Service: Sharan 1996

Service
Maintenance
Sharan 1996 ➤
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Edition 03.2018
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Service Department. Technical Information

Service
Maintenance
Heading
1. Engine list
2. Service work
3. General information
4. Descriptions of work:
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5. Exhaust emissions
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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 © 2018 Volkswagen AG, Wolfsburg 00456615020

Sharan 1996 ➤
Maintenance - Edition 03.2018
Contents
1 Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Information on long-life service and time or distance dependent service . . . . . . . . . . . . . . 4
2.2 Service tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Delivery inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 Oil change service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5 Inspection service every 12 months for vehicles ►2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6 Inspection service every 30,000 km for vehicles ►2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.7 Additional work for vehicles ►2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.8 Inspection service for vehicles 2001►2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.9 Interval service 2008► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.10 Inspection service 2008► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.11 Time or distance dependent additional work for vehicles 2001► . . . . . . . . . . . . . . . . . . . . 28
3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1 Raising vehicle with lifting platform or trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.2 Stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3 Entries in service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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3.4 Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.5 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.6 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.7 Countries where diesel has a high sulphur content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.8 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.9 RME fuel (biodiesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.10 Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.11 Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.12 “Countries with hot climate” AG. Vincludes
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4.1 Removable ed
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4.2 Additiveaut container: Extract and replenish new additive or a. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.3 Rear final drive: Check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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4.4 Swivel joints and suspension link mountings: inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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4.5 Front passenger airbag: checking key switch and “On/Off function” . . . . . . . . . . . . . . . . . . 54
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4.6 Diesel particulate filter: Reading ash loading level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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4.7 Automatic gearbox: changing ATF (099 gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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4.8 Automatic gearbox: Change ATF strainer (099 gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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4.9 Automatic gearbox: Check oil level of front wheel drive (099 gearbox) . . . . . . . . . . . . . . . . 55
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4.10 Automatic gearbox: check ATF level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.11 Battery: checking battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . . 56
4.12 Battery: Check using battery tester with printer VAS 5097A or VAS 6161 . . . . . . . . . . . . . . 57
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4.13 Tyres: checking condition, wear pattern, tyre pressure and tread depth . . . . . . . . . . . . . . 57
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4.14 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4.15 Brake fluid level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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4.16 Brake system and shock absorbers: inspecting for leaks and damage . . . . . . . . . . . . . . . . 64
4.17 Brakes, front and rear: checking thickness of brake pads and condition of brake discs . . 65
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4.18 Renewing diesel particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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4.19 Electric windows: checking positioning (open and close functions) . . . . . . . . . . . . . . . . . . 68

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4.20 Carry out vehicle system test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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4.21 Boots: inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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4.22 Haldex coupling: Renew oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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4.23 Haldex coupling: Change oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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4.24 Poly V-belt: checking condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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4.25 V-belt: Check condition and tension (vehicles with 4-cylinder engine) . . . . . . . . . . . . . . . . 71
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4.26 Diesel fuel filter: Renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Contents i
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4.27 Diesel fuel filter: Drain water (not TDI unit injector engine) . . . . . . . . . . . . . . . . . . . . . . . . 73
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4.28 Interior and exterior body: inspecting for corrosion with doors and flaps open . . . . . . . . . . 73
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4.29 Cooling system: checking frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . 74
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4.30 Air filter: cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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4.31 Engine oil level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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4.32 Engine oil: Draining or extracting and replenishing; renewing oil filter . . . . . . . . . . . . . . . . 82
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4.33 Engine and components in engine compartment: inspecting for leaks and damage (from
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above and below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.34 Engine cover panel -top-: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.35 Engine cover -bottom- (noise insulation): Removing and installing . . . . . . . . . . . . . . . . . . 88
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4.36 Road test: performing (driving behaviour, noises, air conditioner etc.) . . . . . . . . . . . . . . . . 89
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4.37 Radio/navigation system: entering PIN of anti-theft coding and storing local radio stations to
station buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.38 Wheel securing bolts: tightening to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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4.39 Tyre repair set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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4.40 Window wiper and washer system and headlight washer system: Checking function . . . . 93
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4.41 Checking wiper blade setting angle: if wiper blades judder . . . . . . . . . . . . . . . . . . . . . . . . 99

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4.42 Wiper blades: Check park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

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4.43 Wiper blade protection: removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

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4.44 Manual gearbox/final drive: Check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4.45 Sunroof: checking function, cleaning and greasing guide rails . . . . . . . . . . . . . . . . . . . . . . 103
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4.46 Track rod ends: checking clearance, firm seating and boots . . . . . . . . . . . . . . . . . . . . . . . . 104
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4.47 Service interval display: recoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
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4.48 Service interval display: resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.49 Power assisted steering: check fluid level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.50 Checking/adjusting headlight setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.51 Door arrester: grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.52 Dust and pollen filter: renew filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.53 Underbody sealant: inspecting for damage to underbody sealant, underbody panels, routing
of lines and plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.54 Clock: setting to correct time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4.55 Camshaft drive belt: Renew (TDI engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4.56 Toothed belt and camshaft drive tensioning roller: Renew (TDI unit injector engine) . . . . 135
4.57 Camshaft drive toothed belt: Renew (4-cylinder petrol engine, 5-valve) . . . . . . . . . . . . . . 135
4.58 Toothed belt: Check for wear (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.59 Camshaft drive toothed belt: Check (4-cylinder petrol engine) . . . . . . . . . . . . . . . . . . . . . . 136
4.60 Spark plugs: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5 Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.1 Exhaust emissions test for petrol engines without OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.2 Exhaust emissions test for petrol engines with OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5.3 Exhaust emissions test for diesel engines without OBD . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.4 Exhaust emissions test for diesel engines with OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
ii Contents
Sharan 1996 ➤
1 Engine list
(VIGG001137; Edition 03.2018)
This chapter provides information on the following subjects:
♦ Petrol engines ⇒ page 1
♦ Diesel engines ⇒ page 2
Note
To ease the search for an engine, the engine codes are listed in
alphabetical order.
Petrol engines
Engines ⇒ Petrol engine Petrol engine Petrol engine Petrol engine
Displace‐ l 2.8 2.0 2.0 1.8
ment
Engine code AAA ABF ADY AJH
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No. of cylinders/valves per 6/2 4/2 4/2 4/5
cylinder
Power kW at rpm 128/5800 110/6000 85/5000 110/5500
Torque Nm at rpm 2351/4200 180/4300 to 4600 170/2400 210/1850 to 4500
Bore ∅ mm 81.0 82.5 82.5 81.0
Stroke mm 90.3 92.8 92.8 86.4
Compression ratio 10.0 10.5
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RON min. 95 unleaded horis 95 unleaded 95 unleaded e o 95 unleaded
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Onboard diagnosis No
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Camshaft drive Chain Toothed belt Toothed belt Toothed belt

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Engines ⇒ Petrol engine Petrol engine Petrol engine Petrol engine

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Displace‐ l 2.8 2.0 1.8 2.8

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Engine code AMY ATM AWC AYL
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Power kW at rpm 128/5800 85/5200 110/5500 150/6200

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Torque Nm at rpm 2351/4200 170/2600 to 4200 210/1850 to 4500 265/3400

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Bore ∅ mm 81.0 82.5 81.0 81.0

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Stroke mm 90.3 92.8 86.4 90.8

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Compression ratio 10.0 10.0 9.5 10.5

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Injection/ignition Motronic M 3.8.1 Motronic ME 7.5 Motronic ME 7.5 Motronic ME 7.1

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RON min. 95 unleaded 95 unleaded 95 unleaded 98 unleaded
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Onboard diagnosis No Yes Yes Yes
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Camshaft drive Chain Toothed belt Toothed belt Chain
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1. Engine list 1
Sharan 1996 ➤
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Engines ⇒ Diesel engine
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Displace‐ l s a 1.9
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Engine code 1Z AHU AFN ANU
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No. of cylinders/valves per erm 4/2 4/2 4/2 4/2
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Power kW at rpm 66/4000 66/4000 81/4150 66/4000
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Torque Nm at rpm 202/1900 210/1900 235/1900 240/1900
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Bore ∅ mm 79.5 79.5 79.5 79.5
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Stroke mm 95.5 95.5 95.5 95.5
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Injection/ignition TDI TDI TDI TDI
DP DP DP unit injector
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Diesel particle filters No No No No
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Onboard diagnosis No Yes No No
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Camshaft drive Toothed belt Toothed belt Toothed belt Toothed belt
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Engines ⇒ Diesel engine Diesel engine Diesel engine Diesel engine
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Displace‐ l 1.9 1.9 1.9 2.0
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Engine code ASZ AUY AVG BRT
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Power kW at rpm 96/4000 85/4000 81/4150 103/4000
Torque Nm at rpm 310/1900 310/1900 235/1900 310/1900
Bore ∅ mm 79.5 79.5 79.5 81.0
Stroke mm 95.5 95.5 95.5 95.5
Injection/ignition TDI TDI TDI TDI
unit injector unit injector DP unit injector
Diesel particle filters No No No yes/no2
Onboard diagnosis Yes No No Yes
Camshaft drive Toothed belt Toothed belt Toothed belt Toothed belt
2) Engine available with and without diesel particulate filter, depending on vehicle
equipment
Engines ⇒ Diesel engine Diesel engine Diesel engine

