
◆ Checking axial clearance => Fig. 2
=> Page 96
◆ Checking radial clearance with plastigage
Wear limit: 0.1 mm
◆ Run-out: max. 0.01 mm

Sharan 1996 ➤
-> Fig. 1 Reworking cylinder head sealing surface
The dimension for reworking is measured through the holes for the cylinder head bolts
a = minimum 139.2 mm
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
-> Fig. 2 Checking camshaft axial clearance
ss
a ac
ce
le
satelettronica
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
◆ VW 387 Universal dial gauge bracket
wit
, is n
◆ Dial gauge
h re
hole
spec
Test sequence
es, in part or in w
t to the co
Check with bucket tappets and chain removed and No. 2 and 4 bearing caps fitted.
rrectness of i
Wear limit: max. 0.2 mm
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.
-> Fig. 3 Valve dimensions
Note:
Valves must not be reworked. Only lapping-in is permitted.
Dimension Inlet valve Exhaust valve

øa mm 26.9 29.9
øb mm 5.963 5.943
c mm 104.84...105.34 103.64...104.14

Sharan 1996 ➤
α <° 45 45
Note:
Care must be taken when disposing of old sodium filled valves. They must be cut through in the centre of the
stem with a hacksaw. When doing this they must be perfectly dry (must not come into contact with water). The
valves prepared in this way can then be thrown into a bucket of water a maximum of ten at a time. When doing
this step back quickly because a sudden chemical reaction causes the sodium filling to burn. After this treatment,
the valves can be put in with the normal scrap.
satelettronica
-> Fig. 4 Sealing transition points between double bearing cap and cylinder head
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Special tools, workshop equipment, testers, measuring isedinstruments
b and auxiliary items required
ara
nte
or eo
h
ut ra
◆ D 454 300 A2 Sealant ss a c
ce
le
un
pt
- Carefully apply a thin coat of sealant "D 454 300 A2" to both edges of sealing surfaces between double
an
d
itte
bearing cap and cylinder head -arrows- using a small screwdriver.
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
-> Fig. 5 Sealing transition points between chain tensioner/cylinder head

thi
s
iva
do
r
rp
cum
fo
en
g
n
t.
yi Co
Cop py
t. rig
◆ D 454 300 A2 Sealant
gh ht
pyri by
Vo
o
by c lksw
cted agen
- Carefully apply a thin coat of sealant "D 454 300 A2" to both edges of sealing surfaces between chain
Prote AG.
tensioner/cylinder head -arrows- using a small screwdriver.

Sharan 1996 ➤
2.2 - Reworking valve seats
◆ Depth gauge
◆ Valve seat refacing tool
Work sequence
Notes:
◆ When repairing engines with leaking valves, it is not sufficient to replace or renew valve seats and valves.
It is also necessary to check the valve guides for wear. This particularly important on high mileage engines
=> Page 102 .
◆ The valve seats should only be reworked just enough to produce a perfect seating pattern. The maximum
permissible reworking dimension must be calculated before work is carried out. If the reworking dimension
is exceeded, the function of the hydraulic tappets can no longer be guaranteed and therefore the cylinder
head should be renewed.
- Remove camshafts => Page 96 .
The max. permissible reworking dimension is calculated as follows:
satelettronica
AG. Volkswagen AG d
agen oes
- Insert valve and press firmly against
Vol seat.
ksw not
gu
y
db ara
ise nte
Note: tho
r eo
s au ra
c
s
If the valve is to be renewed as part of a repair, use a new valve for the calculation.
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
ercia
- -> Measure distance between end of valve stem and upper edge of cylinder head.
m
- Calculate max. permissible reworking dimension from measured distance and minimum dimension.
at
om
ion
c
in t
r
Minimum dimension:
o
his
te
Outer inlet valves 34.0 mm

a
do
riv
Centre inlet valve 33.7 mm

p
cum
or
Exhaust valve 34.4 mm

f
en
ng
t.
yi Co
op py
Measured distance minus minimum dimension
t. C rig
gh ht
yri
= max. permissible reworking dimension. p by
co Vo
by lksw
cted agen
Prote AG.
Example:
- Measured distance 34.4 mm

Minimum dimension 34.0 mm
= max. perm. rework dimension* 0.4 mm
2.2 - Reworking valve seats 87

Sharan 1996 ➤
*) The max. permissible reworking dimension is shown on illustrations for reworking valve seats as
dimension "b".
-> Reworking inlet valve seat
a = 26.2 mm ø
b = Max. permissible reworking dimension*
c = 1.5... 1.8 mm
satelettronica
Z = Cylinder head lower edge
α = 45 °valve seat angle
β = 30 °upper correction angle
γ = 60 °lower correction angle
*) Calculating max. permissible reworking dimension => Page 87 .
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
-> Reworking exhaust valve seat

es, in part or in w
t to the co
a = 29.0 mm ø
b = Max. permissible reworking dimension*
rrectness of i
c = Approx. 1.8 mm
Z = Cylinder head lower edge
l purpos
α = 45 °valve seat angle

β = 30 °upper correction angle
γ = 60 °lower correction angle
nform
mercia
at
*) Calculating max. permissible reworking dimension => Page 87 .

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

Sharan 1996 ➤
2.3 - Renewing camshaft oil seal
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing and installing camshaft sprocket oil seal

nform
ercia
Removing seal on Hall sender => Page 92

m
a
com
ion in
r
te o
thi
◆ 2085 Oil seal extractor

s
iva
do
◆ 3036 Counter hold tool

r
rp
cum
◆ T10071 Puller
fo
en
g

n
t.
yi Co
op
◆ V.A.G 1332 Torque wrench (40...200 Nm) C py
t. rig
gh ht
pyri by
Vo
o
Removing oil seal on camshaft sprocket
c by lksw
cted agen
Prote AG.
2.3 - Renewing camshaft oil seal 89

Sharan 1996 ➤
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
hole
spec
es, in part or in w
t to the co
rrectness of i
satelettronica
l purpos
nform
ercia

m
at
om
io
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
- -> Set camshaft sprocket to TDC No. 1 cylinder by turning the crankshaft. Mark on camshaft sprocket must Cop py
t. rig
gh ht
yri
p by
o Vo
by c lksw
=> Page 60 . Prote
cted AG.
agen
- -> Remove camshaft sprocket. Counter-hold sprocket with 3036 when loosening the bolt.

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
- -> Screw camshaft sprocket securing thorbolt -arrow- into camshaft onto stop by hand,e o to guide seal extractor.
- Unscrew inner part of oil seal extractor
s au 2085 two turns (approx. 3 mm) out of the outer r a part and lock in
c
position with knurled screw. s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
satelettronica
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
- -> Lubricate threaded head of oil seal extractor, place it in position and exerting firm pressure screw it into
oil seal as far as possible.
m
at
om
- Loosen knurled screw and turn inner part of extractor against camshaft until oil seal has been extracted.
ion
c
in t
or
his
e
Installing
at
do
priv
cum
or
Note:
f
en
ng
t.
yi Co
op py
Introduction of PTFE oil seal (identifying characteristics: no annular spring, sealing lip wider). The sealing lip
t. C rig
gh ht
of this oil seal must not be oiled or lubricated. yri
p by
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- Before installing, remove oil remains from camshaft journal with a clean cloth.
- -> Fit assembly tool T10071/1 onto camshaft journal.
- Slide oil seal over assembly tool onto camshaft journal.
- Remove assembly tool.

Sharan 1996 ➤
- -> Press seal in onto limit stop with press sleeve T10071/3 and bolt T10071/4.
satelettronica
AG. Volkswagen AG d
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- -> Install camshaft sprocket.by When tightening camshaft sprocket
Vol
gu
ara
bolt hold sprocket with counter-hold 3036.
Torque setting: 65risNm
ed
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au ra
The rest of the assembly
ss is basically a reverse of the dismantling sequence. c
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Removing seal on Hall sender

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spec
es, in part or in w
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- -> Pull 3-pin connector off Hall sender -arrow-.
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pyri by
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Prote AG.

Sharan 1996 ➤
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Continuation for ed all vehicles
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- Remove au toothed belt guard - upper part. ra
c
ss
- Remove Hall sender housing.
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nl
- Remove washer and hood for Hall sender.
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nf
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satelettronica
orm
- -> Screw bolt 2085/1 into camshaft onto stop by hand, to guide seal extractor.
m
atio
m
- Unscrew inner part of oil seal extractor 2085 two turns (approx. 3 mm) out of the outer part and lock in
o
n in
c
position with knurled screw.

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- -> Lubricate threaded head of oil seal extractor, place it in position and exerting firm pressure screw it into
oil seal as far as possible.
- Loosen knurled screw and turn inner part of extractor against camshaft until oil seal has been extracted.
Installing

Sharan 1996 ➤
Note:
Introduction of PTFE oil seal (identifying characteristics: no annular spring, sealing lip wider). The sealing lip
of this oil seal must not be oiled or lubricated.
- -> Fit guide sleeve T10071/5 onto camshaft journal.

- Slide oil seal over assembly tool onto camshaft journal.
- Remove assembly tool.
AG. Volkswagen AG d
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- -> Press seal in onto limit stop using press sleeve T10071/3. To do this, use bolt M8 x 60 -1-.
wit
, is n
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- Insert Hall sender hood into notch in inlet camshaft.
hole
- Install washer (taper facing outwards) and tighten securing bolt to
spec
25 Nm.
es, in part or in w
t to the co
- Install housing for Hall sender and tighten to
10 Nm.
rrectness of i
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AJH nform
ercia

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- Install upper toothed belt guard.

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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.
- -> Reconnect connector on Hall sender -arrow-.


Sharan 1996 ➤
2.4 - Checking hydraulic bucket tappets
◆ Feeler gauge
◆ Wood or plastic wedge
Notes:
◆ Renew defective tappet complete (cannot be adjusted or repaired).

◆ Irregular valve noises when starting engine are normal.
Test sequence
- Start engine and run until the radiator fan has switched on once.
- Increase engine speed to about 2500 rpm for approx. 2 minutes.
If the hydraulic tappets are wstill

agennoisy, locate defective
AG. Volkswagen AG d
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- Remove pressure ris
ed hose between combi-valve and secondary
nte air pump motor at combi-valve and unclip
pressure hoseut from retainers.
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Note:
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=> Repair group 28; Servicing ignition; Removing and installing parts of ignition Servicing ignition Removing spec

t to the co

- Rotate crankshaft clockwise, until cam of the tappet to be checked is pointing upwards.
rrectne
- Determine play between cam and bucket tappet.

- If the play is in excess of 0.2 mm, renew bucket tappet. If the play is less than 0.1 mm or no play, proceed
with check as follows:
ss o
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f inform
mer
atio
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- -> Push bucket tappet down lightly with a wooden or plastic wedge. If when the bucket tappet is pushed
down a 0.2 mm thick feeler gauge can be pushed between the camshaft and bucket tappet, the bucket
tappet is to be replaced.
Note:
After installing new tappets the engine must not be started for approx. 30 minutes. Hydraulic compensation
elements must settle (otherwise valves will strike pistons).
2.4 - Checking hydraulic bucket tappets 95

Sharan 1996 ➤
2.5 - Removing and installing camshaft
satelettronica
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(with cylinder head installed)

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◆ 3036 Counter hold tool

h re
hole
◆ 3366 Retainer for chain tensioner

spec

es, in part or in w
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◆ AMV 174 004 01 Sealant
◆ D 454 300 A2 Sealant
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Removing
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Sharan 1996 ➤
AG. Volkswagen AG d
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- -> Set camshaft sprocket to TDC No. 1 cylinder by turning the crankshaft. Mark on camshaft sprocket must
s
iva
do

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- Remove pressure hose between combi-valve and secondary air pump motor at combi-valve and unclip
fo
en
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pressure hose from retainers.

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Note:
gh ht
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=> Page 60 .

- Remove camshaft sprocket. When loosening camshaft sprocket bolt counter-hold with 3036.
- Remove Hall sender housing.
- Remove washer and hood for Hall sender.
2.5 - Removing and installing camshaft 97

Sharan 1996 ➤
AG. Volkswagen AG d
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- -> Clean drive chain and camshaft chain sprocket in area of arrows on bearing caps and mark installation
nl
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position with a coloured mark.
an
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Notes:
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◆ Do not mark chain with a centre-punch mark, notch or similar!

h re
◆ The distance between both arrows or the coloured marks equals 16 rollers on the drive chain.
hole
spec
es, in part or in w
t to the co
rrectness of i
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- -> Secure chain tensioner with retainer for chain tensioner 3366.
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Note:
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Hydraulic chain tensioner can be damaged if chain tensioner retainer is overtightened.
p by
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Prote AG.
- -> First remove inlet and exhaust camshafts 3rd and 5th bearing caps.
- Remove double bearing cap.
- Remove both bearing caps at chain sprockets on inlet and exhaust camshafts.

Sharan 1996 ➤
- Remove chain tensioner securing bolts.
- Remove inlet and exhaust camshaft 2nd and 4th bearing caps using alternate and cross-over sequence.
- Remove chain tensioner for inlet and exhaust camshafts and retainer for chain tensioner 3366.
Installing
Notes:
. Volkswagen AG
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◆ When installing the camshafts the cams for No. 1 Cyl. must yV
olk point upwards. not
gu
◆ When installing the bearing caps, ensure that the cap risemarkings
d b
can be read from the inlet side
ara of the cylinder
nte
head. ut
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- Fit drive chain onto both camshafts relevant to the coloured markings.
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Notes:
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io
◆ -> If a new drive chain is used, the distance between notches -A- and -B- in camshafts must be 16 rollers
n
c
in t
or
of the drive chain.
his
te
◆ The illustration shows where on the sprockets the 1st and 16th rollers must be placed.
a
do
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◆ Notch -A- is offset slightly to the inside relative to chain roller -1-.
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cum
or
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f
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rig ht
py by
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by lksw
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Prote AG.
- -> Renew bonded rubber seal for chain tensioner and lightly coat hatched area with sealant "D 454 300 A2".
- Slide chain tensioner between drive chain.
- Oil running surfaces of both camshafts.
- Place camshafts with drive chain and chain tensioner in cylinder head.
- Tighten chain tensioner to
10 Nm
(take note of dowel sleeves).

Sharan 1996 ➤
- -> Tighten inlet and exhaust camshaft 2nd and 4th bearing caps using alternate and cross-over sequence
to
10 Nm
satelettronica
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spec
es, in part or in w
t to the co
rrectness of i
- -> Install both bearing caps at chain sprockets of inlet and exhaust camshafts. Check camshafts for correct
l purpos
positioning -arrows- and tighten bearing caps to

10 Nm
nform
ercia
(note dowel sleeves).

- Remove retainer for chain tensioner 3366.
m
a
com
tion in
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te o
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s
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fo
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co lksw
by
cted agen
Prote AG.
- -> Coat hatched area of double bearing cap lightly with sealant "AMV 174 004 01", install and tighten to
10 Nm
- Install remaining bearing caps and tighten to
10 Nm

n AG. Volkswagen AG dSharan 1996 ➤
lkswage oes
not
4-cyl. injection engined (5-valve),
by
Vo Mechanics - Edition gu 02.2005
ara
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ris
(take note of dowel sleeves). tho eo
au ra
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un
pt
an
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itte
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ab
ility
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wit
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ole,
spec
t to the co
rrectness
- -> Install camshaft sprocket (narrower shoulder facing outwards and TDC mark visible) and tighten securing
o
cial p
f i
bolt to
nform
65 Nm
mer
atio
(use counter-hold tool 3036).
om
n
c
i
or
n thi
te
sd
iva
o
pr
satelettronica
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> Recheck position of camshafts relative to one another -arrows-.

- Install washer (taper facing outwards) and tighten securing bolt to
25 Nm.
- Install housing for Hall sender and tighten to
10 Nm.
- Install cylinder head cover.
10 Nm.
Note:
After installing new tappets the engine must not be started for approx. 30 minutes. Hydraulic compensation
elements must settle (otherwise valves will strike pistons).

Sharan 1996 ➤
2.6 - Checking valve guides
◆ VW 387 Universal dial gauge bracket

◆ Dial gauge
Test sequence
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
- -> Insert new valve into guide
ss until end of valve stem is flush with end of guide.
Due to the slight difference
in stem dimensions, ensure that only an inlet valve is used in the inlet guide and an exhaust valve in the
ce
le
un
pt
exhaust guide.
an
d
itte
y li
- Determine rock.
rm
ab
Wear limit: 0.8 mm

pe
ility
ot
wit
, is n
If rock tolerance is exceeded:

h re
hole
spec
- Replace cylinder head.

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
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pyri by
Vo
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by
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Prote AG.

wage es n
yV
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b ua
4-cyl. injection enginerise(5-valve),
d Mechanics - Edition 02.2005 ran
tee
tho
u or
2.7 - Replacing valve stem seals ss
a ac
ce
le
un
pt
an
d
itte
y li
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ab
ility
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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
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fo
satelettronica
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
(with cylinder head installed)
◆ 3122 B Spark plug spanner

◆ 3362 Valve spring compressor and press piece 3362/1
◆ 3364 Puller
◆ VW 653/3 Pressure hose
2.7 - Replacing valve stem seals 103

Sharan 1996 ➤
◆ 3365 Valve stem seal fitting tool
Removing
- Remove camshafts => Page 96 .

- Remove the bucket tappets and place them with the contact surface downwards. When doing this ensure
that the tappets are not interchanged.
n AG. Volkswagen AG
- Remove spark plugslkswith
wage spark plug socketdoand
es n extension 3122B.
- Set piston of appropriate
db
yV
o
cylinder to "bottom deadot g
centre".
ua
r
satelettronica
e an
ris tee
tho or
au ac
ss
ce
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nl
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hole
spec
es, in part or in w
t to the co
rrectness of i
- -> Screw pressure hose VW 653/3 into the spark plug thread.
l purpos
- Insert thrust piece 3362/1 in valve spring depressor 3362.

- Mount valve spring depressor 3362 with securing bolts screwed in on cylinder head.
nform
ercia
- Position fitting tool for compressing valve springs to one of the following positions
outer inlet valves: lower position,
m
at
centre inlet valve: upper position,

om
io
exhaust valve: lower position

n
c
in t
or
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ate
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en
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Prote AG.

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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- Connect pressure hose to compressed air d by system
V supplying gu
ara
at least 6 bar ise nte
satelettronica
or eo
and remove valve springs. auth
ra
- -> Pull off valve stem seals with valve
ss stem seal puller 3364. c
ce
le
un
pt
an
d
Installing
itte
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
- -> To prevent damage to the new valve stem seals, place plastic sleeve -A- on valve stem.
tion in
- Oil sealing lip of valve stem seal -B- insert in fitting tool 3365 and carefully push into valve guide.
r
te o
thi
s
iva
do
- Install spark plugs with spark plug socket and extension 3122B and tighten to
r
rp
cum
30 Nm.
fo
en
g
- Install camshafts => Page 96 .