Displace‐ l 1.9 2.0 1.9
ment
Engine code BTB BVH BVK
No. of cylinders/valves 4/2 4/2 4/2
per cylinder
Power kW at 110/4000 100/4000 85/4000
rpm
Torque Nm at 310/1900 310/1900 310/1900
rpm
Bore ∅ mm 79.5 81.0 79.5
2 1. Engine list
Sharan 1996 ➤
Engines ⇒ Diesel engine Diesel engine Diesel engine

Displace‐ l 1.9 2.0 1.9
ment
Engine code BTB BVH BVK
Stroke mm 95.5 95.5 95.5
Compression ratio 19.0 18.5 18.0
Injection/ignition TDI TDI TDI
unit injector unit injector unit injector
Diesel particle filters No yes/no2 No
Onboard diagnosis Yes Yes Yes
Camshaft drive Toothed belt Toothed belt Toothed belt
2) Engine available with and without diesel particulate filter, depending on vehicle
equipment
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1. Engine list 3
Sharan 1996 ➤
2 Service work
Information on long-life service and time or distance dependent
service ⇒ page 4
Service tables ⇒ page 6
Delivery inspection ⇒ page 11
Oil change service ⇒ page 12
Inspection service every 12 months ►2000 ⇒ page 15
Inspection service every 30,000 km ►2000 ⇒ page 17
Additional work ►2000 ⇒ page 19
Inspection service 2001►2007 ⇒ page 22
Interval service 2008► ⇒ page 24
Inspection service 2008 ► ⇒ page 26
Additional work based on time and/or distance 2001 ►
satelettronica
⇒ page 28
2.1 Information on long-life service eand time

AG. Volkswagen AG d
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or distance dependent service
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Service identification ⇒ page 4 tho
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LongLife service ⇒ page 4 ss
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Time or distance dependent service ⇒ page 5
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Service interval display ⇒ page 6

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2.1.1 Service identification

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– Check vehicle data sticker ⇒ page 39 to determine whether spec

es, in part or in w
the vehicle is equipped with PR number “QG0”, “QG1” or

t to the co
“QG2”. The PR number is decisive for the service intervals

⇒ page 7 .
Vehicle IDs with the following PR number
rrectness of i
“QG1” indicates LongLife service

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“QG0” or “QG2” indicates time or distance dependent service

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2.1.2 LongLife service

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atio
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Vehicles with PR number “QG1”

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or c
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The LongLife service enables long service intervals, depending

t
sd
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on individual driving style and the conditions under which the ve‐
o
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For the LongLife service a special LongLife engine oil is required
AG.
⇒ page 8
Vehicles with PR number “QG1” are fitted at the factory with active
LongLife service. This means that these vehicles have a flexible
service interval display and are fitted with the following compo‐
nents:
♦ Flexible service interval display in dash panel insert
4 2. Service work
Sharan 1996 ➤
♦ Engine oil level sensor

♦ Brake pad wear indicator (if fitted)
For vehicles with LongLife service the service interval is deter‐
mined by the control unit and is indicated on service interval
display (SID) ⇒ page 6 .
Therefore the service intervals for LongLife service are flexible.
These flexible service intervals apply to all types of service
gen Ain‐
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cluding an engine oil change. yV
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2.1.3 Time or distance dependent service au
tho e or
ac
ss
For vehicles with time or distance dependent service with PR
ce
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number “QG0/QG2” the non-flexible service intervals are set by
pt
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Volkswagen according to predetermined mileage or time values.
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For normal operating conditions achieving these service intervals
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ility
is technically assured.
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Therefore the service intervals for time or distance dependent
hole
service are non-flexible.
spec
es, in part or in w
For vehicles
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♦ Which were delivered without extended servicing intervals
(ESI) (PR number “QG0” = without ESI, PR number “QG2” =
rrectness of i
ESI cannot be activated)
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♦ or for which the extended servicing interval (ESI) was stopped

♦ When no LongLife engine oil was used
nform
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the time or distance dependent service applies.

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These non-flexible service intervals apply to all types of service
n in
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including an engine oil change.
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Vehicles are “not” factory-fitted with components for LongLife

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service. For maintenance the time or distance dependent inter‐ Cop py
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vals (non-flexible intervals) apply.
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For these vehicles the LongLife service is not factory-activated.
Therefore, these vehicles have a non-flexible service interval dis‐
play (SID) ⇒ page 6 and for maintenance the time or distance
dependent intervals (non-flexible intervals) apply. These vehicles
are fitted with the following components:
♦ Non-flexible service interval display in dash panel insert
For these vehicles the LongLife service is not factory-activated.
Therefore, these vehicles have a non-flexible service interval dis‐
play (SID) ⇒ page 6 and for maintenance the time or distance
dependent intervals (non-flexible intervals) apply. These vehicles
are fitted with the following components:
2. Service work 5
Sharan 1996 ➤
2.1.4 Service interval wadisplay

. Volkswagen AG
does gen AG
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Introduction of extended ris servicing intervals (ESI) ⇒ page 6
ed
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Flexible service interval
ss
au
display (only vehicles with LongLife serv‐ ra
c
ice, PR number QG1) ⇒ page 6
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pt
an
Non-flexible service interval display (only vehicles with time or
d
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distance dependent service, PR number “QG0/QG2)”
erm
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⇒ page 6
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Service interval display: resetting ⇒ page 111
h re
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spec
Service interval display: recoding ⇒ page 104
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Introduction of extended servicing intervals (ESI)
rrectne
Ask your importer if the extended servicing interval (ESI) is avail‐
able for your country.
ss o
Flexible service interval display (only vehicles with LongLife serv‐
cial p
f in
ice, PR number QG1)
form
mer
atio
Calculation of service intervals:
m
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i
♦ To calculate the service intervals for vehicles with LongLife
or
n thi
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service, input values such as distance driven, fuel consump‐

t
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tion, oil temperature and load of diesel particulate filter are

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evaluated.
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♦ The result of the evaluation is a value for the deterioration of Cop py
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the oil due to thermal loading.
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♦ The oil deterioration is the deciding factor concerning the dis‐
by
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tance that can still be driven to the next service.
AG.
Note
For vehicles with long-life service (PR number QG1) but which
are serviced according to time or distance dependent service, the
service interval display must be recoded to “non-flexible”
⇒ page 104 .
Non-flexible service interval display (only vehicles with time or

distance dependent service, PR number “QG0/QG2)”
Calculation of service intervals:
♦ To calculate the service interval for vehicles with time or dis‐
tance dependent service the non-flexible service intervals are
set by Volkswagen according to predetermined mileage or
time values.
♦ For normal operating conditions achieving these service in‐
tervals is technically assured.
2.2 Service tables

Service intervals ⇒ page 7
VW engine oil standards ⇒ page 8
Filter change intervals ⇒ page 9
Toothed belt change intervals ⇒ page 10
Spark plug change intervals ⇒ page 11
6 2. Service work
Sharan 1996 ➤
Note
n AG. Volkswagen A
♦ For combined kilometre and time display
olks
waapplies:
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occurs first. db
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♦ Depending on conditions under
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ho which the vehicle is used eo
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⇒ page 41 and vehicle equipment,
ss
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extra service work must c
be performed in addition to the interval service, inspection
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un
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service or interval service inspection.
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♦ It is also possible, to perform additional work outside the serv‐
ab
ility
ice intervals with regard to the entries in the service schedule
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2.2.1 Service intervals
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Caution
rrectne
Applies only to diesel engines
ss
• In some countries, diesel has a higher sulphur content.
o
cial p
satelettronica
f in
• The high sulphur content leads to excessive wear of cyl‐
form
mer
inders and it considerably reduces the cleanliness of pis‐
atio
tons.
om
n
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i
or
n
♦ Therefore, in countries with elevated sulphur content in
thi
te
diesel fuel, the engine oil and, if necessary, the diesel fuel
sd
iva
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filter should be changed every 7,500 km.

p
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♦ Countries where diesel has a high sulphur content.

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⇒ page 40 C py
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Note
♦ If an extremely uneconomical driving style is adopted or the

vehicle is used in extreme conditions ⇒ page 41 , the short‐
est interval for an oil change service is “7,500 km or 1 year”.
♦ However, other intervals apply for other countries. Your im‐
porter will inform you about this.
SHARAN
SERVICE INTERVALS ►2007
from-to Engine/Engine code Service: Indicated on
PR No./Remarks Intervals service interval display SID
(includes oil change)
Since in‐ Diesel in countries where sul‐ Oil change service YES
troduc‐ phur content in fuel is high every 7,500 km or 1 year
tion ⇒ page 40
►2000 Petrol and diesel: Oil change service YES
all vehicles every 15,000 km or 1 year
Inspection YES
every 12 months
Inspection YES
every 30,000 km
2001►2 Petrol and diesel: Oil change service YES
007 QG0/QG2 or QG1 vehicles every 15,000 km or 1 year
coded to non-flexible interval Inspection service: Time or dis‐ YES
tance dependent
every 30,000 km or 2 years
2. Service work 7
AG. Volkswagen AG d
agen oes
Sharan 1996 ➤ Volksw not
gu
y
Maintenance - Edition 03.2018 rise
d b ara
nte
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au ra
SHARAN ss c
ce
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un
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SERVICE INTERVALS ►2007
an
d
itte
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PR No./Remarks Intervals service interval display SID
pe
ility
ot
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Petrol: Inspection service: Long-life NO
hole
spec
QG1 vehicles flexible from 15,000 km to max.
es, in part or in w
30,000 km or 2 years
t to the co
4-cylinder TDI (DP): Inspection service: Long-life YES
QG1 vehicles flexible from 15,000 km to max.
rrectness of i
2002►2 4-cylinder TDI (unit injector): Inspection service: Long-life YES
l purpos
007 QG1 vehicles flexible from 15,000 km to max.

nform
ercia
From in‐ 4-cylinder TDI (unit injector): Inspection service: Long-life YES
troduc‐ QG1 vehicles flexible from 15,000 km to max.
m
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com
ti
tion with diesel particulate filter 30,000 km or 2 years
on in
►2007 and additive system
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Sharan 2002►
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SERVICE INTERVALS 2008►
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PR No./Remarks Intervals Prote
service interval display SID
AG.
Since in‐ Diesel in countries where sul‐ Oil change service YES
troduc‐ phur content in fuel is high every 7,500 km or 1 year
tion ⇒ page 40
2008► Petrol and diesel: Oil change service YES
QG0/QG2 or QG1 vehicles every 15,000 km or 1 year
coded to non-flexible interval Interval service: YES
every 30,000 km or 2 years
Petrol and diesel: Interval service: YES
QG1 vehicles flexible according to SID from
15,000 km or 1 year up to max.
Petrol and diesel: Inspection: NO
all vehicles after 3 years/max. 60,000 km,
then every 2 years/60,000 km
Note
For combined kilometre and time display applies: whichever oc‐

curs first.
2.2.2 VW engine oil standards
Caution
Only engine oils approved by VW may be used, up-to-date in‐

formation ⇒ ServiceNet, Technical information, Inspection and
maintenance, Approved oils , or ask your importer.
8 2. Service work
Sharan 1996 ➤
SHARAN
VW ENGINE OIL STANDARDS
With LongLife service (QG1) Without LongLife service (QG0, QG2)
PETROL ENGINES
4-cylinder engines 504 001, alternatively 4-cylinder engines ►2007 501 01/502 00
VR6 engines without FSI 2
4-cylinder engines 2008► 502 00
503 00
VR6 engines ►2007 502 00/505 01
VR6 engines 2008► 502 00
DIESEL ENGINES
4-cylinder engines without 507 001 Diesel engines without unit 505 00/505 01
diesel particulate filter alternatively 506 01 2 injector
Unit injector engines without 505 01
diesel particulate filter
4-cylinder engines with 507 001 4-cylinder engines with die‐ 507 001
diesel particulate filter and alternatively 2 sel particulate filter and ad‐ alternatively 506 01 2
506 01
additive system3 ditive system3
1) Combination product: 504 00/507 00
satelettronica
2) Combination product: 503 00/506 00/506 01
3) Vehicles with diesel particulate filter (fitted at the factory) can be identified by
PR No. 7GG, 7MB, 7MG or 7GA on the vehicle data sticker.
Note
Vehicles with retrofitted diesel particulate filter are allocated in the

table to diesel engines without diesel particulate filter.
AG. Volkswagen AG d
agen oes
2.2.3 Filter change intervals by Volksw not
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SHARAN utho eo
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FILTER CHANGE INTERVALS s
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ENGINE OIL FILTER1) 2)

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Vehicles with According to service interval display

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LongLife serv‐
ot
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ice QG1
, is n
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hole
All other vehi‐ Every 15,000 km or 1 year

spec
cles
es, in part or in w
t to the co
AIR FILTER
All engine 2008► Every 90,000 km or 6 years
types
rrectness of i
►2007 Every 90,000 km or 4 years

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DIESEL FUEL FILTER

All diesel en‐ Diesel Diesel not Biodiesel
gines con‐ conforming (RME)
nform
ercia
forming to EN 590
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to EN
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com
tio
590
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Change Every Every Every

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60,000 30,000 km 30,000 km

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km
um
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Drain Every
yi
Every Every
Co
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water 30,000 15,000 km 15,000 km t. C rig
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2. Service work 9
Sharan 1996 ➤
SHARAN
FILTER CHANGE INTERVALS
For unit injector engines draining water is de‐
leted.
DUST AND POLLEN FILTER
All engine Every 30,000 km or 2 years
types
1)Anew engine oil filter must be installed at every engine oil
change.
2)Only applies to diesel engines: in some countries, diesel has a
high sulphur content. The high sulphur content leads to excessive
wear of cylinders and it considerably reduces the cleanliness of
pistons. Therefore, in countries with elevated sulphur content in
diesel fuel, the engine oil and, if necessary, the diesel fuel filter
should be changed every 7,500 km. Countries where diesel has
a high sulphur content. ⇒ page 40
2.2.4 Toothed belt change intervals

• If the engine is fitted with toothed belt or timing chain can be
satelettronica
found in the engine list.
Note
The camshaft drive with timing chain is maintenance-free!
SHARAN
TOOTHED BELT CHANGE INTERVALS
Diesel engines
Engine Engine Model Change inter‐ Tensioning
type code year val roller
1.9 l 1Z, AFN, Since Every 90,000 swa
gen AG. V---
olkswagen AG
does
TDI AVG, intro‐ kmby
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TDI PD ANU, AUY ►2003 aEvery
ut 60,000
Every 60,000 or
ac
ss km km
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2004► Every 90,000 Every 180,000

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km km
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ASZ, Since Every 90,000 Every 180,000

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BTB, duction
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BVH, BVK
spec
es, in part or in w
Petrol engines
t to the co
1.8 l 5 V AJH, Since Every 180,000 ---

AWC intro‐ km
duction
rrectness of i
2.0 l ABF, Since No prescribed

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ADY, ATM intro‐ change inter‐

duction val,
nform
ercia
toothed belt
drive with test
m
at
interval,
om
io
see time and/

n
c
in t
or
or distance de‐
his
ate
pendent addi‐
do
priv
tional work
cum
for
⇒ page 28
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ng
t.
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rig ht
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10
by lksw
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2. Service work Prote AG.
Sharan 1996 ➤
2.2.5 Spark plug change intervals

• Spark plug designation and specified torque: Power unit ⇒
Rep. gr. 28 → Repairing ignition system → Test data.
Note
For technical reasons it is possible that several cross references

are not directed to the correct chapter. In this case select the pro‐
cedure manually in the information.
SHARAN
Spark plug change intervals
Engine type Engine code Change intervals
Petrol engines All engine codes EVERY 60,000 km
• Mileage more than 60,000 km in 4 years
EVERY 4 years
• Mileage less than 60,000 km in 4 years
satelettronica
2.3 Delivery inspection
Work to be completed for delivery inspection Page
– Battery (also second battery below front passenger seat, if fitted): Check battery ⇒ page 56
terminals by hand for tightness
– Battery (and second battery below passenger seat, if fitted): Check using battery ⇒ page 57
tester with printer VAS 5097A or VAS 6161 (always see workshop manual)
AG. Volkswagen AG d
agen
– Service interval Vol
ksdisplay:
w resetting oes
not ⇒ page 111
by gu
ara
– Radio cardrise (part of radio/radio-navigation system
d
nteoperating instructions): Attach ra‐
dio serial
utho number and fixed code number sticker onto e o radio card
ra
s a c
– Radio/navigation
s system: entering PIN of anti-theft coding and storing local radio ⇒ page 89
ce
le
stations to station buttons

un
pt
an
d
itte
– All switches, electrical consumers, gauges and other controls: Check function
y li
rm
ab
pe
– Clock: setting to correct time ⇒ page 134

ility
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– Front passenger front airbag: Check key switch and “On/Off function” ⇒ page 54
h re
hole
spec
– Set switch to “ON”

es, in part or in w
t to the co
– Electric windows: Carry out initialisation ⇒ page 68

– Check vehicle interior for cleanliness: Front and rear seats, interior trim, carpets/
mats, windows
rrectness of i
– Seat and carpet protective coverings: remove.

l purpos
– Fit all equipment which has been packed inside vehicle (if part of original equipment):
Mats, wiper arms, spoilers, roof aerial, wheel trims/hub caps, tyre valve extensions
nform
ercia
– Edge protection on doors (plastic film): remove.

m
– Wiper blade protection: removing ⇒ page 101

com
tion in
– Check vehicle exterior for cleanliness: Paintwork, decorative parts, windows, wiper
r
te o
thi
blades and surfaces

s
iva
do
r
– Wheel securing bolts: Tighten to prescribed torque settings (fit corrosion protection ⇒ page 90
rp
cum
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caps onto wheel bolts before fitting wheels trims)