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.7 - Replacing valve stem seals 105

Sharan 1996 ➤
17 - Lubrication
1 - Removing and installing parts of the lubrication system

1.1 - Removing and installing parts of the lubrication system
Notes:
◆ If large quantities of metal shavings or small metal particles are found in the engine oil during an engine
repair this can be due to partial seizure of crankshaft or conrod bearings. In this case it is not only necessary
to thoroughly clean the oil passages, but also to replace the oil cooler and oil filter to prevent subsequent
damage.
◆ The oil level must not be above the max. mark - danger of damage to catalyst!
Marking => Page 112 , Fig. 1
satelettronica
Dismantling and assembling oil filter bracket
=> Page 113 .
Checking oil pressure => Page 126 .
Engine oil specifications:
Use engine oil fulfilling VW standard 500 00, 501 01 or 501 02. Only in exceptional cases: Multi-grade or single-
grade oils according to API-SF or SG.
Note:
You can also use engine oil fulfilling VW standard 503 00. This engine oil is appropriate for extended service
intervals (ESI). gen AG
. Volkswagen AG
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Vehicles with engine code AWC ed
b ara
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Dismantling and assembling oil filter bracket ss
au ra
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=> Page 118 .
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Checking oil pressure and oil pressure switch => Page 128 y li
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Engine oil specificationswith long-life service wit

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New VW standard (specially developed, ageing resistant)

spec
First filling: VW standard: 503 00 (VW TL 52 173)

es, in part or in w
t to the co
Note:
rrectness of i
Engines are filled at the factory with oil meeting VW standard 503 00. This engine oil is matched to long service
intervals. However, you can also use the engine oils listed below.
l purpos
Engine oils conforming to VW standard 500 00, 501 01 or 502 00 can be used furthermore. The oil must then
be changed every 12 months or every 15,000 km and the service interval display must be programmed corre‐
nf
ercia
spondingly. Procedure:
rm
m
atio
om
n in
=> Maintenance manual

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106 17 - Lubrication
Sharan 1996 ➤
4-cyl. injection engine
en AG. Vol(5-valve),
kswagen AG Mechanics - Edition 02.2005
ag does
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Vol
Continuation for all vehicles ed
by gu
ara
ris nte
o
Oil system capacity1): au
th eo
ra
ss c
with oil filter 4.5 ltrs.
ce
le
un
pt
an
d
itte
1) Up-to-date figures:
y li
erm
ab
ility
=> Exhaust emissions test binder
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
e
satelettronica
t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1 15 Nm
2 Sealing flange
D 176 404 A2
=> Page 38
3 Chain tensioner with tensioning rail, 15 Nm
◆ Check for wear
◆ When installing, pretension spring and fit
4 Chain sprocket
◆ For oil pump drive
◆ Check for wear
1.1 - Removing and installing parts of the lubrication system 107

Sharan 1996 ➤
5 Cylinder block
◆ Dismantling and assembling pistons and conrods
=> Page 48
AG. Volkswagen AG d
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
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thi
s
iva
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en
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t.
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Cop py
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Vo
co lksw
by
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Prote AG.
6 Dipstick
◆ The oil level must not be above the max. mark!
◆ Markings => Fig. 1
7 Guide
◆ For dipstick
◆ Secured to intake manifold with bracket
8 Guide tube
9 Oil spray jet
◆ For piston cooling
10 Pressure relief valve, 27 Nm
◆ Opening pressure: 1.3...1.6 bar
11 Suction pipe
◆ Clean strainer if soiled
12 O-ring
Sharan 1996 ➤
◆ Renew
lkswage es n
o ot g
byV ua
satelettronica
d ran
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tho
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a ac
ss
ce
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un
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an
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itte
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rm
ab
pe
ility
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
13 Baffle plate
com
14 Sump tion in
r
te o
thi

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D 176 404 A2
fo
en
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op
=> Page 123 C py
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15 15 Nm yri
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◆ Loosen and tighten with jointed wrench 3185 Prote
cted AG.
agen
◆ Remove with socket extension 3249
16 Oil level/temperature sender (G266)
◆ Only vehicles with engine code AWC
◆ Black 3-pin connector
17 Seal
◆ Renew
◆ Oil before assembling

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
tho eo
au ra
ss c
ce
e
nl
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du
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itte
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ab
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
satelettronica
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.
18 10 Nm
19 20 Nm
20 Bracket
◆ For air pipe between charge air cooler and turbocharger => Page 228 , Removing and installing parts
of charge air cooling: engine code AWC
21 Oil drain plug, 30 Nm
◆ Renew plug with attached seal
22 Gasket
◆ Renew
23 Oil return pipe
◆ From turbocharger
=> Page 223 , item 24
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
satelettronica
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.
24 Oil pump
◆ With pressure relief valve of 12 bar
◆ Before installing, check that both dowel sleeves for centralizing oil pump/cylinder head are fitted
25 Chain sprocket
◆ For oil pump
◆ Check for wear
26 25 Nm
27 Roller chain
◆ Check for wear
28 Dowel sleeves
◆ Check for tight fit

Sharan 1996 ➤
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
-> Fig. 1 Markings on oil dipstick
wit
, is n
h re
1- max. mark
hole
spec
2- min. mark
es, in part or in w
a- Area above hatched field up to max. mark: Do not replenish with engine oil!
t to the co
b- Oil level within hatched field: can be replenished with engine oil
c- Area from min. mark up to hatched field: replenish with max. 0.5 ltr. of engine oil!
rrectness of i
satelettronica
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Sharan 1996 ➤
1.2 - Dismantling and assembling oil filter bracket: engine code AJH
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
Notes:
is n
h re
ole,
spec
◆ All hose connections secured by spring-type or tensioning clips.

◆ Tensioning clips are always to be replaced with spring-type clips.

t to the co
1 O ring
◆ Fit onto shoulder of pipe
rrectne
2 Connecting pipe
ss o
3 T-piece
cial p
f inform
◆ With non-return valve

mer
4 Connecting hose
atio
om
◆ To connection on intake manifold

n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.2 - Dismantling and assembling oil filter bracket: engine code AJH 113
Sharan 1996 ➤
satelettronica
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
hole
spec
es, in part or in w
t to the co
rrectness of i
5 Pipe/hose assembly
l purpos
◆ For crankcase breather

6 Retaining clip
nform
ercia

7 0.25 bar oil pressure switch (F22), 25 Nm
m
at
om
io
◆ Identification: blue
n
c
in t
r

o
his
te
◆ If sealing ring is leaking nip open and replace.

a
do
priv

um
for
en
g
◆ Identification: black
n
t.
yi Co
op
◆ Checking => Page 126 C py
t. rig
◆ If sealing ring is leaking nip open and replace. gh ht
pyri by
Vo
o
9 Oil supply pipe by c lksw
cted agen
Prote
◆ To turbocharger
AG.
=> Page 219 , item 5
Sharan 1996 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
satelettronica
m
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.
10 Banjo bolt, 30 Nm
11 Seal
◆ Renew
12 Oil temperature sender (G8)
◆ For oil temperature gauge
◆ Tighten to 10 Nm
13 15 Nm + 1/4 turn (90 °) further
◆ Renew
14 Seal
◆ Renew
◆ Oil before installing
◆ Fit into groove on oil cooler
Sharan 1996 ➤
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
satelettronica
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
15 Oil cooler
en
ng
t.
yi Co
◆ Ensure clearance to adjacent components Cop py
. rig
◆ Coat area outside oil seal contacting oil filter bracket with sealant "AMV 188 100 02"
t
gh ht
yri by
◆ See note cop Vo
by lksw
=> Page 106 cted agen
Prote AG.
16 25 Nm
17 Oil filter
◆ Observe change intervals
◆ Loosen with strap wrench
◆ Tighten by hand
◆ Observe installation instructions on oil filter
◆ With pressure relief valve approx. 4 bar
gen AG
. Volkswagen AG
does Sharan 1996 ➤
swa
4-cyl. injection engine Volk (5-valve), Mechanics no- t Edition 02.2005
g
by ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
satelettronica
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
19 Sealing plug, 40 Nm
20 Spring
◆ For pressure relief valve, approx. 4 bar
21 Piston
22 Gasket
◆ Renew
23 Non-return valve, 8 Nm
Sharan 1996 ➤
1.3 - Dismantling and assembling oil filter bracket: engine code AWC
lkswage es n
o ot g
byV ua
d ran
ir se
satelettronica
o tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
r
Notes:
o
his
ate
do
riv
◆ All hose connections secured by spring-type or tensioning clips.

p
cum
or
◆ Tensioning clips are always to be replaced with spring-type clips.

f
en
ng
t.
yi Co
Cop py
1 O ring
t. rig
gh ht
yri by
◆ Fit onto shoulder of pipe cop Vo
by lksw
cted agen
Prote AG.
2 Connecting pipe
3 T-piece
4 Connecting hose
◆ To connection low on intake manifold
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
satelettronica
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
5 Pipe/hose assembly
i
or
n thi
te

sd
iva
o
pr
6 Retaining clip
um
r
fo
en
ng

t.
yi Co
op
C py
ht. rig
rig ht
◆ If sealing ring is leaking nip open and replace. py by
co Vo
by lksw
8 Oil supply pipe cted agen
Prote AG.
◆ To turbocharger
9 Banjo bolt, 30 Nm
10 Seal
◆ Renew
◆ Identification: black
1.3 - Dismantling and assembling oil filter bracket: engine code AWC 119
Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
12 15 Nm + 1/4 turn (90 °) further

hole
spec
◆ Renew
es, in part or in w

t to the co
13 Seal
◆ Renew
rrectness of i
◆ Oil before installing

◆ Fit into groove on oil cooler
l purpos
14 Oil cooler
nform
ercia
◆ Coat area outside oil seal contacting oil filter bracket with sealant "AMV 188 100 02"
◆ See note
m
a
com
ti
=> Page 106

on in

r
te o
thi
15 25 Nm
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 ➤
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
satelettronica
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.
16 Oil filter
◆ Observe change intervals
◆ Loosen with strap wrench
◆ Tighten by hand
◆ Observe installation instructions on oil filter
◆ See note
=> Page 106
◆ With pressure relief valve approx. 4 bar
19 Spring
20 Piston
1.3 - Dismantling and assembling oil filter bracket: engine code AWC 121
Sharan 1996 ➤
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
satelettronica
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
21 Gasket
Co
Cop py
◆ Renew
t. rig
gh ht
yri by
22 Non-return valve cop Vo
by lksw
cted agen
◆ Insert in oil filter bracket (is no longer screwed into oil filter bracket) Prote AG.
Sharan 1996 ➤
1.4 - Removing and installing sump
◆ 3185 Jointed extension socket wrench
satelettronica
AG. Volkswagen AG d
agen oes
o lksw not
V
◆ 3249 Socket d by gu
ara
se nte
◆ V.A.G 1331 Torquethwrench
ori (5...50 Nm) eo
◆ D176 404 A2 Silicone
s au sealant ra
c
◆ Hand drill with plastic brush
s
ce
le
un
pt
an
d
◆ Flat scraper
itte
y li
erm
ab
ility
Removing
ot p
wit
is n
h re

ole,
spec
- Drain engine oil.

t to the co
Note:
Observe disposal regulations!

rrectne

ss o
cial p
- Detach the oil return pipe for the exhaust gas turbocharger from the sump.
inform
- Remove the securing screw for the air pipe bracket from the sump.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.4 - Removing and installing sump 123

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
- -> Pull 3-pin connector off oil level/temperature sender (G266) -1-.
hole
spec
- Detach turbocharger oil return pipe -2- from sump.
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
- -> Remove the securing screws -arrows- for bracket for charge air system air pipe from the sump.
Co
Cop py
t. rig
gh ht
yri
Continuation for all vehicles p by
o Vo
by c lksw
cted agen
Prote AG.
- Loosen oil sump bolts using jointed extension socket wrench 3185. (Remove using socket 3249.)
- Remove sump, it may be necessary to release sump by tapping lightly with a rubber head hammer.
- Remove sealant residue on cylinder block with a flat scraper.
- -> Remove sealant residue on the sump with a rotating brush, e.g. a hand drill with a plastic brush (wear
eye protection).
- Clean sealing surface, must be free of oil and grease.
Installing
Notes:
◆ Note the use by date of the sealant.
Sharan 1996 ➤
◆ Sump must be installed within 5 minutes of applying silicone sealing compound.
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
- -> Cut off tube nozzle at forward marking (nozzle approx. 3 mm ø).
- Apply silicone sealing compound, as shown, to clean sump sealing surface. Sealing compound bead must
rrectness of i
be.
- 2...3 mm thick.
l purpos
- and run on inside of bolt holes -arrows-.
Note:
nform
ercia
satelettronica
The sealing compound bead must not be thicker, otherwise excess sealing compound will enter the sump and
m
at
om
may block the oil suction pipe strainer.
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.
- -> Apply silicone sealing bead as shown to the clean sealing surface of the sump. (The illustration shows
the position of the sealant bead on the cylinder block).
- Install sump immediately and tighten all sump bolts lightly.
Note:
After installing sump the sealant must be allowed to dry for approx. 30 minutes before engine oil is replenished.
- Tighten sump bolts to
15 Nm.
- Tighten sump/gearbox bolts to
40 Nm.

- Tighten sump/oil return pipe to
10 Nm.
- Tighten sump/air pipe bracket to
1.4 - Removing and installing sump 125

Sharan 1996 ➤
20 Nm.
1.5 - Checking oil pressure and oil pressure switch: engine code AJH
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
satelettronica
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
◆ V.A.G 1342 Oil pressure tester

◆ V.A.G 1527 B Diode test lamp
◆ V.A.G 1594 A Adapter set
Test conditions
• Engine oil level OK. Checking => Page 112 , Fig. 1

• Engine oil temperature at least 80 °C (radiator fan must have run once)
Note:
Functional check and servicing the optical and acoustic oil pressure warning:
Sharan 1996 ➤
Checking oil pressure switch
satelettronica
- -> Remove the 1.4 bar oil pressure switch (F1) -A- and screw it into the tester.
- Screw tester into the oil filter bracket in place of the oil pressure switch.
- Connect brown wire of tester to earth (-).
- Connect diode test lamp V.A.G 1527 B using aux. cables from V.A.G 1594 A to battery positive (+) and 0.25
bar oil pressure switch (F22) -B-.
LED must light up.
- Start engine and increase speed slowly.

At
0.15...0.35 bar
the LED must go out. Otherwise renew 0.25 bar oil pressure switch (F22).
=> Page 114 , item 7 .
- Connect diode test lamp to 1.4 bar oil pressure
agen
AG.switch
Volkswa(F1) -A-.
gen AG
does
At olksw not
y V gu
1.2...1.6 bar risedb ara
nte
The LED must light up. Otherwise
ut
ho renew oil pressure switch. eo
ra
=> Page 114 , item 8 . ss a c
ce
le
un
pt
Check oil pressure

an
d
itte
y li
rm
ab
- Check oil pressure at different speeds:

pe
ility
2 000 rpm: at least 2.0 bar

ot
wit
, is n
Above 2 000 rpm: maximum 7.0 bar.

h re
hole
spec
If the specifications are not obtained:

es, in part or in w
t to the co
- Rectify mechanical damage, e.g. bearing damage.

- Renew oil filter bracket with pressure relief valve => Page 111 , item 24 .
rrectness of i
At higher engine speeds, the oil pressure must not exceed

l purpos
7.0 bar
nform
ercia
If the specification is exceeded:

m
- Check oil galleries.

com
tion in
- If necessary, replace oil filter bracket with pressure relief valve

r
te o
=> Page 111 , item 24

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.
1.5 - Checking oil pressure and oil pressure switch: engine code AJH 127
Sharan 1996 ➤
1.6 - Checking oil pressure and oil pressure switch: engine code AWC
satelettronica
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
◆ V.A.G 1342 Oil pressure tester

rrectness of i

l purpos
Test conditions
nform
ercia
• Engine oil level OK. Check => Page 112 , Fig. 1

m
at
om
ion
c
in t
r
Note:
o
his
ate
do
riv
Functional check and servicing the optical and acoustic oil pressure warning:
p
cum
for
en
ng
t.
yi Co
=> Current flow diagrams, Electrical fault finding and Fitting locations . Cop py
rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Sharan 1996 ➤
Checking oil pressure switch
- -> Remove oil pressure switch (F1) and screw into tester.
- Screw tester into the oil filter bracket in place of the oil pressure switch.
- Connect brown wire of tester to earth (-).
- Connect diode test lamp V.A.G 1527 B using auxiliary cables from V.A.G 1594 A to battery positive (+) and
oil pressure switch.
LED must not light up.
satelettronica
If the LED lights up:
- Renew oil pressure switch (F1) .

=> Page 119 , item 11 .
If the LED does not light up:
- Start engine and run at idling speed.

At
1.2...1.6 bar pressure
the LED must light up; otherwise renew oil pressure switch (F1) => Page 119 , item 11 .
AG. Volkswagen AG d
agen oes
Check oil pressure olksw not
y V gu
d b ara
rise nte
- Check oil pressure at different speeds: utho eo
ra
2 000 rpm: 2.7...4.5 bar ss a c
Above 2 000 rpm: maximum 7.0 bar.
ce
le
un
pt
an
d
itte
y li
If the specifications are not obtained:

rm
ab
pe
ility
ot
- Rectify mechanical damage, e.g. bearing damage.

wit
, is n
- Renew oil filter bracket with pressure relief valve => Page 111 , item 24 .
h re
hole
spec
At higher engine speeds, the oil pressure must not exceed

es, in part or in w
t to the co
7.0 bar
If the specification is exceeded:

rrectness of i
- Check oil galleries.

l purpos
- If necessary, replace oil filter bracket with pressure relief valve

=> Page 121 , item 17 .
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.
1.6 - Checking oil pressure and oil pressure switch: engine code AWC 129
Sharan 1996 ➤
19 - Cooling system
1 - Removing and installing parts of cooling system

1.1 - Removing and installing parts of cooling system
Warning!
cramped conditions:
Notes:
satelettronica
◆ When the engine is warm the cooling system is under pressure. If necessary release pressure before com‐
mencing repair work.
◆ Hoses are secured with spring-type clips. In cases of repair agenonly use spring-type
AG. Volkswagen AG d
o s clips.
◆ Assembly tool VAS 5024 or hose clip pliers V.A.Gy1921 Volksw are recommended for efitting
not spring-type clips.
gu
◆ When installing coolant hoses route stress-free,iseso
d b that they do not come into contact withara other components
nte
(observe markings on coolant connection and thor hose). eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
Perform cooling system leakage test with cooling system tester V.A.G 1274 and adapters V.A.G 1274/8 and
y li
erm
ab
V.A.G 1274/9.
ility
ot p
wit
, is n
Parts of cooling system body side =>Page 131 .
h re
hole
spec
Parts of cooling system engine side => 138 .
es, in part or in w
t to the co
Coolant hose connection diagram =>Page 148 .
rrectness of i
l purpos
Test cooling system leakage using cooling system tester V.A.G 1274 and adapters V.A.G 1274/1 A and V.A.G
1274/7.
nf
ercia
or
Parts of cooling system body side =>Page 134 .

m
m
atio
om
n in
c
Parts of cooling system engine side => 142 .

or
thi
te
sd
iva
Coolant hose connection diagram =>Page 150 .

o
r
rp
cu
o
m
f
en
ng

t.
yi Co
Cop py
ht. rig
ht
Draining and filling with coolant=> Page 152 .
rig by
copy Vo
by lksw
cted agen
Prote
Coolant mixture ratios => Page 152 , draining and filling with coolant
AG.
130 19 - Cooling system

Sharan 1996 ➤
1.2 - Parts of cooling system body side: engine code AJH
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
satelettronica
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
g
1 Rubber mounting
n
t.
yi Co
op
2 Upper coolant hose C py
t. rig
gh ht
◆ Check securely seated pyri by
Vo
co
◆ Coolant hose connection diagram =>Page 148
by lksw
cted agen
Prote AG.
3 Radiator
=>Page 156
◆ After replacing renew entire coolant
4 Radiator fan thermo-switch (F18), 35 Nm
◆ For electric fan
◆ Switching temperatures:
Stage 1
on: 92...97 °C
off: 84...91 °C
Stage 2
on: 99...105 °C
off: 91...98 °C
1.2 - Parts of cooling system body side: engine code AJH 131
Sharan 1996 ➤
satelettronica
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
5 Connector
l purpos
◆ Black, 3 pin
◆ For radiator fan thermo switch
nform
ercia
6 10 Nm
7 Reinforcing strip
m
a
com
tio
8 Connector
n in
r
te o
◆ Black
thi
s
iva
◆ For right radiator fan (V35)

do
r
rp
cum
9 Retaining clip
fo
en
ng
t.
◆ Check seated securely
yi Co
op py
10 Right radiator fan (V35)
. C rig
ht ht
rig by
py
◆ Removing and installing co Vo
by lksw
=>Page 156 cted agen
Prote AG.
11 Fan ring
12 Rubber grommet

Sharan 1996 ➤
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
satelettronica
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
13 Washer
te
sd
va
14 Rubber washer
i
o
pr
cum
r
fo
15 Bush
en
ng
t.
yi Co
16 Connector . Cop py
rig
ht
◆ Black rig ht
py by
◆ For left radiator fan (V7)
co Vo
by lksw
cted agen
17 Left radiator fan (V7) Prote AG.