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ng
t.
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op
– Tyre pressure of all 4 wheels and spare wheel: Correct ⇒ page 59
C py
t. rig
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– Engine and components in engine compartment, boots, brake system, axles, gear‐ ⇒ page 86
pyri by
Vo
co
box/final drive, steering, hoses, fluid reservoirs: Visual check for leaks and damage
by lksw
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(without removing engine compartment cover for noise insulation)
AG.
– Vehicle underside (floor pan): Visual check for damage ⇒ page 133
2. Service work 11
AG. Volkswagen AG d
agen oes
olksw not
Sharan 1996 ➤ d by
V gu
ara
e nte
Maintenance - Edition 03.2018 horis
eo
aut ra
ss c
Work to be completed for delivery inspection Page
ce
e
nl
pt
du
an
– Window wash/wipe system and headlight washer system: Check function and set‐ ⇒ page 93
itte
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tings; replenish with Windscreen Clear - G 052 164- to maximum
ab
ility
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– Engine oil level: Check and replenish oil if necessary. Observe oil specification ⇒ page 82
wit
, is n
h re
– Engine and components in engine compartment: visual check for leaks and damage ⇒ page 86
hole
(from above)
spec
– Coolant level: Check it is at maximum es, in part or in w ⇒ page 74
t to the co
– Power assisted steering: check fluid level. ⇒ page 126
– Brake fluid level: Check level is at maximum ⇒ page 64
rrectness of i
– Number and function of keys: Check, wipe off grease if necessary
l purpos
– Owner's literature: check that literature is complete and prepare for delivery to cus‐
tomer.
nform
ercia
– LongLife engine oil sticker: Attach to right side of lock carrier ⇒ page 34
m
at
om
io
• Valid only for vehicles with LongLife service, PR number QG1
n
c
in t
or
his
Note: Gradual deletion from week 04/07
ate
do
riv
– Hotline sticker: Apply to the inside of glove box cover ⇒ page 34

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Note: Gradual deletion
Co
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– Vehicle data sticker: Stick into service schedule opyri
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Vo ⇒ page 35
ht
♦ Service schedule:
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Prote AG.
– Enter pre-delivery inspection, and tick box for the first service:
♦ Interval service for vehicles with long-life service (PR No. QG1) 1)
♦ Oil change service for vehicles with flexible service (PR No. QG0/QG2)1)
– Complete vehicle data in service schedule, see “Vehicle delivery documentation”
– Road test: performing (driving behaviour, noises, air conditioner etc.) ⇒ page 89
1) Service identification ⇒ page 4
2.4 Oil change service

The sequence of the individual service tasks has been tested and
optimised. Therefore, it should be followed to avoid unnecessary
interruptions in the work.
Note
Inform the customer if faults are found during service and repair
measures are necessary.
Oil change service for vehicles ►2000 ⇒ page 12 .

Oil change service for vehicles 2001► ⇒ page 14 .
2.4.1 Oil change service for vehicles ►2000
Note
12 2. Service work
Sharan 1996 ➤
Caution

• The high sulphur content leads to excessive wearAof cyl‐
G. Volkswagen AG d
inders and it considerably reduces the cleanliness
kswagen of pis‐ oes
not
tons. y Vol gu
db a ran
ise
♦ Therefore change engine oil anduthdiesel fuel filter every
or tee
or
7,500 km in countries where the
ss a diesel has a high sulphur ac
content.
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le
un
pt
an
d

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⇒ page 40
erm
ab
ility
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– Ask the customer if they require:
ole,
spec
• New wiper blades.
t to the co
• Replenish Windscreen Clear G 052 164 (cleanser and anti-
freeze).
satelettronica
rrectne
– Check if storage life date of first aid box has been exceeded
and if warning triangle is fitted.
ss
– Removing and installing engine cover -bottom- (noise insula‐
o
cial p
f i
tion tray) ⇒ page 88
nform
mer
atio
m

o
n
c
i
or
n thi
te
sd
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Work to be completed for oil change service Page

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– Toothed belt: Check for wear ⇒ page 135

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• Only valid for diesel engines
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– Diesel fuel filter: Drain cted
⇒ page 73
agen
Prote AG.
• For vehicles with diesel engine using biodiesel according to EN 14214

• Only valid for vehicles with diesel engine ►1996
• Not valid for TDI unit injector
– Engine oil: Drain or extract1, renew oil filter ⇒ page 82

– Front and rear brake pads/linings: Check thickness ⇒ page 65
– Engine oil: Replenish ⇒ page 82
– Service interval display: Reset (only vehicles with multi-function display) ⇒ page 111
– Enter date of next service on sticker and attach sticker to driver side door pillar (B- ⇒ page 34
pillar).
1) For vehicles with V6 engines only drain engine oil.
2. Service work 13
Sharan 1996 ➤
2.4.2 Oil change service for vehicles 2001►
Note
♦ The oil change service is always a time or distance dependent

service “QG0/QG2” ⇒ page 5
♦ Inform the customer if faults are found during service and re‐
pair measures are necessary.
Caution

tons.
♦ Therefore change engine oil every 7,500 km in countries
where the diesel has a high sulphur content.
satelettronica
♦ Countries where diesel has a high sulphur content. en AG. Volkswagen AG
⇒ page 40 olks
wag does
no
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– Ask the customer if they require: au ra
c
ss
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ab
freeze).
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spec
t to the co
rrectne

s
Work to be completed for oil change service Page

s o
cial p
f i
– Diesel fuel filter: Drain ⇒ page 73

nform
mer
atio
• Only valid for vehicles with diesel engine using biodiesel according to EN 14214
om
n
c
• Not valid for TDI unit injector

or
n thi
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pr
cum
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fo
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– Brakes, front and rear: checking thickness of brake pads and condition of brake discs ⇒ page 65
t.
yi Co
op py
– Removable towing bracket: checking ⇒ page 45
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– Service interval display: resetting ⇒ page 111
Prote AG.
– Service interval display: Recode to non-flexible type display (15,000 km/1 year) ⇒ page 104
• Only applies for vehicles with PR number QG1.
– Enter date of next service on sticker and attach sticker to driver side door pillar (B- ⇒ page 34
pillar).
14 2. Service work
Sharan 1996 ➤
n AG. Volkswagen AG do
lkswage es n Maintenance - Edition 03.2018
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1) For vehicles with oV6
r engines only drain engine oil.
i tee
th or
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2.5 Inspection service every 12 months for
ce
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vehicles ►2000
du
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Note
wit
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Caution
rrectness of i
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♦ Therefore change engine oil and diesel fuel filter every
sd
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7,500 km in countries where the diesel has a high sulphur

rp
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content.
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♦ Countries where diesel has a high sulphur content. C py
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⇒ page 40
gh ht
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freeze).
Work to be completed for inspection service Page
Electrics
– Check function of front lighting: side lights, dipped beam, main beam, fog lights, turn
signals, hazard warning lights
– Check function of rear lighting: brake lights (including 3rd brake light), tail lights, re‐
versing lights, rear fog light, number plate light, luggage compartment light, turn
– Interior and glove compartment lights, cigarette lighter, warning lamps and horn:
Check function
– Carry out vehicle system test ⇒ page 68
Vehicle exterior
tings
– Wiper blades: Check for damage; check park position; only if wiper blades “judder”: ⇒ page 101
Check setting angle
2. Service work 15
Sharan 1996 ➤

Electrics
– Door arrester: grease. ⇒ page 132
Tyres
– Summer tyres [1], winter tyres [2], all-season tyres [3]: enter type of tyre ____
– Spare wheel: Check condition, wear pattern of tyre, tyre pressures, enter tread depth: ⇒ page 57
_______ mm
– Tyre repair set: Check if bottle is damaged or used; check and enter use-by date of ⇒ page 93
tyre sealant __________
• If fitted
– Rear right wheel: Check condition, wear pattern of tyre, tyre pressures, enter tread ⇒ page 57
depth: _______ mm
– Rear left wheel: Check condition, l wage pattern of tyre, tyre
kswear espressures,
not enter tread ⇒ page 57
o
depth: _______ mm d by
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– Front left wheel: Check or
thcondition, wear pattern of tyre, tyre pressures, e o enter tread ⇒ page 57
u ra
depth: _______ mm ss a c
ce
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– Front right wheel: Check condition, wear pattern of tyre, tyre pressures, enter tread ⇒ page 57
un
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satelettronica
depth: _______ mm
an
d
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ab
Underside of vehicle
ility
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– Engine oil: Drain or extract1; Renew oil filter (Inspection service with engine oil ⇒ page 82
wit
is n
change)
h re
ole,
spec
– Engine and components in engine compartment: inspect for leaks and damage (from ⇒ page 86
below)
t to the co
– Gearbox, final drive and drive shaft boots: inspect for leaks and damage. ⇒ page 70
– Swivel joints: Visual check of swivel joint boots for leaks and damage rrectne ⇒ page 53
– Brake system: inspect for leaks and damage. ⇒ page 64
s

s o
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– Track rod ends: checking clearance, firm seating and boots ⇒ page 104
inform
mer
– Exhaust system: inspect for leaks, firm seating and damage.

atio
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Engine compartment
o
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or

thi
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(from above)
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t.
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– Window wash/wipe system: Replenish with Windscreen Clear - G 052 164- (only if ⇒ page 93
Co
op py
customer requires). t. C rig
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– Cooling system: Check frost protection and coolant level / specification -25 °C (in ⇒ page 74
cop Vo
by lksw
countries with arctic climate -35 °C) actual value (measured value): ____ °C
cted agen
Prote AG.
– Toothed belt: Check condition ⇒ page 135
• Only valid for vehicles with diesel engine
• Only valid for vehicles with diesel engine ►1996

– Brake fluid level (dependent upon brake pad/lining wear): check. ⇒ page 64
Final checks
– Headlight adjustment: checking ⇒ page 127
• Only applies to vehicles ►1996
– Service sticker “Your next service”: enter next due date and attach sticker to driver ⇒ page 34
side door pillar (B-pillar).
16 2. Service work
Sharan 1996 ➤