=>Page 156
18 Securing bracket
◆ For lower coolant hose
19 Lower coolant hose
20 Air intake ducting
21 Rubber bush
1.2 - Parts of cooling system body side: engine code AJH 133
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Sharan 1996 ➤ auth or
ac
ss
ce
e
nl
pt
du
1.3 - Parts of cooling system body side: engine code AWC
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
. rig
satelettronica
t
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1 Rubber mounting
2 Radiator
=>Page 156
◆ After replacing renew entire coolant
3 10 Nm
4 Radiator fan thermo-switch (F18), 35 Nm
◆ Switching temperatures:
Stage 1
on: 92...97 °C
off: 84...91 °C
Stage 2
on: 99...105 °C
off: 91...98 °C

Sharan 1996 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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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
satelettronica
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.
5 Connector
◆ Black, 3 pin
◆ For radiator fan thermo switch
6 Rubber bush
7 Bracket
◆ For charge air cooler
8 Air ducting
9 9 Nm
10 Right radiator fan (V35)
◆ With fan ring
◆ Only vehicles with optional equipment
=>Page 156
11 Bracket
◆ For lower coolant hose
1.3 - Parts of cooling system body side: engine code AWC 135
Sharan 1996 ➤
en A02.2005
G. Volkswagen AG
ag does
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y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
satelettronica
t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
12 Left radiator fan (V7)

◆ With fan ring
=>Page 156
13 Connector
◆ Black, 2-pin
◆ For radiator fan
14 Charge air cooler
=> Page 240
16 Quick-release coupling
◆ With retaining clip
17 O-ring

Sharan 1996 ➤
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
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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
satelettronica
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.
18 Upper coolant hose
◆ Check securely seated
1.3 - Parts of cooling system body side: engine code AWC 137
Sharan 1996 ➤
1.4 - Parts of cooling system engine side: engine code AJH
1 15 Nm
satelettronica
2 To turbocharger agen
AG. Volkswagen AG d
oes
lksw not
◆ Coolant hose connection diagram =>Page 148 d by
Vo gu
ara
e
3 Coolant circulation pump (V50) horis nte
eo
ut
◆ Black 2-pin connector s s a ra
c
◆ Checking =>Page 162
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
5 O-ring
spec
◆ Renew
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.
6 Connection
7 To heat exchanger
8 To rear heat exchanger
◆ Location: In rear left wheel housing

Sharan 1996 ➤
9 Retaining clip
10 Coolant temperature sender (G62)
◆ Blue, 4 pin
◆ With coolant temperature gauge sender (G2)
◆ For engine control unit
◆ If necessary release pressure in cooling system before removing
◆ Checking:
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
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erm
ab
ility
ot p
satelettronica
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f
11 Connector
inform
12 Air conditioner cut-off thermo switch (F163) and radiator fan 3rd speed thermo switch (F165)
mer
atio
◆ Brown, 4 pin
om
n
c
i
or
n
◆ On vehicles with air conditioning:
thi
te
sd
iva
o
pr
c
=> Heating, air conditioning; Repair group 87
um
r
fo
en
ng
t.
yi Co
◆ A plug is fitted on vehicles without air conditioner t. Cop py
rig
gh ht
yri by
13 10 Nm cop Vo
by lksw
cted agen
14 Coolant temperature sender (G110) Prote AG.
◆ 2-pin
◆ On vehicles with air conditioning
=> Heating, air conditioning; Repair group 87
1.4 - Parts of cooling system engine side: engine code AJH 139
Sharan 1996 ➤
15 Bracket
16 To top of radiator
satelettronica
◆ Check securely seated . Volkswagen AG
◆ Coolant hose connection diagramk=>Page swa
gen AG 148 does
not
ol
17 Lower coolant hose d byV gu
ara
ise nte
◆ Check seated securely tho r eo
◆ Coolant hose connection s au diagram =>Page 148 ra
c
s
18 Oil cooler
ce
e
nl
pt
du

an
itte
=>Page 113 , Dismantling and and assembling oil filter bracket: engine code AJH y li
erm
ab
19 From rear heat exchanger ility
ot p
wit
, is n
h re
◆ Location: In rear left wheel housing
hole
spec
20 20 Nm
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.
21 Coolant pipe
22 Cap
◆ Check with cooling system tester V.A.G 1274 and adapter V.A.G 1274/9
◆ The pressure relief valve must open at a pressure of 1.4 ...1.6
23 Seal
◆ Note installation position on cap

Sharan 1996 ➤
24 Expansion tank
◆ Carry out leak test of cooling system with cooling system tester V.A.G 1274 and adapter V.A.G1274/8
◆ Observe markings
=> Page 152 , Draining and filling coolant
lkswage es n
o ot g
byV ua
d ran
ir se tee
satelettronica
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
25 From heat exchanger

erm
ab

ility
ot p
wit
26 Connection, 30 Nm
, is n
h re
◆ For coolant supply pipe/hose

hole
spec
27 Coolant supply pipe

es, in part or in w
t to the co
◆ For turbocharger
28 Coolant pump
rrectness of i

l purpos

=> Page 159
nform
ercia
29 Toothed belt
m
at

om
io
◆ Check for wear

n
c
in t
r
◆ Do not kink
o
his
te

a
do
riv
=> Page 60
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.4 - Parts of cooling system engine side: engine code AJH 141
Sharan 1996 ➤
1.5 - Parts of cooling system engine side: engine code AWC
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
satelettronica
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.
1 Bracket
◆ For coolant circulation pump
2 Coolant circulation pump (V50)
◆ Black 2-pin connector
3 10 Nm
4 To heat exchanger
5 Connector
◆ Black, 2-pin
◆ Coolant temperature sender
6 Retaining clip

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
satelettronica
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
7 Connector cted agen
Prote AG.
◆ Black, 2-pin
◆ For coolant shortage indicator sender
8 Cap
◆ Note installation position of seal in cap
◆ Renew seal if damaged
◆ Check with coolant system tester V.A.G 1274 and adapters V.A.G 1274/1A and V.A.G 1274/7
◆ The pressure relief valve must open at a pressure of 1.4 ...1.6
9 Expansion tank
◆ Perform leak test of cooling system with cooling system tester V.A.G 1274 and adapter V.A.G1274/7
◆ Observe markings
=> Page 152 , Draining and filling coolant
1.5 - Parts of cooling system engine side: engine code AWC 143
Sharan 1996 ➤
satelettronica
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
10 From heat exchanger

rrectne
11 O-ring
ss
12 20 Nm
o
cial p
f in
13 Coolant pipe
form
mer

atio
m

o
n
c
i
or
◆ From bottom of radiator

thi
te

sd
iva
o
r

p
cum
r
fo

en
ng
t.
yi Co
op
◆ To top of radiator C py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
satelettronica
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
hole
spec
es, in part or in w
t to the co
rrectness of i
16 Oil cooler
l purpos

=>Page 118 , Dismantling and assembling oil filter bracket: engine code AWC
nform
ercia
17 15 Nm
m
at
18 Connection
om
ion
c
◆ For thermostat
in t
or
his
e
19 O-ring
at
do
riv
◆ Renew
p
cum
for
en
ng
t.
yi Co
op
◆ Removing and installing C py
t. rig
=> Page 161
gh ht
pyri by
◆ Observe installation position,
o Vo
by c lksw
cted
=> Page 161 Removing and installing thermostat
agen
Prote AG.
Sharan 1996 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
satelettronica
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
ercia
21 Connection, 30 Nm
m
◆ For coolant supply pipe/hose

com
tion in

r
te o
thi
s
iva
do

r
rp
cum
fo
23 Coolant pump
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
yri
◆ Removing and installing p by
co Vo
lksw
=> Page 159
by
cted agen
Prote AG.
24 Toothed belt
◆ Check for wear
◆ Do not kink
=> Page 60
25 Coolant return pipe

Sharan 1996 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
r
satelettronica
o
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.
26 Coolant temperature sender (G62)

◆ Black, 2-pin
◆ For engine control unit
◆ Checking:
27 Connection
Sharan 1996 ➤
4-cyl. injection engine (5-valve), Mechanics - . VEdition
olkswagen02.2005
en AG AG ag does
ksw
1.6 - Coolant hose connection diagram: dengine code AJH
not
Vol gu
by ara
e nte
ris
utho eo
ra
a 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
satelettronica
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.
1 Cylinder block/cylinder head

2 Turbocharger
4 Connection
5 Heating system heat exchanger
6 Expansion tank
7 Coolant pipe
8 Gearbox oil cooler
◆ Only on vehicles with automatic gearbox

Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
10 Radiator orise nte
eo
h
11 Loweraut coolant hose ra
ss c
12 Oil cooler
ce
le
un
pt
an
d
itte
y li
14 Coolant pump
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
149
co Vo
by lksw
cted agen
1.6 - Coolant hose connection diagram: engine code AJH
Prote AG.
Sharan 1996 ➤
1.7 - Coolant hose connection diagram: engine code AWC
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
15 Turbocharger
16 Connection
s

s o
cial p
18 Heating system heat exchanger

inform
19 Expansion tank
mer
atio
20 Coolant pipe
om
n
c
21 Gearbox oil cooler

i
or
n thi
e
◆ Only on vehicles with automatic gearbox

t
sd
iva
o
r

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

Sharan 1996 ➤
satelettronica
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
25 Oil cooler
hole
spec
26 Coolant pump/coolant thermostat
es, in part or in w
t to the co
27 Cylinder head/cylinder block
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.
1.7 - Coolant hose connection diagram: engine code AWC 151

lkswage es n
Vo ot g
Sharan 1996 ➤ d by ua
ran
ir se
4-cyl. injection
tho engine (5-valve), Mechanics - Edition tee
or 02.2005
au ac
ss
1.8 - Draining and filling cooling system
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.
satelettronica
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
◆ T10007 Refractometer
◆ VAS 5024 Assembly tool for spring-type clamps
Not illustrated:
◆ VAS 6096 Cooling system charging
Draining

- Open cap on coolant expansion tank.
Warning !
Steam can be released when the cap is removed from the expansion tank. Cover cap with a cloth and open
carefully.

Sharan 1996 ➤
- Pull the bottom hose off the radiator.
satelettronica
- -> Pull out retaining clip -arrow- for lower coolant hose and remove coolant hose from quick-release coupling
on radiator.
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
- -> To drain coolant from engine also remove coolant hose from oil cooler -arrow-.
es, in part or in w
t to the co
Note:
Observe disposal regulations!

rrectness of i
l purpos
Filling
Notes:
nform
mercia
◆ Only use coolant additive G 12 in accordance with TL VW 774 F.

at
om
io
Distinguishing feature: coloured violet

n
c
in t
r
◆ G 12 and coolant additives marked "In accordance with TL VW 774 F" prevent frost and corrosion damage,
o
his
e
scaling and also raise boiling point of coolant. For this reason the system must be filled all year round with
at
do
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frost and corrosion protection additives.

p
cum
or
◆ G 12 violet (in accordance with TL VW 774 F) can be mixed with the previous coolant additives G 11 and
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G 12 red!
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◆ Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in
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countries with tropical climates.
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◆ Protection against frost must be assured to about -25 °C (in arctic climatic countries to about -35 °C).
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◆ The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer Prote AG.
countries. The anti-freeze ratio must be at least 40 %.
1.8 - Draining and filling cooling system 153

Sharan 1996 ➤
◆ If for climatic reasons a greater frost protection is required, the amount ofVoG 12 can be increased, but only
lkswagen AG
up to 60 % (frost protection to about -40 °C), as otherwise frostsw protection
agen
AG. is reduced dagain
oes and cooling
effectiveness is also reduced. by Vol
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◆ The refractometer T10007 is recommended for determining the current anti-freeze density.
l purpos
◆ If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.
nform
Recommended mixture ratios:
mercia
at
satelettronica
om
Vehicle Anti-freeze Anti-freeze G 122) Water2)
ion
c
equipment to propor‐
in t
or
tion1)
his
ate
do
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one -25 °C 40 % 2.8 ltr. 4.2 ltr.

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heat ex‐ -35 °C 50 % 3.5 ltr. 3.5 ltr.

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two -25 °C 40 % 3.6 ltr. 5.4 ltr.
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heat ex‐ -35 °C 50 % 4.5 ltr. 4.5 ltr.
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changers Prote
cted AG.
agen
two -25 °C 40 % 3.8 ltr. 5.8 ltr.

heat ex‐ -35 °C 50 % 4.8 ltr. 4.8 ltr.
changers
and addi‐
tional water
heater
1) The amount of anti-freeze must not exceed 60 %; frost protection and cooling effect will decrease if
amount of anti-freeze is too high.
2) The amounts of coolant given in table refer to vehicles with manual gearbox. For vehicles with automatic
gearbox the amounts of G12 and water both increase by approx. 0.1 ltr.
Work sequence
With cooling system charging unit VAS 6096
- Screw adapter V.A.G 1274/7 or 8 onto expansion tank.

- Fill coolant circuit using cooling system charging unit VAS 6096.
=> Operating instructions for cooling system charging unit VAS 6096
Not using cooling system charging unit VAS 6096
- Push lower coolant hose onto radiator and secure with spring-type clip.

Sharan 1996 ➤
- -> Install lower coolant hose and secure with retaining clamp -arrow-.
satelettronica
AG. Volkswagen AG d
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- -> Push coolant hose onto oil cooler connection and secure with a spring-type clamp.
ab
ility
- Turn off heater control.

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- Press top radiator hose down.

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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
- -> Fill with coolant slowly up to max. mark on expansion tank. Filling takes approx. 5 minutes.
p
cum
or
- Start engine and run at increased idling speed (about 2500 rpm) while filling expansion tank up to MAX.
f
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marking with coolant.

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With and without cooling system charging unit VAS 6096
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cted agen
- Fit cap to expansion tank cap.
Prote AG.
- Run engine until radiator fan cuts-in.

- Then continue to run engine for about 10 minutes at increased idling speed (about 2500 rpm).
- Check coolant level and top-up if necessary. When the engine is at normal operating temperature, the
coolant level must be on the MAX. marking and, when the engine is cold, between the MIN. and MAX.
marking.
1.8 - Draining and filling cooling system 155

Sharan 1996 ➤
Warning !
Steam can be released when removing the cap from the expansion tank. Cover cap with a cloth and open
carefully.
- Install noise insulation tray.
1.9 - Removing and installing radiator
satelettronica
AG. Volkswagen AG d
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d by ara
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nl
pt
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erm
ab
ility
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es, in part or in w
t to the co
rrectness of i
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nf
ercia
◆ VAS 5024 Assembly tool for spring-type clips

orm
m
atio
Removing
om
n in
or c
thi

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Prote AG.
Sharan 1996 ➤
- Pull upper coolant hose off radiator.

- Detach bottom coolant hose from the clips on the air ducting.
- Pull air duct hoses off charge air cooler.
- Remove air pipe between charge air cooler and throttle valve control part
=> Page 225 , Removing and installing parts of charge air cooling: engine code AJH
- Pull connectors off thermo switch, secondary air pump motor and radiator fan.
- Remove the thermo switch.
- Remove reinforcement strut.
- Unscrew fan ring securing bolts and remove fan ring with fan.
Vehicles with air conditioning system:
- Observe additional information and removal work => Page 157 .
- Remove securing bolts on sides of radiator.

- Remove radiator downwards.
- Unbolt charge air cooler from radiator.
- Pull out retaining clip for upper coolant hose and remove coolant hose from quick-release coupling of radi‐
satelettronica
ator.
- Unhook lower coolant hose from retainer on air ducting.
- Remove retainer for lower coolant hose.
- Remove air pipe between charge air cooler and throttle valve control part
=> Page 228 , Removing and installing parts of charge air cooling: engine code AWC
- Pull connectors off thermo-switch and radiator fan.
Vehicles with air conditioning system:
- Observe additional information and removal work => Page 157 .

AG. Volkswagen
agen AG do
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Remove securing bolts on sides of radiator.
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- Remove radiator downwards. orise tee
- Unbolt charge air cooler from aradiator.
ut
h or
ac
ss
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Additional information and removal work on vehicles with air conditioner

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ility
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Warning!
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The air conditioning system refrigerant circuit must not be opened.

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spec
t to the co
Note:
rrectne
To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are
not stretched, kinked or bent.
ss
- Remove retaining clamp(s) from refrigerant pipes.

o
cial p
f inform

mer
atio
om
- Remove radiator grille with frame:

c
i
or
n thi
te
sd
a
=> General body repairs, Exterior; Repair group 66; Trims; Removing and installing radiator grille with frame
iv
o
pr
Trims Removing and installing radiator grille with frame

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- Removing left headlight: C py
t. rig
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pyri by
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cted agen
Prote AG.
1.9 - Removing and installing radiator 157

Sharan 1996 ➤
=> Electrical system; Repair group 94; Servicing headlight Servicing headlight
- Unscrew fan ring securing bolts and remove fan ring with fan.

lkswage es n
o ot g
- Remove securing bolts on sides of radiator. byV ua
ed ran
- Remove condenser from cooler. oris tee
- Secure condenser to body so that refrigerantaupipes/hoses are not stressed.
th or
ac
- Remove radiator downwards. ss
ce
e
- Unbolt charge air cooler from radiator.
nl
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Installing
erm
ab
ility
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spec
- Electrical connections and routing:
es, in part or in w
t to the co
rrectness of i
satelettronica
l purpos
- Check headlight adjustment and adjust if necessary:
nf
ercia
orm
m
=> Maintenance
atio
om
n in
or c
- Installing radiator grille with frame:
thi
te
sd
iva
o
r
rp
cu
=> General body repairs, Exterior; Repair group 66; Trims; Removing and installing radiator grille with frame
o
m
f
Trims Removing and installing radiator grille with frame
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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cted agen
Prote AG.

Sharan 1996 ➤
1.10 - Removing and installing coolant pump
AG. Volkswagen AG d
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pe
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
n in
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te o
thi
s
iva
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Co
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Notes:
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co Vo
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cted agen
Prote AG.
◆ Always renew seals and gaskets.
◆ The lower part of the toothed belt guard need not be removed.
◆ The toothed belt should be left in position on the crankshaft sprocket.
◆ Cover toothed belt with a cloth to protect it from coolant before removing coolant pump.
Removing
- Drain coolant => Page 152

- Remove ribbed belt => Page 28 .
- Remove tensioning element for ribbed belt.
- Remove upper and centre parts of toothed belt guard => Page 60 , Removing, installing and tensioning
toothed belt.
1.10 - Removing and installing coolant pump 159

Sharan 1996 ➤
- Take toothed belt off coolant pump toothed belt sprocket => Page 60 , Removing, installing and tensioning
toothed belt.
- -> Unscrew coolant pump securing bolts -1- and remove coolant pump -2-.
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Installing ed
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Installation is carried
au out in the reverse order, when doing this note r a the
c following:
ss
ce
le
satelettronica
un
pt
- Moisten new O-ring with coolant.
an
d
itte
- Insert coolant pump into cylinder block and tighten securing bolts.
y li
erm
ab
ility
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wit
is n
Note:
h re
ole,
spec
The coolant pump plug faces downwards.
t to the co

- Install ribbed belt => Page 28 .
rrectne

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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Cop py
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co lksw
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Prote AG.