. Volkswagen AG
Electrics swa
gen AG does
k not
Vol gu
– Road test: performing (driving behaviour,
se
db
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noises, air conditioner etc.) ara
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⇒ page 89
ri
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1) For vehicles with V6 engines only drain
autengine oil. ra
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nl
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du
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2.6 Inspection service every 30,000 km for erm
ab
ility
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vehicles ►2000
wit
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spec
Note
es, in part or in w
t to the co
rrectness of i
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Caution
nf
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m
m
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or c
thi
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♦ Therefore change engine oil and diesel fuel filter every
yi Co
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7,500 km in countries where the diesel has a high sulphur . C rig
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content.
rig by
copy Vo
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agen
Prote AG.
⇒ page 40

freeze).
Scope of work Page
Electrics
Check function
2. Service work 17
Sharan 1996 ➤
Scope of work Page

Electrics
Vehicle exterior
– Sunroof: Check function, clean guide rails and lubricate with special grease - G 000 ⇒ page 103
450 02-
tings
Check setting angle
Tyres
_______ mm
• If fitted
satelettronica
depth: _______ mm
– Rear left wheel: Check condition, wear pattern of tyre, tyre pressures, enter tread ⇒ page 57
depth: _______ mm
– Front left wheel: Check condition, wear pattern of tyre, tyre pressures, enter tread ⇒ page 57
depth: _______ mm n AG. Volkswagen AG do
lkswage es n
– Front right wheel: Check condition,
byV
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t gu
ara enter tread ⇒ page 57
depth: _______ mm o
ir se
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th eo
Underside of vehicle s au ra
c
s
– Engine oil: Drain or extract ; Renew oil filter (Inspection service with engine oil
1 ⇒ page 82
ce
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nl
pt
du
change)
an
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ab
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below).
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– V-belt: Check condition and tension ⇒ page 71

h re
hole
spec
• Only valid for vehicles with 4-cylinder engines

es, in part or in w
t to the co
– Rear final drive: Check oil level ⇒ page 53
rrectness of i
• Only valid for Sharan 4motion

l purpos
• Only valid for Sharan ►1996 syncro

nf
ercia
– Swivel joints: Visual check of swivel joint boots for leaks and damage ⇒ page 53
rm
m
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t.
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– Underbody sealant: inspecting for damage to underbody sealant, underbody panels, ⇒ page 133
Cop py
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routing of lines and plugs
t
gh ht
pyri by
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Engine compartment
c by lksw
cted agen
Prote AG.
(from above)
customer requires).
18 2. Service work
Sharan 1996 ➤
Scope of work Page

Electrics
– Cooling system: Check frost protection and coolant level/specification -25°C actual
AG. Volkswagen AG d
⇒ page 74
value (measured lkswvalue): ____ °C (countries
agen oes with arctic climate -35°C)
not
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– Toothedisebelt:
d b Check condition ara
n ⇒ page 135
r tee
tho or
• Only
ss
valid for diesel engines
au ac
ce
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nl
pt
du
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erm
ab
• Only valid for vehicles with DP diesel engine 1997►, using diesel according to EN
ility
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590
wit
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• Drain water at 30,000 km for the first time, then every 60,000 km thereafter
hole
spec
es, in part or in w
t to the co
Final checks
rrectness of i
• Only applies to vehicles 1997►
l purpos
satelettronica
nform
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2.7 Additional work for vehicles ►2000

n
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Depending on conditions under which the vehicle is used
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⇒ page 41 and vehicle equipment, extra service work must be
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performed in addition to the oil change service or inspection serv‐
Prote AG.
ice.
It is also possible, to perform additional work outside the service
intervals with regard to the entries in the service schedule (or
sticker: your next service).
Every 30,000 km
Additional work Page
– Fuel filter: Renew ⇒ page 72
• Only valid for vehicles with diesel engine using diesel not conforming to EN 590
– Haldex coupling: Change oil (all-wheel drive) ⇒ page 70
• Additional work as a separate charge!
– Dust and pollen filter: Renew filter element, clean housing and water drain valve ⇒ page 133
Every 60,000 km
– Poly V-belt: checking condition ⇒ page 70
2. Service work 19
Sharan 1996 ➤

– Changing oil filter of Haldex coupling ⇒ page 70
n AG. Volkswagen AG
• Only valid for vehicles with petrol engine driving more than l wage km in 4 years does n
ks60,000
o ot g
yV ua
edb ran
– Spark plugs: renewing ris ⇒ page or136
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th
au ac
ss
• Only valid for vehicles driving more than 60,000 km in 4 years
ce
le
un
pt
an
d
• Spark plug designation ⇒ Rep. gr. 28
itte
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rm
ab
pe
ility
– Fuel filter: Renew ⇒ page 72
ot
wit
, is n
h re
• Only valid for vehicles with diesel engine using diesel according to EN 590
hole
spec
es, in part or in w
– Automatic gearbox: Check final drive oil level ⇒ page 55
t to the co
– Automatic gearbox: check ATF level. ⇒ page 55
– Camshaft drive toothed belt and toothed belt tensioning roller: Renewing ⇒ page 135
rrectness of i
• Only valid for TDI unit injector engines ►2003
l purpos
satelettronica
nform
mercia
a
com
tion in
Every 90,000 km
r
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s
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– Air filter: cleaning housing and renewing filter element ⇒ page 76
en
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t.
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• Every 4 years or every 90,000 km whichever occurs first
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– Camshaft drive toothed belt: renew. ⇒ page 134
by
cted agen
Prote AG.
• Only valid for TDI engines

At 90,000 km, then every 30,000 km thereafter

– Camshaft drive toothed belt: check. ⇒ page 136
• Only valid for 4-cylinder petrol engines without prescribed change interval
Every 100,000 km
• Valid for vehicles with diesel engine and driving more than 100,000 km in 4 years
20 2. Service work
Sharan 1996 ➤
Every 180,000 km
AG. Volkswagen AG d
Additional work agen oes Page
olksw not
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b ara
– Camshaft drive toothed rise belt: renew.
d
nte ⇒ page 135
th o eo
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• Only valid for 1.8
ss a
l 5V petrol engine c
ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
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Every 12 months
h re
hole
spec
es, in part or in w
t to the co
– Exhaust emissions test (EET): perform. ⇒ page 143
rrectness of i
• Only valid for vehicles with commercial passenger transport, e.g. taxis
l purpos
• Applies only to Germany
nf
ercia
or
satelettronica
m
m
atio
om
n in
Every 2 years
or c
thi
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sd
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iv
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rp
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– Brake fluid change ⇒ page 60
f
en
ng
t.
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op py
• Additional work as a separate charge! t. C rig
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pyri by
Vo
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by
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Prote AG.
3 years after initial registration and then every 2 years


Every 4 years
– Air filter: clean housing and renew filter element ⇒ page 76
• Only valid for vehicles driving less than 90,000 km in 4 years
– Spark plugs: renew ⇒ page 136

• Only valid for vehicles driving less than 60,000 km (petrol engines) or 100,000 km
(diesel engines) in 4 years
2. Service work 21
Sharan 1996 ➤
AG. Volkswagen
n AG do
wage es n
olks ot g
2.8 Inspection service for vehicles
V
by ua
ed ran
ris tee
2001►2007
tho
or
au ac
ss
♦ Valid for vehicles with long-life service (PR number QG1)
ce
le
un
pt
an
d
itte
♦ Valid for vehicles with time or distance dependent service (PR
y li
rm
ab
number QG0 or QG2)
pe
ility
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wit
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Note
hole
spec
es, in part or in w
t to the co
rrectness of i
Caution
l purpos
nform
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m
a
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t
ion in
r
te o
satelettronica
thi
tons.
s
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c
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en
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t.
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op py
t. C rig
gh ht
⇒ page 40 pyri by
Vo
co lksw
by
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Prote AG.

freeze).
Work to be completed for inspection Page
Electrics
– Battery (and second battery below passenger seat, if fitted): Check using battery tester ⇒ page 57
with printer VAS 5097A or VAS 6161 (always see workshop manual)
Check function
Vehicle exterior
– Sunroof: Check function, clean guide rails and lubricate with special grease - G 000 ⇒ page 103
450 02-
– Window wash/wipe system and headlight washer system: Check function and settings ⇒ page 93
22 2. Service work
Sharan 1996 ➤

Electrics
Check setting angle
Tyres
_______ mm
• If fitted
depth: _______ mm
– Rear left wheel: Check condition, wear pattern of tyre, tyre pressures, enter tread ⇒ page 57
depth: _______ mm
– Front left wheel: Check condition, wear pattern of tyre, tyre pressures, enter tread ⇒ page 57
satelettronica
depth: _______ mm
– Front right wheel: Check condition, wear pattern of tyre, tyre pressures, enter tread ⇒ page 57
depth: _______ mm
– Engine oil: Drain or extract1; Renew oil filter ⇒ page 82
AG. Volkswagen AG d
– Automatic gearbox: check ATF level. ksw
agen oes
not
⇒ page 55
Vol
by gu
ara
• From model year 2006: not ron is vehicles with 099 (AG4) gearbox in countries
ed
nte with hot
climate aut
ho eo
ra
ss c
ce
e
– Automatic gearbox: Check final drive oil level ⇒ page 55

nl
pt
du
an
itte
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erm
below).
ab
ility
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– V-belt: Check condition and tension ⇒ page 71

wit
, is n
h re
hole
• Only valid for vehicles with 4-cylinder engines

spec
es, in part or in w
t to the co
– Swivel joints: Visual check of swivel joint boots for leaks and damage ⇒ page 53
– Manual gearbox/final drive: Check oil level ⇒ page 103
rrectness of i

l purpos
• Valid for Sharan ►1996 syncro

nf
ercia
• Valid for Sharan 4motion

rm
m
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om

n in
or c
thi

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f
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t.
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op py
– Underbody sealant: inspecting for damage to underbody sealant, underbody panels, ⇒ page 133
t. C rig
gh ht
routing of lines and plugs yri
p by
o Vo
by c lksw
Engine compartment cted agen
Prote AG.