Sharan 1996 ➤
1.11 - Removing and installing thermostat
satelettronica
lkswage es n
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ir se tee
tho
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a ac
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un
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pe
ility
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hole
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es, in part or in w
t to the co

rrectness of i
Removing
l purpos
Note:
Always renew gaskets and sealing rings.

nform
mercia
- Drain coolant => Page 152

com
tion in
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te o
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Prote AG.
1.11 - Removing and installing thermostat 161

Sharan 1996 ➤
lkswage es n
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ed ran
- -> Pull coolant hose off connecting flangethor -3-.
is tee
or
- Unbolt securing bolts -4- of connectingau flange -3- and remove connecting flange -3- with ac thermostat -1-.
ss
ce
e
nl
Installing
pt
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an
itte
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erm
ab
ility
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- Moisten new O-ring -2- with coolant.
h re
- Fit connecting flange -3- with thermostat -1- into engine block.
hole
spec
- Tighten securing bolts -4-.
satelettronica
es, in part or in w
t to the co
rrectness of i
l purpos
1.12 - Checking coolant circulation pump
nform
ercia
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
◆ V.A.G 1594 A Auxiliary test set
◆ Current flow diagram
Check conditions
• -> Fuse No. 18 must be OK (for vehicles with engine cold AJH).
satelettronica
lkswage es n
o ot g
• -> Fuse No. 16 must d by Vbe OK (for vehicles with engine ucode
ara AWC).
ir se nte
tho eo
Test sequences au ra
c
s
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nl

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ility
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es, in part or in w
t to the co
rrectness of i
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nform
ercia
- -> Remove the securing nuts -arrows- for the heat shield for the coolant circulation pump (V50), from the
m
at
om
bulkhead.
ion
c
- Pull the heat shield forward slightly.

in t
or
his
e
- Pull 2-pin connector off coolant circulation pump (V50).

at
do
priv
cum
for
en
ng
t.
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Cop py
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co lksw
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cted agen
Prote AG.
1.12 - Checking coolant circulation pump 163

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
le
un
pt
an
d
itte
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erm
ab
ility
- -> Pull 2-pin connector off continued coolant circulation pump (V51) -arrow- .
ot p
wit
is n
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ole,
spec
t to the co
satelettronica
rrectness o
cial p
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mer
atio
om
n
c
i
or
n thi
te
sd
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Functional check
i
o
pr
cum
r
fo
en
ng
- -> Connect contacts of coolant circulation pump (V50) or continued coolant circulation pump (V51) to battery
t.
yi Co
op
using adapter cables from V.A.G 1594 A. C py
t. rig
Pump must run.
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If pump does not run: Prote AG.
- Replace pump.
If pump runs:
Checking activation
- Switch ignition off and on again.
- -> Connect diode test lamp V.A.G 1527 B to disconnected connector for coolant circulation pump (V50) or
continued coolant circulation pump (V51) using adapter cables from V.A.G 1594 A

Sharan 1996 ➤
LED must light up.
Note:
This check must be performed within 3 minutes of switching ignition off.
If the LED does not light up:
- Locate and rectify open circuit using current flow diagram:
AG. Volkswagen AG d
agen oes
olksw not
yV gu
satelettronica
d b ara
ise nte
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itte
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ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
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or c
thi
te
sd
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Cop py
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rig ht
py by
co Vo
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cted agen
Prote AG.
1.12 - Checking coolant circulation pump 165

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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Sharan 1996 ➤ aut
h
ra
s c
4-cyl. injection engine (5-valve), Mechanics - Edition 02.2005 s
ce
e
nl
pt
du
an
20 - Fuel supply system
itte
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erm
ab
ility
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hole
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1 - Removing and installing parts of fuel supply system
es, in part or in w
t to the co
1.1 - Removing and installing parts of fuel supply system
rrectness of i
l purpos
Notes:
nform
ercia
◆ Hose connections are secured with either spring-type or clamp-type clips.

◆ Always replace clamp-type clips with spring-type clips.
m
at
◆ Fuel hoses in engine compartment must only be secured with spring-type clips. The use of clamp or screw-
om
ion
type clips is not permissible.
c
in t
or
◆ Assembly tool VAS 5024 or hose clip pliers V.A.G 1921 are recommended for fitting spring-type clips.
his
ate
do
priv
c
Removing and installing fuel tank with attachments and fuel filter: engine code AJH => Page 167 .
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for
en
ng
t.
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op
Removing and installing fuel tank with attachments and fuel filter: engine code AWC => Page 175 . C py
ht. rig
satelettronica
rig ht
py by
Observe safety precautions=> Page 182 .
co Vo
by lksw
cted agen
Prote AG.
Observe rules for cleanliness => Page 183 .
Observe crash fuel shut-off: engine code AWC => Page 186 .
Servicing accelerator mechanism: engine code AJH => Page 195
Adjusting throttle cable: engine code AJH => Page 197
Electronic power control (EPC): engine code AWC => Page 199 .
Activated charcoal filter system => Page 204 .
166 20 - Fuel supply system

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara Sharan 1996 ➤
ise nte
r
4-cyl.
ut
ho injection engine (5-valve), Mechanics eo
ra - Edition 02.2005
s a c
s
1.2 - Removing and installing fuel tank with attachments and fuel filter: engine code AJH
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
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fo
en
ng
t.
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satelettronica
Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note:
After all repairs to the fuel supply unit or the fuel gauge sender unit have been carried out, ensure the the supply
or return flow hoses do not make contact with the fuel tank (pump noises may be transferred).
1 Cap
2 Seal
◆ If damaged only replace together with cap
3 Retaining ring
4 Rubber cup
167
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
5 Gravity valve
agen
Prote AG.
◆ To remove valve unclip upwards out of filler neck

◆ Check valve for through-flow
valve vertical: open,
valve tilted 45 °: closed
6 O-ring
7 Vent valve
◆ Cannot be removed; renew together with filler neck => item 17
◆ Checking =>Page 174 , Fig. 2
8 Pressure retaining valve
◆ For fuel tank venting
◆ Checking => Page 174 , Fig. 3

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
9 Return line
◆ Blue
◆ Clipped onto fuel tank
◆ From fuel return pipe on fuel rail
=> Repair group 24; Servicing injection system; Dismantling and assembling fuel rail and injectors Servicing
injection system Dismantling and assembling fuel rail and injectors
10 Union nut, 75 Nm
◆ Remove and install with spanner 3217
11 Connector
◆ Black, 4 pin
◆ For fuel gauge sender (G) and fuel pump (G6)
12 Flange
◆ Note fitting position on fuel tank => Page 174 , Fig. 1
◆ Underside marked with "V" and "R" for supply and return hoses
169
Sharan 1996 ➤
lkswage es n
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byV ua
d ran
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tho
u or
a ac
ss
ce
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nl
pt
du
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itte
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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
satelettronica
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
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Vo
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cted agen
Prote AG.
13 Supply hose
14 Sealing ring
◆ When installing, insert seal "dry" into fuel tank opening
◆ Moisten with fuel only when installing flange item 12
15 Return hose
16 6 Nm
17 Filler neck
◆ With expansion tank and vent valve

Sharan 1996 ➤
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
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ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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fo
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t.
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18 Vent pipe Prote AG.

◆ To junction piece between activated charcoal filter and solenoid valve 1 for activated charcoal filter
=>Page 206 , Servicing parts of activated charcoal filter system: engine code AJH
19 Grommet
20 Retaining ring
21 Non-return valve
◆ Check for freedom of movement
22 Vent pipe
23 25 Nm
24 Fuel tank
◆ Support with engine and gearbox jack V.A.G 1383 A when removing
171
Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
au ra
ss c
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e
nl
pt
du
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itte
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erm
ab
ility
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
25 Securing strap
l purpos
◆ Note differing length

◆ Note installation position
nf
ercia
26 20 Nm
orm
27 Bracket
m
atio
m
◆ For fuel filter

o
n in
or c
28 Supply line
thi
te
sd
a
◆ Black
iv
o
r
rp
cu

o
m
f
en
◆ To fuel supply pipe on fuel rail:

ng
t.
yi Co
Cop py
t. rig
=> Repair group 24; Servicing injection system; Dismantling and assembling fuel rail and injectors Servicing
gh ht
yri by
injection system Dismantling and assembling fuel rail and injectors cop Vo
by lksw
cted agen
Prote AG.
29 Fuel filter
◆ Installation position: Arrow points in through-flow direction
30 Fuel gauge sender (G)

Sharan 1996 ➤
satelettronica
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
hole
spec
31 Fuel delivery unit
es, in part or in w
t to the co
=> Page 183
◆ Checking fuel pump
rrectness of i
=> Page 187
32 Strainer
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.
173
Sharan 1996 ➤
-> Fig. 1 Installation position of fuel delivery unit flange
Marking on the flange must align with marking on the fuel tank -arrows-.
Note:
After installing fuel delivery unit flange, check that the supply, return and breather pipes are still clipped onto
the fuel tank.
satelettronica
-> Fig. 2 Checking vent valve
AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
Valve in rest position: Closed orised
nte
h eo
aut ra
Valve pushed in direction of arrow: Open 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
-> Fig. 3 Checking pressure retaining valve

atio
om
n
c
i
or
n thi
e
From the gravity valve direction the pressure retaining valve is open in both directions of flow -arrow -1-.
t
sd
iva
o
pr
cum
r
fo
From junction piece for activated charcoal filter and solenoid valve 1, it permits flow in one direction only -arrow
en
ng
t.
2-. Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
1.3 - Removing and installing fuel tank with attachments and fuel filter: engine code AWC
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
satelettronica
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.
Notes:
◆ Following all work on fuel delivery unit or fuel gauge, ensure that the fuel supply and return hoses do not
touch the fuel tank (transmission of pump noise).
◆ Fuel pump relay (J17)
=> Page 182 , Fig. 4 .
1 Cap
2 Securing clip
3 Seal
4 Retaining ring
1.3 - Removing and installing fuel tank with attachments and fuel filter: engine code
AWC 175
Sharan 1996 ➤
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
5 Rubber cup
un
pt
an
d
6 Gravity valve
itte
y li
rm
ab
◆ To remove valve unclip upwards out of filler neck
pe
ility
◆ Check valve for through-flow
ot
wit
, is n
valve vertical: open,

valve tilted 45 °: closed h re
hole
spec
7 O-ring
es, in part or in w
t to the co
8 Vent valve
◆ Cannot be removed, replace together with filler neck => item 14
rrectness of i
◆ Checking =>Page 181 , Fig. 2

l purpos
9 Pressure retaining valve

◆ For fuel tank venting
◆ Checking => Page 182 , Fig. 3
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 ➤
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
satelettronica
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.
10 Return line
◆ Blue
◆ From fuel return pipe on fuel rail
11 Supply line
◆ Black
◆ To fuel manifold
12 Connector
◆ Black, 4 pin
◆ For fuel gauge sender (G) and fuel pump (G6)
13 6 Nm
14 Filler neck
◆ With expansion tank and vent valve
AWC 177
Sharan 1996 ➤ agen
AG. Volkswagen AG d
oes
ksw
by
Vol - Edition 02.2005 not gu
ara
ed nte
oris e
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
satelettronica
p
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.
15 Vent pipe
◆ To junction piece between activated charcoal filter and solenoid valve 1
=>Page 209 , Servicing parts of activated charcoal filter system: engine code AWC
16 Grommet
17 Retaining ring
18 Vent pipe
19 Non-return valve
◆ Check for freedom of movement
20 25 Nm
21 Fuel tank
◆ Support with engine and gearbox jack V.A.G 1383 A when removing

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
satelettronica
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
22 Securing strap
◆ Note differing length
23 20 Nm
24 Bracket
◆ For fuel filter
25 Supply line
◆ Black
◆ To fuel supply pipe on fuel rail:
26 Fuel filter
◆ Fitting position: Arrow points in direction of flow
27 Union nut, 75 Nm
◆ Remove and install with spanner 3217
AWC 179
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
satelettronica
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
28 Fuel delivery unit

◆ Note fitting position on fuel tank => Page 181 , Fig. 1
=> Page 183
◆ Removing and installing fuel gauge sender => Page 185
◆ Checking fuel pump
=> Page 187
29 Sealing ring
◆ When installing, insert seal "dry" into fuel tank opening
◆ Moisten with fuel only when installing flange of fuel delivery unit

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
-> Fig. 1 Installation position of fuel delivery unitssflange c
ce
e
nl
pt
du
an
itte
y li
Marking on sender must align with the marking on fuel tank -arrows-.
erm
ab
ility
ot p
Blue or blue marked return pipe -1- to connection with identification -R-.
wit
, is n
h re
hole
Black supply pipe -2- to connection with identification -V-.
spec
satelettronica
es, in part or in w
t to the co
Note:
After installing fuel delivery unit flange, check that the supply, return and breather pipes are still clipped onto
the fuel tank.
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.
-> Fig. 2 Checking vent valve
Valve in rest position: Closed
Valve pushed in direction of arrow: Open
AWC 181
Sharan 1996 ➤
-> Fig. 3 Checking pressure retaining valve
From the gravity valve direction the pressure retaining valve is open in both directions of flow -arrow -1-.
From junction piece for activated charcoal filter and solenoid valve 1, it permits flow in one direction only -arrow
2-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
satelettronica
-> Fig.4 Fuel pump relay (J17)
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
-Relay position 21-
ility
ot
wit
, is n
h re
The relay is located on the lower relay carrier of the multi-function unit.
hole
spec
es, in part or in w
Notes:
t to the co
◆ If tools are necessary to pull relays or control units out of the relay plate, first disconnect battery earth strap.
◆ Before disconnecting battery earth strap obtain code for radios with anti-theft coding.
rrectness of i
l purpos
1.4 - Safety precautions when working on the fuel supply system

nform
mercia
a
com
tion in
Warning!
r
te o
thi
s
iva
cramped conditions:
do
r
rp
um
fo
en
ng
t.
yi Co
op
◆ Ensure sufficient clearance to all moving or hot components. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
When removing and installing the fuel gauge sender or fuel pump (fuel delivery unit) from a full or partly full fuel
tank the following must be observed:
Warning!
◆ Before commencing work, switch on exhaust extraction system and place an extraction hose close to the
sender opening in the fuel tank to extract escaping fuel fumes.
If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displace‐
ment greater than 15 m3/h can be used.
◆ Prevent skin contact with fuel! Wear fuel-resistant gloves!

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V
◆ For reasons of safety, remove fuse No. 14 from fuseedholder
by before opening the fuel system gu
arabecause the
fuel pump can be activated by the driver's door contact
thoris switch. nte
eo
au ra
ss c
ce
le
un
pt
1.5 - Rules for cleanliness
an
d
itte
y li
erm
ab
ility
ot p
satelettronica
wit
is n
When working on the fuel supply/injection system, pay careful attention to the following "5 rules":
h re
ole,
spec
◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
t to the co
◆ Carefully cover opened components or seal, if the repair cannot be carried out immediately.
◆ Only install clean components:
Only unpack replacement parts immediately prior to installation.
rrectne
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
◆ When the system is open:
s
Do not work with compressed air if this can be avoided.
s o
cial p
Do not move vehicle unless absolutely necessary.
f inform
mer
atio
om
n
1.6 - Removing and installing fuel delivery unit
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.
◆ 3217 Ring nut spanner
1.4 - Safety precautions when working on the fuel supply system 183
AG. Volkswagen AG d
agen oes
olksw not
Sharan 1996 ➤ d byV gu
ara
e
4-cyl. injection engine (5-valve),horis Mechanics - Edition 02.2005 nte
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
rrectnes
s o
cial p
f in
Removing
form
mer
atio
m

o
n
c
i
or
n thi
- With the ignition switched off disconnect battery earth strap.
te
sd
a
- Remove cover from fuel delivery unit.

iv
o
pr
c
- Pull 4-pin connector and supply and return pipes off flange.
um
r
fo
en
ng
satelettronica
t.
yi Co
Cop py
Warning! ht. rig
rig ht
Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connec‐ py by
co Vo
lksw
by
cted agen
Prote AG.
Note:
- Remove union nut with union nut tool 3217.
- Pull flange and seal out of the opening in fuel tank.

- Release delivery unit by turning to left out of bayonet connection and remove.
- Pull fuel delivery unit and seal out of opening in the fuel tank.
Note:
If the delivery unit is to be renewed then drain old delivery unit before disposal.
Installing
- Installation of the fuel delivery unit is carried out in the reverse order.
Notes:
◆ When inserting the fuel delivery unit ensure that the fuel gauge sender is not bent.
◆ Insert seal for flange or fuel delivery unit dry into opening of fuel tank.
◆ Moisten seal with fuel only when installing flange or fuel delivery unit.
◆ Ensure fuel hoses are seated securely.

Sharan 1996 ➤
◆ After installing fuel delivery unit, check that the supply, return and vent pipes are still clipped onto fuel tank.

◆ -> Note installation position of fuel delivery unit flange:
The marking on flange must align with marking on fuel tank -arrows-.
AG. Volkswagen AG d
satelettronica
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
◆ -> When the fuel delivery unit is correctly installed the fuel gauge sender float points in direction of travel A: 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
◆ -> Note installation position of fuel delivery unit flange: Prote
cted AG.
agen
The marking on flange must align with marking on fuel tank -arrows-.
1.7 - Removing and installing fuel gauge sender: engine code AWC
Removing
- Removing fuel delivery unit
1.6 - Removing and installing fuel delivery unit 185

Sharan 1996 ➤
=> Page 183 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
- -> Release and pull off the terminals for ut wires -3- and -4-.
ho eo
ra
- Lift retaining tabs -1- and -2- with a sscrewdriver
s a
and pull fuel gauge sender out downwards c -arrows-.
ce
e
nl
pt
du
Installing
an
itte
y li
erm
ab
- Insert fuel gauge sender in the guides on the fuel delivery unit and push up until it engages.
ility
ot p
- Installing fuel delivery unit
wit
, is n
satelettronica
=> Page 183 .
h re
hole
spec
es, in part or in w
t to the co
1.8 - Crash fuel shut-off: engine code AWC
rrectness of i
Function
l purpos
Vehicles with an airbag are fitted with a crash fuel shut-off system. It reduces the danger of a fire in a crash as
nform
ercia
the fuel pump is switched off via the fuel pump relay.
Simultaneously this system provides improved starting characteristics for the engine.
m
at
When the door is opened the fuel pump is activated for 2 seconds to build-up the pressure in fuel system.
om
ion
c
in t
or
When opening the fuel system: his

ate
do
priv
cum

for
en
ng
t.
yi Co
op
- Check activation of fuel pump relay using current flow diagram and V.A.G 1466 A: C py
t. rig
gh ht
pyri by
Vo
o
=> Current flow diagrams, Electrical fault finding and Fitting locations by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
1.9 - Checking fuel pump
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
◆ 3217 Union nut spanner

pe
ility
◆ V.A.G 1318 Pressure tester

ot
wit
, is n
◆ V.A.G1318/17 Adapter
h re
◆ V.A.G 1318/11 Adapter

hole
spec
◆ V.A.G 1318/16 Adapter

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
187
o
by c lksw
cted
agen
Prote AG.
Sharan 1996 ➤
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
satelettronica
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
◆ V.A.G 1348 Fuel quantity comparison meter

thi
te
sd
a
◆ V.A.G 1466 Test system

iv
o
pr

um
r
fo

en
ng
t.
yi Co
◆ V.A.G 1715 Multimeter Cop py
◆ VAS 5024 Assembly tool for spring-type clip
t. rig
gh ht
yri
◆ Measuring container
p by
co Vo
by lksw
◆ Current flow diagram Prote
cted AG.
agen

Sharan 1996 ➤
Check conditions
• Fuse No. 14 must be OK.
-> Fuse holder for vehicles with engine code AJH.
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
-> Fuse holder for vehicles with engine code AWC.
erm
ab
ility
ot p
wit
is n
satelettronica
h re
ole,
spec
t to the co
Note:
Note description of function of crash fuel shut-off for vehicles with engine code AWC=>Page 186 .
rrectne
Checking function and voltage supply
ss o
cial p
Note:
f inform
mer
Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap
atio
m
must be disconnected. Obtain radio code first if necessary.

o
n
c
i
or
n thi
e
- Remove cover from fuel delivery unit.

t
sd
iva
- Briefly operate starter. Fuel pump must be
o
pr
cum
r
fo
heard to run.
en
ng
t.
- Switch off ignition. Cop
yi Co
py
t. rig
gh ht
If the fuel pump does not run: yri
p by
o Vo
by c lksw
cted agen
Prote AG.
- -> Separate the 6-pin connector -arrow- left behind the battery.
1.9 - Checking fuel pump 189

Sharan 1996 ➤
- -> Connect remote control V.A.G 1348/3A to contact 2 of connector and battery positive (+) using adapter
cable V.A.G 1348/3-2 and adapter cable from V.A.G 1594 A.
satelettronica
- -> Pull 2-pin connector from cylinder No. 1 injector -arrow-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
- -> Connect remote control V.A.G 1348/3A to contact 1 of connector and battery positive (+) using adapter
spec
cable V.A.G 1348/3-2 and adapter cable from V.A.G 1594 A.

t to the co

rrectne
- Operate remote control.
Fuel pump runs:

ss o
cial p
- Check activation of fuel pump relay using current flow diagram and V.A.G 1466 A:
inform
mer
atio
om
n
c
i
or
Fuel pump does not run:

thi
te
sd
iva
o
r
- Pull 4-pin connector off flange of fuel delivery unit.

p
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
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
- -> Connect diode test lamp V.A.G 1527 B with auxiliary cables from V.A.G 1594 A to the outer contacts of
an
itte
y li
the connector.
erm
ab
- Operate remote control.
ility
ot p
LED must light up
wit
, is n
h re
hole
LED does not light up:
spec
es, in part or in w
t to the co
- Locate and eliminate open circuit using current flow diagram:
satelettronica
rrectness of i
LED lights up (voltage supply OK.):
l purpos
- Remove union nut with union nut tool 3217.
nf
ercia
- Check that the electrical wires between flange and fuel pump are connected.
orm
m
atio
m
If no open circuit can be found:

o
n in
or c
thi
e
- Fuel pump defective, renew fuel delivery unit =>Page 183 , Removing and installing fuel delivery unit.
t
sd
iva
o
r
rp
cu
o
Checking delivery rate m

f
en
ng
t.
yi Co
op py
Check conditions t. C rig
gh ht
pyri by
Vo
co
• Voltage supply OK.
by lksw
cted agen
Prote
• Remote control V.A.G 1348/3A connected.
AG.
Test sequence
- Remove filler cap from fuel tank filler neck.

- -> Pull supply pipe/hose -arrow- off supply pipe of fuel rail and collect leaking fuel with a cloth.
1.9 - Checking fuel pump 191

Sharan 1996 ➤
Warning! AG. Volkswagen AG d

agen
Fuel system is under pressure! Before opening the Vosystem
lksw place a cloth around
oes
nothe
t gu connection. Then release
pressure by carefully loosening the connection.
ed by ara
n ris tee
utho or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
- Connect pressure gauge V.A.G 1318 to the fuel supply pipe using adapter 1318/10.
- Fit hose V.A.G 1318/16 onto the adapter V.A.G 1318/11 on the pressure gauge and hold hose in a measuring
nf
container.
ercia
o
- Open the pressure gauge shut-off tap. The lever then points in the direction of flow -A-.
rm
m
atio
- Operate remote control V.A.G 1348/3A and slowly close cut-off tap, until pressure gauge shows
satelettronica
om
3 bar.
n in
or c
From this point on do not move position of cut-off tap.
thi
te
sd
- Empty the measuring container.
iva
o
r
- The quantity of fuel delivered by the fuel pump is dependent upon battery voltage. Therefore connect the
rp
cu
o
m
multimeter with adapter cables from V.A.G 1594 A to the vehicle battery.
f
en
ng
t.
yi
- Operate remote control for
Co
op py
30 seconds
t. C rig
gh ht
yri
and measure battery voltage p by
co Vo
by lksw
cted agen
Prote AG.
- -> Compare the quantity of fuel delivered with specification.
*) Minimum delivery cm3/30 seconds
**) Voltage at fuel pump with engine stopped and pump running (approx. 2 volts less than battery voltage).
Example:
During the test a voltage of 12.2 volts is measured at the battery. As the voltage at the pump is approx. 2 volts
less than the battery voltage then this will equate to a minimum delivery of 550 cm3/30 s.
If the minimum delivery rate is not attained:
- Check the fuel pipes for possible restrictions (kinks) or blockages.

Sharan 1996 ➤
- -> Pull the supply hose -1- off inlet to fuel filter.
- Connect the pressure gauge V.A.G 1318 to hose with adapter 1318/10.
- Repeat delivery rate check.
If the minimum delivery rate is now attained:
- Renew the fuel filter.
If the minimum delivery rate is again not attained:
satelettronica
- Remove the fuel delivery unit and check the strainer filter for soiling.
Only when up to now no fault has been detected:
If the delivery rate has been attained but nevertheless you suspect a fuel supply system fault (e.g. intermittent
failure of fuel supply system):
- Check the current draw of the fuel pump as follows:

- Reconnect all disconnected fuel pipes.
AG. Volkswagen AG d
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nl
pt
du
an
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erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
- -> Connect multimeter V.A.G 1715 to wire -arrow- for contact 1 of 4-pin connector using the pick-up clamp.
t to the co
- Start the engine and run at idling speed.

- Measure the current draw of the fuel pump.
Specification: max. 8 amps.
rrectness of i
Note:
l purpos
If the fuel system malfunction is intermittent, you can perform the check during a test drive with the help of a
nform
ercia
2nd person.
m
at
om
io
If the current draw is exceeded:

n
c
in t
or
his
te
a
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
193
cted agen
Prote AG.
Sharan 1996 ➤
Checking fuel pump non-return valve
Test conditions
• Remote control V.A.G 1348/3A is still connected.

• Pressure gauge V.A.G 1318 is still connected.
Note:
With this check the fuel supply pipe connections from the fuel delivery unit to the point at which the pressure
gauge V.A.G 1318 is connected will be checked for leaks at the same time.
Test sequence
satelettronica
- -> Close pressure gauge shut-off tap (lever at right angles to throughflow direction - position -B-).
- Separate remote control at short intervals, until a pressure of
Approx. 3 bar
has built up.
- If pressure builds up too high, lower excess pressure by carefully opening the shut-off tap.
Warning!
Danger of spray when opening the shut-offtap, hold container over the free connection of the pressure gauge.
n AG. Volkswagen A G do
wage es n
olks ot g
byV ua
- Watch pressure drop on gauge. After 10 minutes
ris
ed the pressure must not drop below ran
tee
2.5 bar. utho or
a ac
ss
If the pressure drops further:
ce
le
un
pt
an
d
itte
y li
- Check pipe connections for leaks.

rm
ab
pe
ility
ot
If no fault is detected in the wiring:

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 - Accelerator mechanism: engine code AJH

2.1 - Accelerator mechanism: engine code AJH
AG. Volkswagen AG d
agen oes
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d b ara
rise nte
tho eo
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e
nl
pt
du
an
itte
satelettronica
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.
2.2 - Servicing accelerator mechanism
1 Accelerator cable
◆ Adjusting => Page 197
◆ Do not reuse damaged accelerator cable, replace
2 Cable cam
◆ On throttle valve control part
3 Retainer
◆ Adjusting throttle cable => Page 197
4 Support bracket
◆ For accelerator cable
2.1 - Accelerator mechanism: engine code AJH 195

Sharan 1996 ➤
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
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
5 Kickdown switch (F8)

◆ On vehicles with automatic gearbox 099 - 4-speed
◆ On bulkhead
◆ Checking => Page 197 , Adjusting throttle cable on vehicles with automatic gearbox
6 Connector
◆ Black, 2-pin
7 Balance weight
8 Spacer sleeve
9 Accelerator pedal
10 Accelerator pedal stop
11 Stop bolt
12 Rubber ring
13 Accelerator pedal pin

Sharan 1996 ➤
2.3 - Adjusting throttle cable
Work sequence
AG. Volkswagen AG d
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- -> Adjust accelerator cable
s aut by moving the retainer -arrow- at the support r abracket,
c so that the full throttle
position is attained at sthe throttle valve control part.
satelettronica
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.
◆ V.A.G 1526 A Hand multimeter
2.3 - Adjusting throttle cable 197

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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V gu
d by ara
ise nte
or eo
h
aut ra
ss c
◆ V.A.G 1594 A Auxiliary test set
ce
le
un
pt
◆ Distance piece 13 mm
an
d
itte
y li
erm
ab
Work sequence
ility
ot p
wit
is n
h re
ole,
spec
t to the co
satelettronica
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
- -> Clamp distance piece -1-, n thi

te
a = 13 mm,
sd
iva
o
r
between accelerator pedal -2- and stop -3- and hold accelerator pedal in this position.
p
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.
- -> Fully open throttle valve by pulling on the outer cable and locate in this position with the retainer -arrow-.
- Release accelerator pedal.
- Pull 2-pin connector off kick-down switch (F8) in engine compartment (on the bulkhead).

Sharan 1996 ➤
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
- -> Connect hand multimeter V.A.G 1526 A with aux. cables from V.A.G 1594 to kick-down switch.
- Check resistance at switch.
Specification: ∞ω
rrectness of i
- Slowly move accelerator pedal in direction of full throttle.
l purpos
Shortly after the kick-down pressure point the resistance must drop to 0 ω.
At this point the accelerator pedal must be just off the stop.
nf
ercia
orm
m
atio
m
satelettronica
o
3 - Electronic power control (EPC): engine code AWC
n in
or c
thi
te
sd
iva
3.1 - Electronic power control (EPC): engine code AWC
o
r
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Cop py
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Vo
co
3.2 - Function of EPC system
by lksw
cted agen
Prote AG.
With the EPC system the throttle valve is not operated by a cable. There is no mechanical connection between
accelerator and throttle valve.
The position of the accelerator is transmitted to the engine control unit by two accelerator position senders
(variable resistors together in a housing) which are connected to the accelerator pedal.
The position of the accelerator (drivers requirement) is the main input value for the engine control unit.
The throttle valve is operated over the complete revolution and load range by an electric motor (throttle valve
positioner) in the throttle valve control part.
The throttle valve is operated by the throttle valve positioner which is controlled by the engine control unit.
When the engine is not running and the ignition is switched on the engine control unit moves the throttle valve
exactly as prescribed by the accelerator pedal position sender. This means that when the accelerator is de‐
pressed halfway the throttle valve positioner opens the throttle valve by the same amount, the throttle is then
approximately half open.
When the engine is running (under load) the engine control unit can open or close the throttle valve independ‐
ently of the accelerator pedal position sender.
This means that the throttle valve can already be completely open even though the accelerator pedal is de‐
pressed half way.
After evaluating the torque requirements of various components (e.g. air conditioning, automatic gearbox, ABS/
ESP and so on), the engine control unit calculates the optimal throttle valve opening angle for the respective
situation.
This also gives vastly improved consumption and exhaust emission levels at certain load conditions.
It is incorrect to believe that the "EPC" is comprised of one or two components only. The EPC is a system,
which is comprised of all components which have an influence, control or monitor the position of the throttle
2.3 - Adjusting throttle cable 199

Sharan 1996 ➤
G. Volkswage
valve, e.g. the accelerator pedal
lksw
ageposition
nA sender, the
n AG d
oesthrottle valve control unit, the EPC warning lamp, the
not
engine control unit. by
Vo gu
a
ed ran
oris tee
Observe safety precautions=>
au
th Page 182 . or
ac
ss
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
3.3 - Servicing parts of electronic power control (EPC)
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
satelettronica
or c
thi
te
sd
iva
o
r
rp
cu
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m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1 Bracket
2 Connector
◆ Black, 6-pin
3 10 Nm
4 Accelerator pedal position sender (G79)
◆ Not adjustable
◆ The accelerator pedal position passes the position of the pedal on to the engine control unit

Sharan 1996 ➤
3.4 - Checking accelerator pedal position sender AG. Volkswagen AG d

agen oes
olksw not
byV gu
ara
ed
ris nte
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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
satelettronica
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.
◆ V.A.G 1526 Hand multimeter

◆ V.A.G 1598/31 Test box
◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3
Function
Both accelerator pedal position senders -G79- and -G185- on the accelerator pedal pass the driver's require‐
ments on to the engine control unit independently of one another. Both senders are installed together in a
housing.
3.4 - Checking accelerator pedal position sender 201

Sharan 1996 ➤
Check conditions
• -> The fuses must be OK.

Test sequence
satelettronica
- Connect fault reader V.A.G 1551 (V.A.G 1552) and with ignition switched on select engine electronics control
unit with the "Address word" 01:
=> Repair group 01; General to self-diagnosis: Connecting fault reader General to self-diagnosis: Connecting
fault reader
-> Indicated on display:

Rapid data transfer HELP
Select function XXX
- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.
. Volkswage n AG n AG d
wage oes
olks not
-> Indicated on display: by
V gu
ara
ed nte
Read measured value block oris eo
Input display group number XXX th
au ra
c
ss ce
le
un
- Press keys 0, 6 and 2 for the "Display group number 62" and confirm entry with Q key.
pt
an
d
itte
y li
rm
ab
pe
ility
(1...4 = Display zones)

ot
wit
, is n
h re
Read measured value block 62

hole
1 2 3 4
spec
es, in part or in w
t to the co
- Check specification of sender 1 (G79) at idling speed limit stop in display zone 3.
Specification: 6...96 %
- Check specification of sender 2 (G185) at idling speed limit stop in display zone 4.
rrectness of i
Specification: 3...48 %
l purpos
Note:
The engine control unit calculates the voltage values of the angle sender in percent relative to 5 Volt and displays
nform
ercia
these as a percentage figure (5 Volt supply voltage equates to 100 %).

m
a
com
tion in
- Operate the accelerator pedal slowly until fully depressed and observe the angle sender figures in display
r
te o
zones 3 and 4:
thi
s
iva
do
r
rp
The percent figures in display zone 3 must rise evenly. The tolerance range of 6...96 % is not covered
um
fo
en
completely.
ng
t.
yi Co
The percent figures in display zone 4 must rise evenly. The tolerance range of 3...48 % is not covered . Cop py
completely.
ht rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
Note:
The figure displayed in display zone 3 must always be approximately double that displayed in display zone 4.
- Press the ⇒key.

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
If the display does not indicate as described:
- Check accelerator pedal

swa
genposition
AG. Volkswsender
agen AG
voltage
does supply and wiring connections =>Page 203 .
k not
Vol gu
by ara
Checking voltage
ris supply and wiring to control unit
ed nte
tho eo
au ra
- Pull 6-pin
ss connector off accelerator pedal position sender.c
ce
- Switch ignition on.
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
satelettronica
t to the co
rrectness o
cial p
f inform
mer
- -> Connect multimeter to measure voltage at the following contacts of the connector using adapter cables
atio
from V.A.G 1594 A

om
Contact 1 + earth
n
c
i
or
Contact 1 + 5
thi
te
sd
a
Contact 2 + earth
iv
o
pr
Contact 2 + 3
cum
r
fo
Specification: minimum 4.5 V

en
ng
t.
yi
Co
Cop py
t. rig
gh ht
yri by
If no voltage is present: op Vo
by c lksw
cted agen
Prote AG.
- Remove battery.
- -> Connect test box V.A.G 1598/31 to control unit wiring harness. The engine control unit remains discon‐
nected.
3.4 - Checking accelerator pedal position sender 203

Sharan 1996 ➤
. Volkswagen AG
gen AG d
- -> Check wiring for openVcircuit
olks
wa between test box and
oes
n6-pin
ot g connector using current flow diagram.
Contact 1+ socketed72 by ua
ran
Contact 2+ socketthoris 73 tee
Contact 3+ socket
s au 36 or
ac
Contact 4+ socket 35
s
ce
le
un
pt
an
d
itte
y li
Wire resistance: max. 1.5 ω
rm
ab
pe
ility
- Additionally check wires for short to one another, to vehicle earth and to battery positive.
ot
wit
, is n
satelettronica
h re
hole
spec
If no fault is detected in the wiring:
es, in part or in w
t to the co
- Renew accelerator pedal position sender
rrectness of i
l purpos

nform
ercia

m
a
com
ti
- On vehicles with automatic gearbox the gearbox control unit must be matched additionally:
on in
r
te o
thi
=> Self-diagnosis for automatic gearbox 09B - 5-speed; Repair group 01; Performing self-diagnosis; Initiating
s
iva
do
basic setting Performing self-diagnosis Initiating basic setting

r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
4 - Activated charcoal filter system
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4.1 - Activated charcoal filter system
4.2 - Function
Depending upon the air pressure and ambient temperature, fuel vapour will form above the level of fuel in the
tank.
The activated charcoal filter system prevents these HC emissions escaping to the atmosphere.
Fuel vapours pass through a gravity valve (which closes at an angle of 45 °) located at the highest point in the
tank and through a pressure retention valve into the activated charcoal filter in limited quantities.
The activated charcoal stores these vapours like a sponge.

Sharan 1996 ➤
. Volkswagen AG
gen AG d
When the Lambda control isVoactivelksw when driving (engine
a oes warm), the activated charcoal filter solenoid valve
not
(N80), also called regeneration
ed by valve), is activated (pulsed) from
gu
ara engine control unit depending upon load and
engine speed. The opening
thoris
period is dependent on the input signals.
nte
e or
au ac
ss
During the purging procedure (regeneration of activated charcoal), the intake manifold vacuum draws fresh air
ce
e
nl
through the vent opening on the activated charcoal filter. The fuel vapours stored in the activated charcoal and
pt
du
an
fresh air are fed in pulses for combustion.
itte
y li
erm
ab
ility
ot p
The pressure retention valve prevents fuel vapours from being drawn from the tank when the activated charcoal
wit
filter solenoid valve (N80) is open and intake manifold vacuum is present. It thus ensures that the evacuation
, is n
h re
of the activated charcoal filter has priority.
hole
spec
es, in part or in w
With no voltage (e.g. wiring open circuit), the activated charcoal filter solenoid valve (N80) is closed and the
t to the co
activated charcoal filter will not be purged.
Notes:
rrectness of i
l purpos
◆ Hose connections are secured with either spring-type or clamp-type clips.