– Poly V-belt: checking condition ⇒ page 70
2. Service work 23
Sharan 1996 ➤

Electrics
(from above)
customer requires).
– Cooling system: Check frost protection and coolant level/specification -25°C actual ⇒ page 74
value (measured value): ____ °C (countries with arctic climate -35°C)
Final checks

AG. Volkswagen AG d
agen oes
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satelettronica
2.9 Interval service 2008► d by Vol not
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♦ The interval service is a time or distance dependent service

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“QG0/QG2” ⇒ page 5 and also a long-life service ⇒ page 4
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♦ The interval service always includes an engine oil change!
wit
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Additional type-specific tests ensure an extended oil change

h re
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service.
spec
♦ If the interval service is performed together with an inspection t to the co

service, see chapter ⇒ page 26 for additional work to be
carried out.
rrectne
♦ The prerequisites for the interval service with a running period

of max. 2 years or 30,000 km can only be fulfilled if engine oil
for long-life service is used or replenished.
ss o
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tons. Prote AG.

⇒ page 40

freeze).
24 2. Service work
Sharan 1996 ➤
Interval service – scope of work Page
– Battery (and second battery below passenger seat, if fitted): Check us‐ ⇒ page 57
ing battery tester with printer VAS 5097A or VAS 6161 (always see
workshop manual)
– Summer tyres [1], winter tyres [2], all-season tyres [3]: enter type of tyre
____
– Tyre pressure of all 4 wheels and spare wheel: Correct ⇒ page 57
– Spare wheel: Check condition and wear pattern of tyre; enter tread ⇒ page 57
depth: _______ mm
– Tyre repair set: Check if bottle is damaged or used; check and enter ⇒ page 93
use-by date of tyre sealant __________
satelettronica
• If fitted
AG. Volkswagen AG d
agen oes
lksw not
– Checking tyre age d by
Vo gu
ara ⇒ page 57
ise nte
– Rear right wheel: tCheck
ho
r condition and wear pattern of tyre; enter e o tread ⇒ page 57
depth: _______ssmm
au ra
c
– Rear left wheel: Check condition and wear pattern of tyre; enter tread ⇒ page 57
ce
e
nl
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depth: _______ mm
an
itte
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erm
– Front left wheel: Check condition and wear pattern of tyre; enter tread ⇒ page 57
ab
ility
depth: _______ mm
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wit
, is n
– Front right wheel: Check condition and wear pattern of tyre; enter tread ⇒ page 57
h re
depth: _______ mm
hole
spec
es, in part or in w

t to the co
– Brakes, front and rear: checking thickness of brake pads and condition ⇒ page 65
of brake discs
rrectness of i
– Brake system and shock absorbers: inspecting for leaks and damage ⇒ page 64
l purpos

– Engine oil: Replenish, observe oil specification ⇒ page 82
nf
ercia
orm
m

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om
n in
c
– “Next service” sticker: Enter a cross at the position for next service due, ⇒ page 34
or
thi
oil change service or interval service according to flexible service in‐

te
sd
a
terval display or month/year/km and enter date/odometer reading as

iv
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necessary; enter a cross at the position for supplementary information

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(e.g. renew toothed belt) and changing brake fluid and enter date/od‐
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ometer reading; attach sticker to driver side door pillar (B-pillar). Cop py
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Prote AG.
2. Service work 25
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
2.10 Inspection service 2008► d byV
olksw not
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aut ra
Note ss c
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♦ The inspection service does not include an oil change and is itte
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not indicated on the service interval display (SID) ⇒ page 6 .
erm
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ility
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wit
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spec
es, in part or in w
t to the co
Caution
rrectness of i
l purpos

nf
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tons.
orm
m
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n in
c
satelettronica
or
thi
te
sd
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⇒ page 40
rp
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t.
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Cop py
.
ht rig
rig ht
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Prote AG.
freeze).
Scope of work Page
Electrics
– Front lights - Check function: Side lights, dipped beam, main beam, fog
lights, turn signals, hazard warning lights
– Rear lights - check function: Brake lights (including 3rd brake light), tail
lights, reversing lights, rear fog light, number plate light, turn signals, hazard
warning lights, luggage/load compartment lights
– Interior and glove compartment lights, cigarette lighter, sockets, warning
lamps and horn: Check function
Vehicle exterior
– Sunroof: Check function, clean guide rails and lubricate with special grease ⇒ page 103
-G 000 450 02-
– Window wash/wipe system and headlight washer system: Check function, ⇒ page 93
spray jet settings and for damage
– Wiper blades: Check for damage, park position and setting angle if wiper ⇒ page 101
blades “judder” (not hingeless wiper)
Tyres
– Summer tyres [1], winter tyres [2], all-season tyres [3]: enter type of tyre
____
26 2. Service work
Sharan 1996 ➤
Scope of work Page

– Tyre pressure of all 4 wheels and spare wheel: Check ⇒ page 59
– Spare wheel: Check condition and wear pattern of tyre; enter tread depth: ⇒ page 57
_______ mm
– Tyre repair set: Check if bottle is damaged or used; check and enter use- ⇒ page 93
by date of tyre sealant __________
• If fitted
– Checking tyre age ⇒ page 57

– Rear right wheel: Check condition and wear pattern of tyre; enter tread ⇒ page 57
depth: _______ mm
– Rear left wheel: Check condition
gen AG
. Volkswaand
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G do pattern of tyre; enter tread depth: ⇒ page 57
_______ mm Volkswa es n
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by ua
– Front leftriswheel:
ed Check condition and wear pattern ranof tyre; enter tread depth:
tee ⇒ page 57
_______uth mm
o
or
s a ac
– Front right wheel: Check condition and wear pattern of tyre; enter tread
s ⇒ page 57
ce
le
depth: _______ mm
un
pt
an
d
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satelettronica
pe
– Automatic gearbox: Check ATF level, fill ATF as required ⇒ page 55
ility
ot
wit
, is n
– Engine and components in engine compartment: inspect for leaks and dam‐ ⇒ page 86
h re
age (from below).
hole
– Poly V-belt: checking condition spec ⇒ page 71

es, in part or in w
t to the co
– Poly V-belt: Check tension ⇒ page 71
• Only valid for vehicles without automatic tensioning roller

rrectness of i
l purpos
– Swivel joints and axle mountings: Visual check of swivel joint boots for leaks ⇒ page 53
and damage
nform
ercia
– Manual gearbox/final drive: Check oil level, replenish if necessary ⇒ page 103
m
a
com
tio

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• Valid for Sharan ►1996 syncro

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gh ht
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– Brake system and shock absorbers: inspecting for leaks and damage ⇒ page 64
p by
co Vo
by lksw
cted
– Brakes, front and rear: checking thickness of brake pads and condition of ⇒ page 65
agen
Prote AG.
brake discs
– Underbody sealant: inspecting for damage to underbody sealant, under‐ ⇒ page 133
body panels, routing of lines and plugs
Engine compartment
– Engine and components in engine compartment: visual check for leaks and ⇒ page 86
damage (from above)
– Window wash/wipe system: Replenish fluid -G 052 164- (only if customer ⇒ page 93
requires)
– Cooling system: checking frost protection and coolant level ⇒ page 74
Specification -25°C (in countries with arctic climate -35°C)/actual value (meas‐
ured value): ____°C, replenish if necessary.
– Power assisted steering: Check oil level, replenish if necessary ⇒ page 126
Final checks
2. Service work 27
Sharan 1996 ➤
Scope of work Page