◆ Always replace clamp-type clips with spring-type clips.
◆ Assembly tool VAS 5024 or hose clip pliers V.A.G 1921 are recommended for fitting spring-type clips.
nf
ercia
orm
m
atio
om
n in
c
satelettronica
or
thi
te
sd
iva
o
r
Servicing parts of the activated charcoal filter system: engine code AJH=> Page 206 .
rp
cu
o
m
f
en
ng
t.
yi Co
Servicing parts of the activated charcoal filter system: engine code AWC => Page 209 . t. Cop py
rig
gh ht
yri by
Checking activated charcoal filter solenoid valve 1: engine code AWC => Page 212 . op Vo
by c lksw
cted agen
Prote AG.
Checking fuel tank breather: engine code AJH => Page 214 .
Checking fuel tank breather: engine code AWC => Page 215 .
4.2 - Function 205

Sharan 1996 ➤
4.3 - Servicing parts of the activated charcoal filter system: engine code AJH
satelettronica
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
1 Connections
h re
ole,
2 Bracket
spec
◆ For activated charcoal filter

t to the co
3 Junction piece
4 Vent pipe
◆ From pressure retaining valve on fuel tank
rrectne
=> Page 167 , Removing and installing fuel tank with attachments and fuel filter: engine code AJH
5 Activated charcoal filter
ss o
◆ Location: in front right wheel housing

cial p
f in
◆ Remove wheel housing liner to remove

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

Sharan 1996 ➤
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
satelettronica
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.
6 10 Nm
7 From air hose
◆ Overview of turbocharging:
engine code AJH:
=>Page 233
8 Throttle valve control part
9 Air cleaner lower part
10 Activated charcoal filter solenoid valve 1 (N80)
◆ When the engine is warm the valve will be activated from the engine control unit (pulsed)
◆ Checking activation:
=> Repair group 01; Final control diagnosis; Performing final control diagnosis Final control diagnosis Per‐
forming final control diagnosis
11 Connector
◆ 2-pin
◆ For activated charcoal filter solenoid valve 1 (N80)
4.3 - Servicing parts of the activated charcoal filter system: engine code AJH 207
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
satelettronica
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.
12 Vent pipe
◆ To atmosphere
◆ Secured to body
13 O-ring

Sharan 1996 ➤
4.4 - Servicing parts of the activatedagecharcoal filter system: engine code AWC
n AG. V gen AG olkswa
does
lksw n o ot g
yV ua
db ran
ir se tee
ho
aut or
ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
satelettronica
n
c
i
or
n thi
te
sd
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o
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cum
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fo
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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.
1 Connector
2 Bracket
◆ For activated charcoal filter
3 Junction piece
4 Vent pipe
=> Page 175 , Removing and installing fuel tank with attachments and fuel filter: engine code AWC
◆ Location: in front right wheel housing
◆ Remove wheel housing liner to remove
4.4 - Servicing parts of the activated charcoal filter system: engine code AWC 209
Sharan 1996 ➤
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
6 10 Nm utho
or
a ac
7 Junction piece ss
ce
le
un
pt
8 Vent pipe
an
d
itte
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◆ Black with white markings

rm
ab

pe
ility
◆ To upper connecting pipe on fuel rail:

ot
wit
, is n
h re
hole
spec

es, in part or in w
t to the co
9 Non-return valve
◆ For activated charcoal filter system
rrectness of i
◆ Grey connection faces junction piece -item 7 -

10 Vent pipe
l purpos
engine code AWC:
nform
ercia
=>Page 236
m
11 Air cleaner lower part

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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
satelettronica
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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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.

13 Connector
◆ Green, 2-pin
◆ For activated charcoal filter solenoid valve 1 (N80)
14 Vent pipe
◆ To atmosphere
◆ Secured to body
15 O-ring
4.4 - Servicing parts of the activated charcoal filter system: engine code AWC 211
Sharan 1996 ➤
4.5 - Checking activated charcoal filter solenoid valve 1: engine code AWC
In a no-current situation the solenoid valve is closed.
Checking activation:
satelettronica
◆ V.A.G 1551 Fault reader
Note:
AG. Volkswagen AG d
agen o
The vehicle system tester V.A.G 1552 can be used instead of the fault Volreader V.A.G 1551, howeverotaguprint-out
ksw es n
is not possible. ise
d by ara
n r tee
ho
aut or
ac
ss
ce
le
un
pt
an
d
itte
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ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
◆ V.A.G 1551/3 Cable
Test conditions
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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
• -> Fuse No. 14 must be OK.
• Coolant temperature must be at least 80 °C, =>display group 04, display zone 3.
Functional check
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select the engine control unit with the
"Address word" 01. Connecting fault reader and selecting engine control unit:
fault reader

Select function XXX
- Press keys 0 and 8 for the "Read measured value block" function and confirm entry with Q key.
olkswagen AG
swa
gen AG
.V
does
olk not
Read measured bvalueyV block gu
ara
Input display ed group number XXX
ris nte
ho eo
aut ra
s c
- Press
s keys 0, 7 and 0 for "Display group number 70" and confirm entry with Q key.
ce
e
satelettronica
nl
pt
du
-> Indicated on display: an

itte
y li
erm
(1...4 = Display zones) ab

ility
ot p
Read measured value block 70 wit

, is n
1 2 3 4 h re
hole
spec
- Press key 4 for the "Basic setting" function ("Tank venting valve diagnosis" will be initiated)
es, in part or in w
t to the co
Note:
rrectness of i
The engine must not be loaded during this diagnosis because the diagnosis will be interrupted and will not be
started again until the engine is revved-up.
l purpos

nf
ercia
orm
System in basic setting 70

m
atio
m
1 2 3 4
o
n in
or c
thi
When the diagnosis is initiated by the engine control unit, the display in display zone 4 jumps from "Test OFF"
te
sd
a
to "Test ON".
iv
o
r
rp
cu
o
m
f
en
ng
- Run engine at idling speed until the specification "TVV OK" is displayed in display zone 4.
t.
yi Co
Cop py
t. rig
Note:
gh ht
pyri by
Vo
o
by c lksw
cted agen
TVV stands for tank vent valve (activated charcoal filter solenoid valve 1).
Prote AG.
If the specification "TVV OK" is obtained:
- Press ⇒key.
If "TVV not OK" appears in display zone 4:
- Initiate the final control diagnosis and activate the activated charcoal filter solenoid valve 1 (N80):
4.5 - Checking activated charcoal filter solenoid valve 1: engine code AWC 213
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Sharan 1996 ➤ orise nte
h eo
4-cyl. injection engine (5-valve),
aut Mechanics - Edition 02.2005 ra
c
ss
ce
le
4.6 - Checking fuel tank breather: engine code AJH
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
◆ V.A.G 1368 Vacuum tester

te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
satelettronica
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
◆ V.A.G 1390 Hand vacuum pump
Test sequence
- -> Pull breather pipe/hose -5- from activated charcoal filter -1- off the throttle valve control part -3-.
- Connect hand vacuum pump V.A.G 1390 to pipe/hose -5-.
- Pull breather pipe/hose -4- from fuel tank off activated charcoal filter and connect to -connection A- of vacuum
tester V.A.G 1368.
- Connect vacuum tester V.A.G 1368 -connection B- to breather pipe/hose -2-.
- Set vacuum tester to position -B-.
- Initiate final control diagnosis and select activated charcoal filter solenoid valve 1 (N80):
- Operate hand vacuum pump V.A.G 1390 several times.
Vacuum must not

Sharan 1996 ➤
build up.
If vacuum builds up:

- Check breather connection -6- on activated charcoal filter -1- for soiling, clean if necessary.
AG. Volkswagen AG d
agen oes
If vacuum does not build up: olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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un
pt
an
d
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ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
- -> Connect hand vacuum pump V.A.G 1390 to vacuum tester V.A.G 1368 -connection B-.
- Set vacuum tester to -A/B- position.
l purpos
satelettronica
Vacuum must build up.
nform
ercia
If vacuum does not build up:

m
a
- Check pressure retaining valve => Page 174 , Fig. 3
com
tion in
- Check pipe/hose -1- from fuel tank for blockage.
r
te o
thi
s
iva
do
r
rp
cum
fo
4.7 - Checking fuel tank breather: engine code AWC en

ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
◆ V.A.G 1368 Vacuum tester
4.6 - Checking fuel tank breather: engine code AJH 215

Sharan 1996 ➤
Test sequence agen

AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
ris nte
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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
spec
es, in part or in w
t to the co
- -> Pull breather pipe/hose -3- off activated charcoal filter solenoid valve 1 -1-.
rrectness of i
- Connect vacuum tester V.A.G 1368 -connection A- to activated charcoal filter solenoid valve 1 -1-.
l purpos
- Connect hand vacuum pump V.A.G 1390 to vacuum tester V.A.G 1368 -connection B-.
- Set vacuum tester to -A/B- position.
- Initiate final control diagnosis and select activated charcoal filter solenoid valve 1 (N80):
nform
ercia
satelettronica
m
at
om
io
n
c
in t
or
his
te

a
do
riv
Vacuum must not

p
cum
or
build up.
f
en
ng
t.
yi Co
op py
If vacuum builds up:
. C rig
ht ht
rig by
copy Vo
by lksw
- Check breather pipe/hose -4- on activated charcoal filter for soiling and clean if necessary. Prote
cted AG.
agen
- -> Plug breather hose/pipe -arrow- from activated charcoal filter.

- Initiate final control diagnosis again and select activated charcoal filter solenoid valve 1 (N80):

Vacuum must build up.
- Check pressure retaining valve => Page 182 , Item 3

Sharan 1996 ➤
AG. V4-cyl.
olkswageinjection
n AG d engine (5-valve), Mechanics - Edition 02.2005
agen oes
olksw not
yV gu
db ara
rise 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
- -> Check vent hose/pipe -2- on fuel tank for leaks.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
satelettronica
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.
4.7 - Checking fuel tank breather: engine code AWC 217

Sharan 1996 ➤
21 - Charging
1 - Charge air system with turbocharger

1.1 - Charge air system with turbocharger
Notes:
◆ All hose connections are secured with clips.

◆ Always replace clamp-type clips with spring-type clips. AG. Volkswagen AG d
◆ Assembly tool VAS 5024 or hose clip pliers V.A.G 1921 are recommended agen for fitting spring-type
oes clips.
olksw not
◆ Charge air system must be free of leaks. d by V gu
ara
◆ Renew self-locking nuts. or
ise nte
e th or
s au ac
Observe rules for cleanliness => Page 240 . s
ce
e
nl
pt
du
an
itte
y li
satelettronica
erm
ab
ility
ot p
Removing and installing turbocharger with attachments => Page 219 .
wit
, is n
h re
Removing and installing parts of charge air cooler:
hole
spec
Engine code AJH => Page 225 .
es, in part or in w
t to the co
Removing and installing parts of charge air cooler:
Engine code AWC => Page 228 .
rrectness of i
Overview of turbocharging:
l purpos
Overview of turbocharging:
nf
ercia
o
rm
m
atio
m
Checking charge pressure system:

o
n in
or c
thi
te
sd
iva
o
r
Checking charge pressure system:

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.
218 21 - Charging
AG. Volkswagen AG d
agen
Volksw
oes
not Sharan 1996 ➤
by gu
ised 4-cyl. injection engine (5-valve),
ara
nte Mechanics - Edition 02.2005
or eo
th
1.2 - Removing
ss
au and installing turbocharger and attachments ra
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
satelettronica
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1 Exhaust manifold
2 Gasket
◆ Renew
3 Seal
◆ Renew
4 Connection, 30 Nm
5 From oil filter bracket
◆ On vehicles with engine code AJH:
◆ On vehicles with engine code AWC:
6 Oil supply pipe
1.2 - Removing and installing turbocharger and attachments 219

Sharan 1996 ➤
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
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
satelettronica
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.

8 Coolant return pipe
9 Connection, 35 Nm
10 Washer
11 25 Nm
12 Vacuum hose
◆ To charge pressure control solenoid valve (N75)
engine code AJH:
=>Page 233
engine code AWC:
=>Page 236
220 21 - Charging
Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
rrectne
14 From cylinder block
ss

o
cial p
f i

nform
mer

atio
m
16 10 Nm
o
n
c
i
or
17 Vacuum hose
thi
te
sd
a
◆ To charge pressure control solenoid valve (N75)

iv
o
pr
um
r
fo
en
ng
engine code AJH:

t.
yi Co
=>Page 233 Cop py
. rig
ht ht
rig by
py
engine code AWC:co Vo
by lksw
=>Page 236
cted agen
Prote AG.

Sharan 1996 ➤
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
satelettronica
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
op
19 Spacer sleeve C py
t. rig
gh
◆ Only vehicles with manual gearbox
ht
pyri by
Vo
o
by c
20 Support
lksw
cted agen
Prote AG.
◆ Between turbocharger and cylinder block
21 From air cleaner
engine code AJH:
=>Page 233
engine code AWC:
=>Page 236
22 To charge air cooler
engine code AJH:
=>Page 233
engine code AWC:
=>Page 236
23 Plug, 15 Nm
222 21 - Charging
Sharan 1996 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
satelettronica
m
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.
24 Oil return pipe

◆ To sump
=>Page 110 , item 23
25 Gasket
◆ Renew
26 Turbocharger
◆ Charge pressure control valve and charge pressure control valve vacuum unit are components of the
turbocharger and cannot be replaced individually
◆ Checking charge pressure system:
Engine code AJH
=> Page 242
◆ Checking charge pressure system:
Engine code AWC => Page 246
◆ Before connecting oil supply line, fill turbocharger with engine oil through connecting pipe
◆ After installing turbocharger, run engine about 1 minute at idle, and do not rev it immediately, so that the
oil supply to the turbocharger is ensured.

Sharan 1996 ➤
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
satelettronica
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
27 Front exhaust pipe

en
ng
t.
yi
28 35 Nm
Co
Cop py
. rig
◆ Renew
ht ht
rig by
py
◆ Coat threads and bolt head seating surface with "G 052 112 A3" co Vo
by lksw
cted agen
Prote AG.
224 21 - Charging
Sharan 1996 ➤
1.3 - Removing and installing parts of charge air cooling: Engine code AJH
satelettronica
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
1 Intake hose
an
d
itte
y li
◆ From air filter

erm
ab
ility
2 Pressure regulating valve

ot p
wit
is n

h re
ole,
3 From crankcase breather

spec
4 From charge pressure control solenoid valve (N75)

t to the co
engine code AJH:
=>Page 233
rrectne
5 Air pipe
◆ Secured to cylinder head cover
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
225
AG.
1.3 - Removing and installing parts of charge air cooling: Engine code AJH
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
lksw not
satelettronica
Vo gu
by ara
d
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
6 From activated charcoal filter solenoid valve 1 (N80)
nf
ercia
or
engine code AJH:
m
m
atio
=>Page 233
om
n in
c
7 Air hose
or
thi
e
◆ To turbocharger
t
sd
iva
r
rp
cu
o
engine code AJH:

f
en
ng
t.
=>Page 233
yi Co
Cop py
8 Air hose
t. rig
gh ht
yri by
◆ Overview of turbocharging: cop Vo
by lksw
engine code AJH:
cted agen
Prote AG.
=>Page 233
9 To throttle valve control part
10 Air pipe
226 21 - Charging
Sharan 1996 ➤
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
satelettronica
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
c
11 Bracket
or
thi
te
sd
◆ For air pipe
iva
o
r
rp
12 25 Nm cu
o
m
f
en
ng
13 Bracket
t.
yi Co
op py
◆ For charge air cooler t. C rig
gh ht
yri
14 10 Nm p by
o Vo
by c lksw
15 Charge air cooler cted agen
Prote AG.
16 Vacuum hose/pipe
engine code AJH:
=>Page 233
17 Overrun shut-off valve
1.3 - Removing and installing parts of charge air cooling: Engine code AJH 227
Sharan 1996 ➤
1.4 - Removing and installing parts of charge air cooling: engine code AWC
AG. Volkswagen
agen AG do
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y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
satelettronica
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 Intake hose
◆ From air filter
2 10 Nm
4 Connecting hose
◆ From crankcase breather pipe
5 Vacuum hose
◆ From charge pressure limitation solenoid valve (N75)
engine code AWC:
=>Page 236
228 21 - Charging
Sharan 1996 ➤
satelettronica
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
6 Air pipe
es, in part or in w
t to the co
◆ Secured to cylinder head cover

7 Vent pipe
◆ With connecting piece
rrectness of i
◆ For non-return valve in activated charcoal filter system

l purpos
engine code AWC:
=>Page 236
nform
ercia
8 Air hose
m
at
◆ Note assembly markings

om
io
◆ To turbocharger
n
c
in t
or
his
te
engine code AWC:

a
do
riv
=>Page 236
p
cum
for
en
9 Air hose
ng
t.
yi Co
op
◆ To throttle valve control part (J338) C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.4 - Removing and installing parts of charge air cooling: engine code AWC 229
agen AG olksw
Sharan 1996 ➤ wage
n AG. V does
olks not
d by V Mechanics - Edition 02.2005
gu
a
e ran
ris tee
utho or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
satelettronica
um
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
10 Vent hose
◆ From EGR valve (N18)
engine code AWC:
=>Page 236
11 Air pipe
12 O-ring
13 Charge pressure sender (G31)
14 6 Nm
15 Air pipe
16 Bracket
◆ For charge air cooler
=> Page 240
230 21 - Charging
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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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
satelettronica
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.
18 Air hose
◆ Note assembly markings
19 Bracket
◆ For air pipe -item 21 -
20 20 Nm
21 Air pipe
◆ Adjust longitudinally in bracket -item 19 - so that air pipe is not installed under tension
22 Vent hose
engine code AWC:
=>Page 236
1.4 - Removing and installing parts of charge air cooling: engine code AWC 231
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
satelettronica
or eo
th
au ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
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
nf
ercia
24 Air pipe
orm
m
◆ From turbocharger
atio
m
o
n in
or c
engine code AWC:

thi
te
=>Page 236
sd
iva
o
r
rp
cu
25 25 Nm
o
m
f
en
ng
26 Bracket
t.
yi Co
op
C py
t. rig
gh
◆ Secured to cylinder block
ht
pyri by
Vo
co
27 25 Nm
by lksw
cted agen
Prote AG.
◆ Renew
28 Bracket
◆ Secured to sump
232 21 - Charging
Sharan 1996 ➤
1.5 - Overview of turbocharging: engine code AJH
AG. Volkswagen AG d
agen oes
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y V gu
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c
satelettronica
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un
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an
d
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wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or

thi
te
sd
va

i
o
pr
cum
r
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
yri
p by
co Vo
lksw
by
cted agen
Prote AG.
3 Vent pipe
=> Page 168 , Item 8
4 Crankcase breather pressure regulating valve
1.5 - Overview of turbocharging: engine code AJH 233

Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
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ab
5 Non-return valve
ility
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wit
, is n
◆ Gray connection faces junction piece h re

hole

spec
es, in part or in w
7 Turbocharger
t to the co
8 Pressure unit
rrectness of i
◆ For charge pressure control valve

l purpos
◆ Integral part of turbocharger cannot be replaced

9 Charge pressure limitation solenoid valve (N75)
nform
ercia
m
at
om
ion
c
in t
or
his
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at
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
234 21 - Charging
AG. Volkswagen AG d
agen oes
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d by
V
Sharan gu 1996 ➤
ara
e nte
4-cyl. injection engine
horis
(5-valve), Mechanics - Edition 02.2005
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
g
satelettronica
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
10 Cylinder head
11 Throttle valve control part (J338)
13 Crankcase breather
14 Fuel pressure regulator
15 Intake manifold
16 Air mass meter (G70)
17 Air cleaner housing
1.5 - Overview of turbocharging: engine code AJH 235

Sharan 1996 ➤
1.6 - Overview of turbocharging: engine code AWC
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
satelettronica
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
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
3 Vent pipe
236 21 - Charging
Sharan 1996 ➤
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
satelettronica
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
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n in
or c
thi
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5 Non-return valve
t
sd
iva

r
rp
cu
o
◆ Gray connection faces junction piece

f
en
ng
t.
yi
Co
Cop py
t. rig
7 Turbocharger pyri
gh by
ht
o Vo
by c lksw
cted
agen
Prote AG.
8 Charge pressure limitation solenoid valve (N75)

◆ Vacuum hoses on solenoid valve=> Fig. 1
1.6 - Overview of turbocharging: engine code AWC 237

Sharan 1996 ➤
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
satelettronica
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
9 Pressure unit
◆ For charge pressure control valve
◆ Integral part of turbocharger cannot be replaced
10 EGR valve (N18) with potentiometer for exhaust gas recirculation (G212)
◆ Check potentiometer for exhaust gas recirculation =>Page 281
◆ Check EGR valve (N18):
11 Cylinder head
12 Throttle valve control part (J338)
13 Charge pressure sender (G31)
238 21 - Charging
AG. Volkswagen AG d
agen oes
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by Vol
Sharan 1996
gu
ara
➤
d
4-cyl. injection engine or(5-valve),
ise Mechanics - Edition 02.2005 nte
eo
th
s au ra
c
s
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
satelettronica
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
15 T-piece
16 Crankcase breather
17 Fuel pressure regulator
18 Intake manifold
19 Air mass meter (G70)
20 Air cleaner housing
1.6 - Overview of turbocharging: engine code AWC 239

Sharan 1996 ➤
-> Fig. 1 Vacuum hoses on charge pressure control solenoid valve (N75)
1- From charge pressure control vacuum unit
=> Page 220 , item 12
2- To intake hose
3- From connection on turbocharger
=> Page 221 , item 17
1.7 - Rules for cleanliness
When working on the exhaust gas turbocharger, pay careful attention to the following "5 rules":
◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
◆ Carefully cover opened components or seal, if the repair cannot be carried out immediately.
◆ Only install clean components:
Only unpack replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
◆ When the system is open:
Do not work with compressed air if this can be avoided.
Do not move vehicle unless absolutely necessary.
satelettronica
1.8 - Safety precautions
G. Volkswagen
Warning! wage
nA AG do
es n
olks
When doing any repair work, especially in the engine d by V compartment, pay attention touthe
ot g
ara following due to the
cramped conditions: rise nte
tho
◆ Route all the various lines (e.g. for fuel,auhydraulics, activated charcoal filter system, coolant,
eo
ra refrigerant,
brake fluid and vacuum pipes and hoses)ss and electrical wiring so that the original positions c are restored.
ce
e

nl
pt
du
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itte
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ab
ility
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Observe following if test and measuring instruments are required during a test drive: wit
, is n
h re
◆ Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this
hole
spec
location.
es, in part or in w
t to the co
If test and measuring instruments are operated from front passenger's seat and the vehicle is involved in
an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the
airbag is triggered.
rrectness of i
l purpos
1.9 - Removing and installing charge air cooler: engine code AWC
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.
240 21 - Charging
Sharan 1996 ➤
◆ V.A.G 1331 Torque wrench. V(5...50

olkswag Nm) AG en AG
agen does
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pe
ility
ot
wit
, is n
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spec
es, in part or in w
t to the co
◆ VAS 5024 Spring-type hose clip pliers
rrectness of i
◆ Hand drill
◆ Drill, 14 mm ø
l purpos
satelettronica
nform
Removing
mercia
a
com
tion in
- Removing front bumper:
r
te o
thi
s
iva
=> General body repairs, exterior, Repair group 63; Front bumper, Removing and installing front bumper
do
r
rp
cum
fo
en
g
- Remove retainer for lower coolant hose.

n
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
- -> Unbolt P.A.S. hydraulic pipe/hose -1- from lock carrier -arrows-.
- -> Drill holes in lock carrier at the marked positions -arrows- (use14 mm ødrill).
1.9 - Removing and installing charge air cooler: engine code AWC 241
Sharan 1996 ➤
- Remove charge air cooler securing bolts and remove charge air cooler.
Installing
- Tighten securing bolts on charge air cooler and hydraulic pipe/hose.
2 - Checking charge air system: engine code AJH

2.1 - Checking charge air system: engine code AJH
2.2 - Checking charge pressure regulation

satelettronica
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
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un
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d
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◆ V.A.G 1397 A Turbocharger tester

y li
rm
ab
pe
ility
Check conditions
ot
wit
, is n
• No faults must be stored in fault memory

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

• Engine oil temperature min. 60 °C
• No leaks on intake and exhaust systems.
rrectness of i
Test sequence
l purpos
- The charge pressure is measured under full load, whilst driving or on a rolling road. Test duration per meas‐
urement max. 10 seconds.
nform
ercia
Observe applicable safety precautions when carrying out a road test => Page 240 .
m
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
242 21 - Charging
Sharan 1996 ➤
Volkswa
- -> Pull off connecting hose between aintake
gen AG manifoldnand
. ge AG
dooverrun
es n shut-off valve at intake manifold and con‐
ksw
nect turbocharger tester V.A.G by V1397 A using T-piece.
ol ot g
ua
- Select measuring range l.rised ran
te
tho eo
au ra
Notes: ss c
ce
e
◆ Operation of turbocharger tester =>operating instructions.
nl
pt
du
an
◆ The pipes/hoses must be connected so that there is no leakage. itte
y li
◆ If boost pressure is measured whilst driving, it is necessary for safety reasons, for a second person to operate
erm
ab
the turbocharger tester.
ility
ot p
◆ Ensure that the pressure hose is not trapped between the bonnet and the body.
wit
, is n
h re
hole
- Measuring charge pressure at full throttle:
spec
es, in part or in w
t to the co
Accelerate with full throttle from 2000 rpm in 3rd gear
or in 2nd driving range.
rrectness of i
- At 3000 rpm press the memory button "M" on turbocharger tester.
Specification: (absolute pressure)
l purpos
1.300 ... 1.400 bar
nform
ercia
If the charge pressure is exceeded:

- Test charge pressure control solenoid valve (N75). (Through-flow in hose from turbocharger via valve to
m
at
om
pressure unit when connector is pulled off).
io
satelettronica
n
c
- Check pressure unit for charge pressure regulating valve is securely mounted on turbocharger.
in t
or
his
e
- Check shaft mounting for charge pressure regulating valve in turbocharger for ease of movement.
at
do
riv
When corroded together, renew turbocharger.

p
cum
for
en
ng
If the charge pressure is not attained:

t.
yi Co
op py
- Check charge pressure control solenoid valve (N75) =>Page 243 .
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
2.3 - Checking charge pressure control solenoid valve
◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715
◆ Adapter set V.A.G 1594
Test conditions
• Carry out final control diagnosis
• Ignition switched off.
Test sequence
2.2 - Checking charge pressure regulation 243

Sharan 1996 ➤
- -> Pull connector -1- off charge pressure control solenoid valve (N75) -2-.
- Check resistance of charge pressure control solenoid valve between contacts.
Specification: 25.0...35.0 ω(at room temperature)
If the specification is not obtained:
- Replace charge pressure control solenoid valve (N75).

2.4 - Checking pressure unit for charge pressure regulating valve
satelettronica
Test conditions
• Engine oil temperature min. 60 °C
Test sequence
- -> Pull connector -1- off charge pressure control solenoid valve (N75) -2-.
agen
AG. Volkswagen AG d
oes
- Remove noise insulation tray. yV
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g b ua
ed ran
oris tee
th or
au ac
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itte
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ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
- -> Start engine and raise to maximum speed briefly by operating throttle. The operating rod -2- for charge
l purpos
pressure regulating valve must

move.
nform
ercia
If the operating rod does not move:

m
at
om
io
- Check charge pressure control valve lever -1- for ease of movement. When corroded together, renew tur‐
n
c
in t
r
bocharger.
o
his
ate
do
riv
If the operating rod does not move, even though the lever is free to move:
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
244 21 - Charging
agen
Prote AG.
Sharan 1996 ➤
- Turbocharger defective. Renew turbocharger => Page 219 , Removing and installing turbocharger with
attachments.
- Interrogating and erasing fault memory: AG. Volkswagen AG d
agen o w es n
olks ot
=> Repair group 01; Fault memory; Interrogating and d b erasing fault memory Fault memory
yV gu Interrogating and
ara
erasing fault memory rise nte
ho e t or
au ac
ss
ce
e
nl
pt
du
2.5 - Checking overrun shut-off valve
an
itte
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ab
ility
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spec
es, in part or in w
t to the co
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ercia
satelettronica
m
at
om
ion
c
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or
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ate
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riv

p
cum
for
en
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t.
Test conditions
yi Co
Cop py
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• Reduced performance or load change judders pyri by
Vo
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by c lksw
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Prote
Test sequence
AG.
Note:
The overrun shut-off valve is located before the turbocharger. It is opened by vacuum pressure during the
overrun phase and at idling speed.
- -> Connect hand vacuum pump V.A.G 1390 to vacuum connection on overrun valve.
- Operate hand vacuum pump.
Overrun valve must open in direction of arrow.
- Operate vent valve on hand vacuum pump.
Overrun valve must close.
Overrun valve does not open or close, renew valve.
2.4 - Checking pressure unit for charge pressure regulating valve 245
Sharan 1996 ➤
Note:
The overrun shut-off valve connections are secured with screw-type clips.
3 - Checking charge pressure system: engine code AWC

3.1 - Checking charge pressure system: engine code AWC
3.2 - Checking charge pressure regulation
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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u ra
Special tools, workshop equipment, testers, measuring
ss a instruments and auxiliary items required c
ce
e
nl
pt
du
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itte
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erm
ab
Note:
ility
ot p
wit
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The vehicle system tester V.A.G 1552 can be used instead of the fault reader V.A.G 1551, however a print-out
h re
hole
is not possible.
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

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t.
yi Co
Cop py
t. rig
Check conditions opyri
gh by
Vo
ht
c by lksw
cted
agen
Prote AG.
246 21 - Charging
Sharan 1996 ➤
Test sequence
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select engine electronics control unit with
"Address word" 01. Connecting fault reader and selecting engine control unit:
fault reader
-> Indicated on display: AG. Volkswagen AG d

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Select function XXX V gu
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- Press keys 0 and 8 for the function "Read measuredaut value block" and confirm entry with Q key. ra
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Read measured value block
rm
ab
Input display group number XXX
pe
ility
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- Press keys 1, 1 and 4 for "Display group number 114" and confirm entry with Q key.
h re
hole
spec
es, in part or in w
satelettronica
t to the co
Read measured value block 114
1 2 3 4
rrectness of i
- Check duty cycle of charge pressure control solenoid valve (N75) in display zone 4 (at full throttle between
l purpos
1 800...2 300 rpm) during a test drive or on a rolling road.

Specification: 5.0...95.0 %
nform
ercia
Observe applicable safety precautions when carrying out a road test => Page 240 .
m
a
com
tio
If the specification is obtained:
n in
r
te o
thi
s
iva
- Change to display group 115 as follows:
do
r
rp
c
V.A.G 1551: Press key 3
um
fo
V.A.G 1552: Press key ↑
en
ng
t.
yi Co
Cop py
t. rig
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yri by
(1...4 = Display zones) op Vo
by c lksw
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Read measured value block 115 Prote AG.
1 2 3 4
- Check actual charge pressure value in display zone 4 at full throttle.
On rolling road
In 3rd gear or in 2nd driving range
During test drive
Vehicles with manual gearbox
- Accelerate in 2nd gear with full throttle.
Vehicles with automatic gearbox.
- Manually select 4th driving range and accelerate vehicle from low speed with full throttle (without kickdown;
gearbox does not downshift).
- At engine speed between 1 800...2 300 rpm, press the print button and read off actual charge pressure value
in display zone 4.
Specification: 1 350 ... 1 750 mbar
- Compare actual charge pressure value with specified charge pressure value in display zone 3
3.2 - Checking charge pressure regulation 247

Sharan 1996 ➤
Difference: max. 100 mbar
Note:
Repeat the test if the full charge pressure had not yet built up, or if the difference between specified and actual
values is too great.
- Press the ⇒key.

- Press keys 0 and 6 for the "End output" function and confirm input with the Q key.
If the charge pressure is exceeded:
- Check charge pressure sender (G31) => Page 250

- Check charge pressure control solenoid valve (N75). (Throughflow in vacuum hose from turbocharger via
solenoid valve to vacuum unit with connector disconnected.)
Vacuum hoses on solenoid valve

=> Page 240 , Fig. 1 .
AG. Volkswagen AG d
agen oes
lksw n
- Check pressure unit for chargeby
V pressure regulating valve isotsecurely
o gu
ara mounted on turbocharger.
- Check vacuum unit =>oPage
ris
ed
253 . nte
th eo
au ra
satelettronica
If the charge pressure is not attained:
ss c
ce
le
un
pt
an
d
- Check charge pressure sender (G31) => Page 250

itte
y li
- Check charge pressure control solenoid valve (N75) => Page 248 .
erm
ab
- Check vacuum unit => Page 253 .
ility
ot p
wit
is n
attachments.
h re
ole,

spec
t to the co
rrectne
3.3 - Checking charge pressure control solenoid valve

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715

te
sd
va
◆ Adapter set V.A.G 1594

i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Check conditions
• -> Fuse No. 14 must be OK.
248 21 - Charging
Sharan 1996 ➤
Test sequence
satelettronica
- -> Unbolt heat shield from bulkhead -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
- Pull 2-pin connector off charge pressure hocontrol
r solenoid valve (N75) -arrow-. eo
ut
- Pull solenoid valve out of bracket (hoses
ss a remain connected). ra
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
- -> Check resistance of charge pressure control solenoid valve between contacts.
nform
ercia
Specification: 25.0...35.0 ω(at room temperature)

m
a
com
tio
If the specification is not obtained:

n in
r
te o
thi
- Replace charge pressure control solenoid valve (N75).

s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
249
co Vo
by lksw
cted 3.3 - Checking charge pressure control solenoid valve
agen
Prote AG.
Sharan 1996 ➤
If the specification is obtained:
- Check specifications in measured value blocks for charge pressure control:

Display groups 110...119
=> Repair group 01; Evaluating measured value blocks; Display groups 110...119 -charge pressure control-
Evaluating measured value blocks Display groups 110...119 -charge pressure control-
3.4 - Checking charge pressure sender
satelettronica
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.

250 21 - Charging
Sharan 1996 ➤
Check conditions
• Self-diagnosis has detected a fault with the charge pressure sender:
satelettronica
Checking voltage supply and wiring to control unit
- -> Pull 4-pin connector off charge pressure sender (F31) -arrow-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
ho
- -> Connect multimeter to measure
aut
voltage to contacts 1 (earth) and 3 (positive)or
acof connector for charge
pressure sender using adapter cables from V.A.G 1594 . ss
ce
le
- Switch on ignition.
un
pt
an
d
Specification: min. 4.5 V

itte
y li

rm
ab
pe
ility
ot
wit
If no voltage is present:
, 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
251
cted agen
Prote AG.
3.4 - Checking charge pressure sender
Sharan 1996 ➤
- Remove battery.
nected.
- -> Check wiring for open circuit between test box and 4-pin connector using current flow diagram:
Contact 1 test box socket 108 . Volkswage
Contact 2 test box socket w98
agen
AG n AG d
oes
Contact 3 test box socketVolks 101 not
gu
by ara
Wire resistance:rismax.
ed
1.5 ω nte
- Additionally check h wires for short to one another, to vehicle earth
o e o and to battery positive.
satelettronica
ut ra
a
Specification:
ss ∞ω c
ce
le
un
If no wiring fault is detected and voltage was present between contacts 1 + 3: pt

an
d
itte
y li
erm
ab
- Check the functions => Page 252 ility
ot p
wit
is n
h re
If no wiring fault is detected and voltage was present between contacts 1 + 3:
ole,
spec
- Renew engine control unit:

t to the co
=> Repair group 24; Engine control unit; Renew engine control unit Engine control unit Renew engine control
unit
rrectne
Checking function
ss o
cial p
- Connect the test box V.A.G 1598/31 to engine control unit wiring harness and to engine control unit.
in
- Connect battery.
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> Reconnect 4-pin connector to charge pressure sender (G31) -arrow-.

- Connect multimeter to measure voltage to sockets 101 (positive) and 108 (earth) using adapter cables from
V.A.G 1594.
- Start engine and measure the basic voltage.
Specification: 1.80...2.00 V
- Raise engine revs by pressing accelerator to
Specification: 2.00...3.00 V
252 21 - Charging
Sharan 1996 ➤
If the specifications are not attained:
- Renew charge pressure sender (G31)

=> Page 230 , item 13 .
3.5 - Checking pressure unit for charge pressure regulating valve
Check conditions
AG. Volkswagen AG d
agen oes
• Engine oil temperature min.
yV
olk60
sw °C not
gu
b ara
ed nte
oris eo
th
satelettronica
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
Test sequence
nform
ercia
- -> Remove heat shield from bulkhead -arrows-.

m

a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
- Pull 2-pin connector off charge pressure control solenoid valve (N75) -arrow-.
3.4 - Checking charge pressure sender 253

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
- -> Start engine and raise to maximum speed by quickly operating throttle. The operating rod -1- for charge
hole
spec
pressure regulating valve must
es, in part or in w
move.
t to the co
If the operating rod does not move:
rrectness of i
l purpos
attachments.
satelettronica
nform
ercia
m
a
com
tion in
r
te o
thi
s
iva
do
3.6 - Checking overrun shut-off valve
r
rp
cum
fo
en
ng
t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Test conditions
• Reduced performance or load change judders
254 21 - Charging
gen AG
. Volkswagen AG
does Sharan 1996 ➤
swa
y V 4-cyl. injection engine (5-valve), Mechanics - Edition 02.2005
olk not
b gu
d ara
ise nte
Test sequence uthor eo
a 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
Note:
inform
mer
The overrun shut-off valve is located before the turbocharger. It is opened by vacuum pressure during the
atio
om
overrun phase and at idling speed.
n
c
i
or
n thi
te
sd
a
- -> Connect hand vacuum pump V.A.G 1390 to vacuum connection on overrun valve.
iv
o
r
satelettronica
p
c
um
r
fo
Overrun valve must open in direction of arrow.
en
ng
t.
yi
- Operate vent valve on hand vacuum pump.
Co
Cop py
Overrun valve must close. ht. rig
rig ht
py by
co Vo
by lksw
Overrun valve does not open or close, renew valve. cted agen
Prote AG.
Note:
The overrun shut-off valve connections are secured with screw-type clips.
3.6 - Checking overrun shut-off valve 255

Sharan 1996 ➤
26 - Exhaust system
1 - Removing and installing parts of exhaust system

1.1 - Removing and installing parts of exhaust system
Notes:
◆ After working on the exhaust system, ensure that the system is not under stress, and that it has sufficient
clearance to the bodywork. If necessary, loosen clamps and align silencer and exhaust pipe so that sufficient
clearance to the bodywork is maintained and the supports are evenly loaded.
◆ Renew self-locking nuts.
◆ Components marked with * will be checked by self-diagnosis:
AG. Volkswagen AG d
agen oes
Vehicles with engineVcode
olks AJH
w not
gu
by ara
ed nte
ris
=> Repair group
th 01; Fault
o memory; Interrogating and erasing e o fault memory Fault memory Interrogating and
au
satelettronica
erasing fault
ss memory
ra
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.
256 26 - Exhaust system

Sharan 1996 ➤
1.2 - Front exhaust pipe and catalyst with attachments
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
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
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.
1 Seal
◆ Renew
2 25 Nm
◆ Renew
3 Front exhaust pipe
4 Catalyst
5 To front silencer
6 Markings
◆ For push-in depth catalyst/front silencer => Fig. 1
1.2 - Front exhaust pipe and catalyst with attachments 257

Sharan 1996 ➤
en AG. 02.2005
Volkswagen AG
ag does
ksw not
y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
satelettronica
at
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.
7 Lambda probe 2 after catalyst (G130)*, 50 Nm