– Headlights: Check adjustment ⇒ page 127
– “Next service” sticker: Enter a cross at the position for next service due, oil ⇒ page 34
change service or interval service according to flexible service interval dis‐
play or month/year/km and enter date/odometer reading as necessary;
enter a cross at the position for supplementary information (e.g. renew
toothed belt) and changing brake fluid and enter date/odometer reading;
attach sticker to driver side door pillar (B-pillar).
2.11 Time or distance dependent additional

work for vehicles 2001►
Depending on conditions under which the vehicle is used
⇒ page 41 and vehicle equipment, extra service work must be
performed in addition to the oil change service, interval service or
inspection service.
It is also possible, to perform additional work outside the service
intervals with regard to the entries in the service schedule (or n AG. Volkswagen AG do
satelettronica
wage
sticker: your next service). yV
olks es n
ot g
b ua
ed ran
oris tee
th or
Note au ac
ss
ce
le
un
pt
♦ As of model year 2008 a new maintenance concept will be
an
d
itte
y li
introduced which changes the accounting procedures for cer‐
erm
ab
tain additional work. The times for renewing the pollen filter,
ility
ot p
air filter, fuel filter and spark plugs were integrated up to model
wit
is n
year 2007 in repair operations in the 30,000 km and 60,000
h re
ole,
km inspection services.
spec
♦ From model year 2008 this is no longer valid. These opera‐
t to the co
tions are carried out as separate charge, which can be recog‐
nised in the maintenance table, signified by the red mark. This
is also valid when changing the brake fluid, renewing the
rrectne
toothed belt, tensioning roller and when performing the ex‐
haust emissions test.
ss
♦ All service operations are integrated as previously in the repair
o
cial p
f
operation for an inspection service.
inform
mer
atio
Every 30,000 km
om
n
c
i
or

thi
te
sd
iva
pr
cum
r
fo
en
– Haldex coupling: Change oil ⇒ page 70

ng
t.
yi Co
Cop py
.
• Only valid for Sharan 4motion
t rig
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pyri by
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co
• Only applies to vehicles up to model year 2009
by lksw
cted agen
Prote AG.
– Diesel fuel filter: Renew ⇒ page 72
• Only valid for vehicles with diesel engine using diesel not conforming to EN 590
28 2. Service work
Sharan 1996 ➤
Every 60,000 km
– Changing oil filter of Haldexwcoupling
agen
AG. Volkswagen AG d
oes ⇒ page 70
olks not
yV gu
rised b ara
nte
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• aut
Only valid for vehicles with petrol engine and driving more than 60,000
ra km in 4 years
ss c
ce
le

un
pt
an
d
itte
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– Spark plugs: renewing ⇒ page 136
erm
ab
ility
ot p
• Only valid for vehicles driving more than 60,000 km in 4 years
wit
is n
h re
ole,
spec
t to the co
– Diesel fuel filter: Renew ⇒ page 72
• Only valid for vehicles with diesel engine using diesel according to EN 590
rrectne
– Camshaft drive toothed belt and toothed belt tensioning roller: Renewing ⇒ –page 135
ss
• TDI unit injector engines ►2003
satelettronica
cial p
f inform
– Automatic gearbox: Change ATF ⇒ page 55
mer
atio
om
n
c
i
or
n thi
e
• Only vehicles with 099 (AG4) gearbox in countries with hot climate
t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
.
At 60,000 km for the first time and then every 120,000 km
ht rig
rig ht
py by
co Vo
by lksw
Additional work Prote
cted AG.
agen
– Automatic gearbox: Change ATF strainer ⇒ page 55

• Only vehicles with 099 (AG4) gearbox in countries with hot climate
Every 90,000 km
– Air filter: cleaning housing and renewing filter element ⇒ page 76
• ►2007: Every 4 years or every 90,000 km whichever occurs first
• 2008►: Every 6 years or every 90,000 km whichever occurs first
• Only valid for TDI engines

• Generally it is not necessary to renew the toothed belt before the actual change
interval is reached. Especially cracks on the belt side are not relevant for service life
• TDI unit injector engines 2004►

• Generally it is not necessary to renew the toothed belt before the actual change
interval is reached. Especially cracks on the belt side are not relevant for service life
2. Service work 29
Sharan 1996 ➤ agen
AG. Volkswagen AG d
oes
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Maintenance - Edition 03.2018 by Vol
gu
ara
d
rise nte
tho eo
au ra
ss c
ce
le
At 90,000 km, then every 30,000 km thereafter
un
pt
an
d
itte
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rm
ab
pe
ility
– Camshaft drive toothed belt: check. ⇒ page 136
ot
wit
, is n
h re
• Only valid for 4-cylinder petrol engines without prescribed change interval
hole
spec
es, in part or in w
– Diesel particulate filter: Read ash loading level ⇒ page 55
t to the co
• Only valid for engines with engine codes BRT, BVH
rrectness of i
• When the ash mass limit is reached, renew diesel particulate filter.
l purpos
nform
ercia
Every 100,000 km
m
a
com
ti
on in
r
te o
thi
s
iva
do
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satelettronica
c
um
fo
en
ng
t.
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Co
Cop py
t. rig
• Only valid for vehicles with diesel engine and driving more than 100,000 km in 4 years
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Every 120,000 km
– Fuel additive container: Extract residual fluid and replenish with new additive fluid ⇒ page 47
• Only valid for engines with engine codes BRT and BVH
• Every 120,000 km or every 4 years whichever occurs first
Every 180,000 km
• Only valid for 1.8 l 5V petrol engine
– Camshaft drive toothed belt tensioning roller: Renew ⇒ page 135
• TDI unit injector engines 2004►
Every 12 months
• Only valid for vehicles with commercial passenger transport, e.g. taxis
30 2. Service work
Sharan 1996 ➤
Every 2 years
– Brake and clutch system: changing brake fluid ⇒ page 60
• Only applies to vehicles ►2007
Every 3 years
– Haldex coupling: Change oil ⇒ page 70
• Only applies to vehicles from model year 2010

satelettronica
3 years after initial registration and then every 2 years
– Exhaust emissions test (EET): perform. n AG. Volkswagen AG do ⇒ page 143
lkswage es n
Vo ot g
• Applies only to Germany by ua
ed ran
oris tee
th or
u
– Brake and clutch system: changing brakess fluid
a ⇒acpage 60
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
Every 4 years
ole,
spec
t to the co

• Only applies to vehicles ►2007 rrectness o
– Spark plugs: renew ⇒ page 136

cial p
f inform
mer

atio
om

n
c
i
or
n thi
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sd
a

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en
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t.
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op
C py
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• Only valid for vehicles driving less than 60,000 km (petrol engines) or 100,000 km
cop Vo
by lksw
cted
(diesel engines) in 4 years
agen
Prote AG.
– Fuel additive container: Extract residual fluid and replenish with new additive fluid ⇒ page 47
• Only valid for engines with engine codes BRT and BVH
• Every 120,000 km or every 4 years whichever occurs first
2. Service work 31
Sharan 1996 ➤
Every 6 years

lkswage es n
o ot g
byV ua
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ir se tee
satelettronica
tho
u or
a ac
ss
ce
e
nl
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du
an
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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
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
32 2. Service work
Sharan 1996 ➤
3 General information
AG. Volkswagen AG d
This chapter provides information on the following subjects: lksw
agen oes
not
Vo gu
by
♦ Raising vehicle with lifting platform or trolley jack rised ara
nte
⇒ page 33 ut
ho eo
ra
s a c
♦ Sticker ⇒ page 34 s
ce
le
un
pt
♦ Entries in service schedule ⇒ page 36
an
d
itte
y li
rm
ab
♦ Connecting vehicle diagnosis tester ⇒ page 36
pe
ility
ot
wit
♦ Vehicle identification number ⇒ page 39
, is n
h re
hole
♦ Vehicle data sticker ⇒ page 39
spec
♦ Countries where diesel has a high sulphur content es, in part or in w
t to the co
⇒ page 40
♦ Engine code and engine number ⇒ page 41
rrectness of i
♦ RME fuel (biodiesel) ⇒ page 41
l purpos
♦ Type plate ⇒ page 41
satelettronica
nform
ercia
♦ Severe operating conditions ⇒ page 41

m
♦ “Countries with hot climate” includes ⇒ page 42
a
com
tion in
3.1 Raising vehicle with lifting platform or
r
te o
thi
s
iva
trolley jack
do
r
rp
cum
fo
en
g
Safety notes ⇒ page 33

n
t.
yi Co
op py
Lifting points for lifting platform or trolley jack ⇒ page 34
t. C rig
gh ht
pyri by
Vo
o
3.1.1 Safety notes:
by c lksw
cted agen
Prote AG.
WARNING
♦ Before driving onto a lifting platform, ensure that there is

sufficient clearance between low-lying vehicle compo‐
nents and lifting platform.
♦ Before driving a vehicle onto a lifting platform it must be
ensured that the vehicle weight does not exceed the per‐
missible lifting capacity of the platform.
♦ Vehicle may be lifted only at points indicated in figure to
avoid damaging vehicle floor pan or tipping vehicle.
♦ Never start engine and engage a gear with vehicle lifted
as long as even one driven wheel has contact with the
floor! Disregarding these warnings risks the danger of an
accident!
♦ If work is to be performed under vehicle, it must be sup‐
ported by suitable jack stands.
3. General information 33
Sharan 1996 ➤
3.1.2 Lifting points for lifting platform or trolley

jack:
Caution
To prevent damage always use a suitable rubber or wooden

block.
On no account should vehicle be lifted at the engine sump,
gearbox or on front or rear axle as this may cause serious
damage.
Front lifting point:

Position support plate at cross reinforcement of floor pan at
marked area -arrow-.
WARNING
Ensure that the side member seats centrally on the mounting
satelettronica
plate of lifting platform.
AG. Volkswagen AG d
Rear lifting point (vehicles without sill panel trim): lksw
agen oes
not
Vo gu
by
Position support plate at mounting bracket at marked area ise d ara
nte
r
-arrow-. ut
ho eo
ra
s a c
s
ce
e
WARNING
nl
pt
du
an
itte
y li
erm
Ensure that the side member seats centrally on the mounting
ab
ility
plate of lifting platform.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Rear lifting point (vehicles with sill panel trim):
rrectness of i
Raise the vehicle only at the point shown in the illustration
-arrow-.
l purpos
Caution
nform
mercia
If the vehicle is not raised at this point, serious damage may

at
om
io
occur to the vehicle. Never raise the vehicle on its sill panel
n
c
in t
r
trim.
o
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
3.2 Stickers
gh ht
pyri by
Vo
o
by c lksw
cted
Attaching “Your next service” sticker ⇒ page 35
agen
Prote AG.
Attaching “data sticker” in customer service schedule