◆ Remove and install with Lambda probe open ring spanner set 3337
◆ Grease only the threads with "G 052 112 A3"; "G 052 112 A3" must not get into the slots on the probe
body
◆ Checking:
=> Repair group 24; Checking functions; Checking Lambda probe and Lambda regulation after catalyst Check‐
ing functions Checking Lambda probe and Lambda regulation after catalyst
8 Connector
◆ Black, 4-pin
◆ Contacts 3 and 4 gold-plated
◆ For Lambda probe 2 after catalyst (G130) and Lambda probe heating (Z29)

Sharan 1996 ➤
lkswage es n
o ot g
byV ua
d ran
ir se
satelettronica
o tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f in
9 Heat shield
form
mer
10 10 Nm
atio
m
11 Securing clip
o
n
c
i
or
n
12 Lambda probe 1 before catalyst (G39)*, 50Nm
thi
te
sd
va
◆ Remove and install with Lambda probe open ring spanner set 3337
i
o
pr
cum
◆ Grease only the threads with "G 052 112 A3"; "G 052 112 A3" must not get into the slots on the probe
r
fo
en
ng
body
t.
yi Co
◆ If sealing ring is leaking nip open and replace. Cop py
t. rig
◆ Checking (engine code AJH): gh ht
pyri by
Vo
co lksw
by
cted
=> Repair group 24; Checking functions; Checking Lambda control Checking functions Checking Lambda con‐
agen
Prote AG.
trol
=> Repair group 24; Checking functions; Checking Lambda probe and Lambda regulation before catalyst
Checking functions Checking Lambda probe and Lambda regulation before catalyst

Sharan 1996 ➤
satelettronica
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
13 Connector
es, in part or in w
◆ For Lambda probe 1 before catalyst (G39) and Lambda probe heater (Z19)
t to the co
Vehicles with engine code AJH:

◆ Black, 4-pin
Vehicles with engine code AWC:
rrectness of i
◆ Black, 6-pin
◆ Contacts gold plated
l purpos
14 From turbocharger
15 Retaining ring
nf
ercia
or
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 ➤
wage es n
-> Fig.1 Insertion depth
yV
olof
ks catalyst/front silencer ot g
b ua
ed ran
ris tee
- Push catalystuthpipe into
o the front silencer pipe up to appropriate or mark.
a ac
ss
Vehicles with manual gearbox: mark -S-
ce
le
un
pt
Vehicles with manual gearbox: mark -A-
an
d
itte
y li
rm
ab
pe
ility
satelettronica
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
1.3 - Silencer with mountings
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
Note:
o
cial p
f inform
Align the exhaust system longitudinally so that the dimensions -a- and -b- are maintained.
mer
atio
om
1 Catalyst
c
i
or
n thi
◆ => Page 257 , item 4

te
sd
va
2 Markings
i
o
pr
cum
r
fo
◆ For insertion depth of catalyst/front silencer => Page 261 , Fig. 1

en
ng
t.
yi Co
3 Clamp t. Cop py
rig
4 Retaining ring
gh ht
pyri by
Vo
o
◆ Renew if damaged by c lksw
cted agen
◆ Note fitting position
Prote AG.
5 Front silencer
6 Rear silencer

AG. Volkswagen AG d
agen oes
olksw not
V
d by Sharan 1996 gu ➤
ara
ise nte
thor Mechanics - Edition 02.2005 eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
satelettronica
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7 Dimension -b- = approx. 50 mm

8 Dimension-a- = ca. 5 mm
9 40 Nm
◆ Renew
2 - Secondary air system: engine code AJH

2.1 - Secondary air system: engine code AJH
Warning!
cramped conditions:
1.3 - Silencer with mountings 263

Sharan 1996 ➤
2.2 - Function
The secondary air system blows air in behind the exhaust valve during a cold start. This produces an oxygen
rich exhaust gas, causing afterburning and reducing the heating-up phase of the catalyst. Activation is per‐
formed by the Motronic control unit (J220) via the secondary air pump relay (J229) to secondary air inlet valve
(N112, change-over valve) and combi-valve.
2.3 - Removing and installing parts of the secondary air system
satelettronica
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
Notes:
l purpos
◆ Components marked with an * are checked by the self-diagnosis:

nf
ercia
orm

m
atio
om
n in
c
◆ Components marked with ** are checked by the final control diagnosis:

or
thi
te
sd
iva
=> Repair Group 01; Self diagnosis; Final control diagnosis Self diagnosis Final control diagnosis
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 ➤
◆ Secondary air pump relay (J299)** =>Page 268 , Fig. 1
1 O ring
◆ Renew
2 Connection
3 Combi-valve
satelettronica
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
rrectne
4 Air channel
◆ In cylinder head
ss
5 10 Nm
o
cial p
f in
6 Secondary air inlet valve (N112)*/**

form
mer
7 Retainer
atio
om
◆ For secondary air inlet valve

n
c
i
or
◆ Bolted to bulkhead
thi
te
sd
a
8 Connector
iv
o
pr
cum
◆ Black, 2-pin
r
fo
en
ng
t.
9 To intake pipe
yi Co
op py
10 Non-return valve
. C rig
ht ht
rig by
py
◆ White connection faces towards secondary air inlet valve (N112) co Vo
by lksw
cted
11 To vacuum reservoir
agen
Prote AG.
2.3 - Removing and installing parts of the secondary air system 265
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut ra
satelettronica
s a c
s
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
io
12 Intake hose
n
c
in t
or
◆ Ensure seated tightly

his
ate
◆ Press together at front to release

do
priv
◆ From air cleaner housing

um
for
en
ng
t.
yi Co
=> Repair group 24; Servicing injection system; Dismantling and assembling air cleaner Servicing injection Cop py
system Dismantling and assembling air cleaner
t. rig
gh ht
pyri by
Vo
o
by c lksw
13 Secondary air pump motor (V101)**
cted agen
Prote AG.
14 Connector
◆ Black, 2-pin
◆ For secondary air pump motor
15 Bracket
◆ Secured to lock carrier
16 Pressure hose
17 Washer

Sharan 1996 ➤
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
satelettronica
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.
18 Rubber bush
19 Bush
20 Connection
◆ For combi-valve
21 Gasket
◆ Renew
22 5 Nm
Sharan 1996 ➤
-> Fig.1 Secondary air pump relay (J299)** -arrow 1-
◆ With fuse S 130 arrow -2-
AG. Volkswagen AG d
agen oes
ksw
Notes: by
Vol not
gu
ara
ed
ris nte
◆ If tools are necessary to pull relays orucontrol
tho
units out of the relay plate, first disconnect e o battery
r earth strap.
◆ Before disconnecting battery earth sstrap
s a
obtain code for radios with anti-theft coding. ac
ce
le
un
pt
an
d
itte
y li
erm
ab
2.4 - Checking combi-valve
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f i
satelettronica
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
Check conditions
t. rig
gh ht
pyri by
Vo
o
by c lksw
• No faults must be stored in fault memory Prote
cted AG.
agen
• Vacuum pipes and hose connections must be free of leaks.
• Vacuum pipes not blocked/kinked.
Test sequence

lkswage es n
o ot g
byV ua
d ran
ir se tee
o
auth or
ac Sharan 1996 ➤
ss 4-cyl. injection engine (5-valve), Mechanics - Edition 02.2005
ce
e
nl
pt
- du
Pull off vacuum hose from combi-valve to secondary air inlet valve (N112).
an
itte
y li
- -> Connect hand vacuum pump V.A.G 1390 to vacuum hose to combi-valve.
erm
ab
ility
ot p
Note:
wit
, is n
h re
hole
Do not use compressed air during the following check!
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
- -> Detach vacuum hose at air cleaner upper part -arrow- and pressurise slightly by blowing into hose.
t.
yi Co
Combi-valve must be closed.Cop py
. rig
satelettronica
t
gh ht
yri by
Note: cop Vo
by lksw
cted agen
Prote AG.
To release, press together the buttons on the hose coupling.

Combi valve must open.
If the combi-valve does not open, or is permanently open:
- Replace combi-valve
=> Page 265 , item 3 .
3 - Secondary air system: engine code AWC

3.1 - Secondary air system: engine code AWC
Warning!
cramped conditions:
3.2 - Function
The secondary air system blows air in behind the exhaust valve during a cold start. This enriches the exhaust
gas with oxygen, causing afterburning and reducing the heat-up phase of the catalyst. Activation is performed
by the Motronic control unit (J220) via the secondary air pump relay (J229) to the combi-valve.
2.4 - Checking combi-valve 269

Sharan 1996 ➤
3.3 - Removing and installing parts of the secondary air system
satelettronica
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Notes:
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spec
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◆ Secondary air pump relay (J299)** =>Page 274 , Fig. 1

nform
ercia
1 Air channel
m
a
com
tio
2 Gasket
n in
r
te o
thi
◆ Renew
s
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rig ht
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co Vo

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Sharan 1996 ➤
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ir se tee
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a ac
ss
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un
pt
an
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
satelettronica
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
3 Combi-valve
4 O-ring
5 Pressure hose
6 EGR valve (N18)*/** with potentiometer for exhaust gas recirculation (G212)*
◆ Check potentiometer for exhaust gas recirculation =>Page 281
7 Connector
◆ Grey, 6-pin
Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
8 Vent hose rise nte
tho eo
◆ To air pipe ss au ra
c
=> Page 230 , item 11
ce
e
nl
pt
du
9 25 Nm
an
itte
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10 10 Nm
erm
ab
ility
11 15 Nm
ot p
wit
, is n
12 Retaining clip
h re
hole
13 Connecting pipe
spec
◆ To throttle valve control part (J338)

es, in part or in w
t to the co
14 Connector
◆ Black, 2-pin
15 Bracket
rrectness of i

l purpos
◆ Secured to cylinder block

nf
ercia
orm
m
atio
om
n in
or c
thi
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sd
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Cop py
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c by lksw
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Prote AG.
Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
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un
pt
16 Rubber bush
an
d
itte
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17 Secondary air pump motor (V101)**

rm
ab
pe
ility

ot
wit
, is n
18 Intake hose
h re

hole
spec

es, in part or in w
◆ From air cleaner housing

t to the co
=> Repair group 24; Servicing injection system; Dismantling and assembling air cleaner Servicing injection
system Dismantling and assembling air cleaner
rrectness of i
l purpos
19 Connection
◆ With mounting for combi-valve and EGR valve (N18)
nform
mercia
a
com
tion in
r
te o
thi
s
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Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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-> Fig.1 Secondary air pump relay (J299)** -relay position 22- by
Vol not
gu
d ara
ise nte
or eo
h
The relay aut
is located on the lower relay carrier of the multi-function unit. ra
ss c
ce
le
Notes:
un
pt
an
d
itte
y li
◆ If tools are necessary to pull relays or control units out of the relay plate, first disconnect battery earth strap.
rm
ab
◆ Before disconnecting battery earth strap obtain code for radios with anti-theft coding.
pe
ility
ot
satelettronica
wit
, is n
h re
hole
spec
3.4 - Checking secondary air pump motor
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
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note:
The vehicle system tester V.A.G 1552 can be used instead of the fault reader V.A.G 1551, however a print-out
is not possible.

Sharan 1996 ➤
Check conditions

• Fuse for secondary air pump relay (J299)
en AG. V
olkswOK.
agen AG
ag does
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Vol
=> Current flow diagrams,
ed Electrical fault finding and Fitting locations
by gu
ara
ris nte
ho eo
ut
• The suction hose
ss
a for secondary air pump is not blocked or kinkedra
c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
satelettronica
t to the co
rrectness o
cial p
f inform
Test sequence
mer
atio
m

o
n
c
i
or
- -> Detach the pressure hose -arrow- from the secondary air pump motor.
thi
te
sd
iva
o
r
Note:
p
cum
r
fo
en
ng
t.
yi
Co
Cop py
ht. rig
rig ht
py by
- Activate the secondary air pump relay (J299) via the final control diagnosis. co Vo
by lksw
cted agen
Prote AG.
The secondary air pump motor must run in intervals and air must exit from outlet connection.
If the motor runs, but little or no air exits:
- Proceed with final control diagnosis until completed.

- Replace secondary air pump motor.=> Page 273 , item 17 .
If the secondary air pump motor does not run at intervals:
- Check activation of secondary air pump motor (V101):
3.4 - Checking secondary air pump motor 275

Sharan 1996 ➤
3.5 - Checking combi-valve
Check conditions
• Hose connections must be free of leaks.
Test sequence agen

AG. Volkswagen AG d
oes
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b
Note: rise
d ara
nte
tho eo
au ra
Do not use compressed
ss air during the following check! c
satelettronica
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
- -> Detach the pressure hose -arrow- from the secondary air pump motor.
rm
m
atio
om
n in
Note:
or c
thi
te
sd
a

iv
o
r
rp
cu
o
m
f
en
ng
- Blow gently into pressure hose of combi-valve.

t.
yi Co
op
Combi-valve must remain closed. C py
t. rig
- Blow hard into pressure hose of combi-valve. gh ht
yri by
Combi-valve must open. cop Vo
by lksw
cted agen
Prote AG.
If the combi-valve does not open, or is permanently open:
- Replace the combi-valve

=> Page 271 , item 3 .

Sharan 1996 ➤
4 - Exhaust gas recirculation system: engine code AWC

4.1 - Exhaust gas recirculation system: engine code AWC
Warning!
cramped conditions:
Notes:
◆ The function and control of the exhaust gas recirculation system is checked by the self-diagnosis of the
Motronic control unit (J220).
◆ Pulsed control makes every conceivable valve position possible.
◆ The cone shaped plunger in the (electric) EGR valve ensures that various cross sectional openings are
possible at different plunger lifts.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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au 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
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
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277
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4.1 - Exhaust gas recirculation system: engine code AWC
AG.
Sharan 1996 ➤
4.2 - Servicing parts of exhaust gas recirculation system
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
satelettronica
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
Notes: sd
iva
o
pr
cum
r
fo

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Interrogating and erasing engine control unit fault memory cop Vo
by lksw
cted agen
Prote AG.
1 Air channel
2 Gasket
◆ Renew

Sharan 1996 ➤
satelettronica
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
3 Combi-valve
es, in part or in w
t to the co
◆ Secondary air system

=>Page 269 , Secondary air system: engine code AWC
rrectness of i
4 O-ring
l purpos
5 Pressure hose
nf
ercia

rm
m
◆ From secondary air pump motor => Page 273 , item 17

atio
om
6 EGR valve (N18)*/** with potentiometer for exhaust gas recirculation (G212)*
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
◆ Check potentiometer for exhaust gas recirculation (G212) =>Page 281
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4.2 - Servicing parts of exhaust gas recirculation system 279

Sharan 1996 ➤
satelettronica
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
7 Connector
wit
, is n
h re
◆ Grey, 6-pin
hole
spec
8 Vent hose
es, in part or in w
t to the co
◆ To air pipe
=> Page 230 , item 11
9 25 Nm
rrectness of i
10 15 Nm
l purpos
11 Retaining clip
12 Connecting pipe
nform
ercia
◆ To throttle valve control part (J338)

13 10 Nm
m
at
om
14 Connection
on
c
in t
r
◆ With mounting for combi-valve and EGR valve (N18)

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

Sharan 1996 ➤
4.3 - Checking potentiometer for exhaust gas recirculation
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i

l purpos

nf
ercia
or

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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4.3 - Checking potentiometer for exhaust gas recirculation 281

Sharan 1996 ➤
Check conditions
lkswage es n
o ot g
yV
• -> Fuse No. 29 must be OK. d b ua
ran
ir se
• The battery voltage must be at least 11.5 V. tho tee
or
• All electrical consumers, e.g. lights and rear auwindow heating must be switched off. ac
ss
ce
le
un
pt
an
d
itte
Test sequence
y li
rm
ab
pe
ility
satelettronica
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
ti
- -> Pull off 6-pin connector (grey) off EGR valve (N18) -arrow-.
on in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> Connect multimeter to measure voltage between contacts 2 (positive) and 4 (earth) of connector using
adapter cables from V.A.G 1594 A.
- Switch on ignition.
Specification: min. 4.5 V
If no voltage is present:

Sharan 1996 ➤
- Remove battery.
nected.
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
- -> Check wiringss for open circuit between test box and 6-pin connector
using current flow diagram.
Contact 2 and test box socket 98
ce
le
un
pt

an
d
itte
y li

erm
ab
Wire resistance: max. 1.5 ω

ility
ot p
- Additionally check wires for short to one another, to vehicle earth and to battery positive.
wit
is n
h re
ole,
spec
If no wiring fault is detected and voltage was present between contacts 2 + 4:

t to the co
- Connect test box V.A.G 1598/31 to engine control unit as well and reconnect 6-pin connector to EGR valve.
- Install battery.
- Connect the fault reader V.A.G 1551 (V.A.G 1552). Then switch ignition on and select engine control unit
rrectne
with the "Address word" 01.

ss
o
cial p
fault reader
inform
mer
- Initiate final control diagnosis and select EGR valve (N18):

atio
om
n
c
i
or
thi
te
sd

iva
o
pr
cum
r
fo
- Connect diode test lamp V.A.G 1527 B to socket 100 of test box and earth using adapters from V.A.G 1594.
en
ng
t.
yi
The LED must flash.
Co
Cop py
- Proceed with final control diagnosis until completed.
t. rig
gh ht
yri
p by
co Vo
by lksw
cted agen
Prote
- Depending on conditions, renew following components:
AG.
LED flashes:
- Renew EGR valve (N18) with potentiometer (G212) => Page 279 , item 6 .
4.3 - Checking potentiometer for exhaust gas recirculation 283

Sharan 1996 ➤
- Re-adapt engine control unit:
=> Repair group 24; Engine control unit; Adapting engine control unit to throttle valve control part and EGR
valve Engine control unit Adapting engine control unit to throttle valve control part and EGR valve
If no wiring fault is detected and the LED does not flash:
- Renew engine control unit:
=> Repair group 24; Engine control unit; Renew engine control unit Engine control unit Renew engine control
unit
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by

cop Vo
by lksw
cted agen
Prote AG.

Service: Sharan 1996

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Service

Service Department. Technical Information

20 - Fuel supply system

All rights reserved.

Copyright © 2010 Volkswagen AG, Wolfsburg 00056606920

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

1.1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

1.2 Removing, installing and tensioning toothed belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

1.4 Checking compression pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

2.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

2.4 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

2.6 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

2.7 Replacing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

1.1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

1.4 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130

1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166

1.8 Crash fuel shut-off: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186

1.9 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187

2.1 Accelerator mechanism: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195

2.3 Adjusting throttle cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197

1.8 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256

2.1 Secondary air system: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263

2.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264

2.4 Checking combi-valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268

00 - Technical datalkswagen AG. Volkswagen AG does no

1.2 - Engine number

1.3 - Engine data

Engine code AJH AWC

1.1 - Technical data 1

Catalyst yes yes

1) In exceptional circumstances min. 95 RON, however with reduced performance

Engine code AJH AWC

10 - Removing and installing engine

1 - Removing and installing engine

◆ 2024 A Lifting tackle

1.1 - Removing and installing engine 3

◆ V.A.G 1306 Drip tray

1.2 - Notes on removing

4 10 - Removing and installing engine

- -> Remove air duct trim -1-.

- Remove air cleaner:

system Dismantling and assembling air cleaner.

Vehicles with engine code AJH

1.2 - Notes on removing 5

Press buttons on hose couplings to do this.

Vehicles with engine code AWC

Press buttons on hose couplings to do this.

- Remove operating cable from gearbox:

6 10 - Removing and installing engine

- Remove drive shafts:

Vehicles with 6-speed manual gearbox 02N

- Remove operating cable from gearbox:

- Remove drive shafts:

- Remove selector lever cable from gearbox:

- Unbolt drive shafts from gearbox flange shaft