⇒ page 35
Attach “Hotline” sticker ⇒ page 36
Attach “Long-life engine oil” sticker ⇒ page 36 .
34 3. General information
Sharan 1996 ➤
3.2.1 Attaching
swa
g“Your
en AG. V next service”
olkswagen AG
does sticker
k not
y Vol gu
Sticker up to week
se
d b 44/2009 ara
nte
ri
ho eo
– Your “nextut service dates” sticker: Enter a cross in position r a for
sa c
next oil change service or inspection service (next service due)
s
ce
le
and enter date/odometer reading

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
Sticker from week 45/2009
l purpos
– Service sticker “Your next service”: Enter a cross in position

for next oil change service or inspection service or legal check
such as legislative inspection or gas system check (next serv‐
nform
ercia
ice due) and enter date and mileage.

m
satelettronica
com
tion in
r
Note
te o
thi
s
iva
do
r
The new sticker is applied gradually from week 45/2009.

rp
cum
fo
en
ng
t.
yi Co
op
Service intervals ⇒ page 7 C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Attach sticker to driver side door pillar (B-pillar) -arrow-.
3.2.2 Attaching “data sticker” in customer

service schedule:
– Attach the lower of the two data stickers -arrow- in the service
schedule.
AG. Volkswagen AG d
agen oes
ksw not
Sharan 1996 ➤ by Vol
gu
ara
d
Maintenance - Edition 03.2018 orise nte
eo
th
au ra
s c
3.2.3 “Long-life engine oil” sticker
s
ce
le
un
pt
an
d
For vehicles with long-life service (PR number QG1), the sticker
itte
y li
rm
(article number K69.5121.50.20) must be attached.
ab
pe
ility
ot
– Attach sticker -arrow- as shown on left side of lock carrier (from
wit
, is n
driver perspective).
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
3.2.4 Attaching hotline sticker

m
a
com
tion in
– Attach hotline sticker to inside of glove compartment cover as
r
te o
shown.
thi
s
iva
do
r
rp
cum
fo
en
satelettronica
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3.3 Entries in service schedule

If a component is changed which has a change interval prescribed
by the manufacturer, e.g. the toothed belt, the new change inter‐
val begins at the time the component is changed.
• Therefore it is very important, every time a component is
changed, to document this in the service schedule.
• This also applies to components which were changed before
the regular change interval.
Note
♦ When using “Genuine parts kits” it must be taken into account

whether it is technically necessary to change all the compo‐
nents included in the genuine parts kits.
♦ If more components are renewed than is technically necessa‐
ry, inform the customer before repair!
3.4 Connecting vehicle diagnostic tester

Special tools and workshop equipment required
Sharan 1996 ➤
♦ Vehicle diagnostic, testing and information system - VAS 5051

B-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
♦ Diagnostic cable - VAS 5051/6A-
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
te
♦ Vehicle diagnosis and service information system - VAS 5052-

a
do
riv
or subsequent units
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Diagnostic cable - VAS 5052/3 A-
Note
Ensure that the selected vehicle diagnostic tester is used only

with the respective diagnostic cable.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
e d
Sharan 1996 oris➤ nte
eo
th
Maintenance
s au - Edition 03.2018 ra
c
s
ce
e
nl
pt
du
an
itte
WARNING
y li
erm
ab
ility
ot p
♦ During a road test, you must always secure testing and
wit
, is n
measuring equipment on the back seat.
h re
hole
spec
♦ Only a passenger may operate these devices while the
es, in part or in w
vehicle is in motion.
t to the co
3.4.1 Installation position of diagnostic con‐
rrectness of i
nector
l purpos
Installation position of diagnostic connector on vehicles ►2000
nf
ercia
⇒ page 38
orm
m
Installation position of diagnostic connector on vehicles 2001►
atio
m
⇒ page 38
o
n in
or c
thi
e
Vehicles ►2000
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
Note
t.
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op
satelettronica
C py
ht. rig
ht
The self-diagnosis connection is located below the ashtray.
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Open ashtray -3-.
– Press flap -1- at both sides slightly in direction of arrow -A-.
The ashtray insert-2- pops out slightly and can be removed.
– Remove ashtray insert -2- from ashtray -3-.
– Release ashtray and pull open ashtray out of centre console.

– Connect connector of diagnostic cable - VAS 5051/6A- to di‐
agnostic connection -arrow-.
Now follow information given on screen to start desired functions.
Vehicles 2001►
Note
The self-diagnosis connection is located below the cover in the

footwell on driver side.
– Connect connector of diagnostic cable - VAS 5051/6A- to di‐

agnostic connection -arrow-.
– Switch on vehicle diagnostic tester .
Now follow information given on screen to start desired functions.
Sharan 1996 ➤
3.5 Vehicle identification number

The vehicle identification number -arrow- is located in the plenum
chamber.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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3.5.1 Interpretation of vehicle identification number:
ce
le
un
pt
an
d
itte
y li
WVW ZZZ 7M Z 1 V 000013
rm
ab
pe
ility
Manufac‐ Filler char‐ Model Filler charac‐ Model year 2001 Production location Serial
ot
wit
, is n
turer's acters ters number
h re
mark
hole
satelettronica
spec
es, in part or in w
t to the co
3.6 Vehicle data sticker
rrectness of i
The vehicle data sticker -arrow- is located behind the right-hand
side of luggage compartment trim.
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
On some vehicles the vehicle data sticker -arrow- is applied in the
cted agen
Prote AG.
recess on the back of front passenger seat (with cover open).
Note
The vehicle data sticker is also found in the service schedule for
the customer.
Sharan 1996 ➤
The sticker contains the following data of the vehicle

1 - Vehicle identification number (chassis number)
2 - Vehicle type, engine output, gearbox
3 - Engine and gearbox code letters, paint number, interior equip‐
ment
4 - Optional equipment, PR numbers
The sticker in service schedule includes the same data. The leg‐
end can be found below the sticker.
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
3.7 Countries where diesel has a high sul‐
ss
ce
le
phur content
un
pt
an
d
itte
y li
erm
ab
Applies only to diesel engines, as diesel fuel in some countries

ility
ot p
has a high sulphur content The high sulphur content leads to ex‐
wit
is n
cessive wear of cylinders and it considerably reduces the clean‐

h re
liness of pistons. Therefore, in countries with elevated sulphur

ole,
spec
content in diesel fuel, the engine oil and, if necessary, the diesel
fuel filter should be changed every 7,500 km.

t to the co
Afghanistan Ghana Cuba Saudi Arabia

Egypt Guatemala Kuwait Senegal
rrectne
Algeria Honduras Laos Zimbabwe

ss
Angola Indonesia Lebanon Sri Lanka and the Mal‐

o
cial p
dives
inform
Argentina Iraq Libya Sudan

mer
atio
m
Armenia Iran Madagascar Surinam

o
n
c
i
or
Bangladesh Jamaica Mali Syria

thi
te
sd
va
Bolivia Jordan Mauritius Tajikistan

i
o
pr
cum
r
fo
Brazil Cambodia Mongolia Tanzania

en
ng
t.
yi Co
Brunei Cameroon Myanmar (Burma) Trinidad and Tobago
Cop py
t. rig
gh ht
Dominican Republic yri
Kazakhstan Nigeria Tunisia
p by
co Vo
by lksw
Ecuador Qatarcted
Pakistan Uruguay
agen
Prote AG.
Ivory Coast Kenya Paraguay Uzbekistan
El Salvador Kyrgyz Republic Peru Venezuela
Gabon Columbia Russian Federation Vietnam
China Republic of Congo Pacific islands, driving on
left
Sharan 1996 ➤
3.8 Engine code and engine number

Engine code and engine number ⇒ Rep. gr. 00
3.9 RME fuel (biodiesel)

For diesel engines without diesel particulate filter RME can be
used as standard, up to model year 2007. From model year 2008
the RME compatibility is no longer valid.
Caution
♦ When filling the tank with biodiesel, only use RME fuel
conforming to EN 14214 (FAME)!
♦ When biodiesel is used which does not conform to the re‐
quired standard, the fuel filter can become blocked.
RME fuel must conform to EN 14214 (FAME).

♦ RME means “Rapeseed Methyl Ester”.
♦ EN means “Euro standard”.
satelettronica
♦ FAME means “Fatty Acid Methyl Ester”.
Characteristics of RME fuel
♦ Performance can slightly be lower when using biodiesel.
♦ Fuel consumption can slightly be higher when using biodiesel.
♦ RME can be used in winter at temperatures to approx. -10 °C
♦ At ambient temperatures below -10 °C we recommend using
winter diesel fuel.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
Note ise
d b ara
nte
or eo
th
u ra
♦ When using
ss a
biodiesel observe the changed intervals for drain‐
c
ing and changing the fuel filter .
ce
le
un
pt
an
d
♦ If it is planned not to use the vehicle for approx. two weeks, it

itte
y li
erm
is recommended to fill the tank with original diesel beforehand

ab
ility
and drive approx. 50 km, to prevent damage to the fuel injec‐

ot p
wit
tion system.
is n
h re
ole,
spec
3.10 Identification plate

t to the co
The type plate -arrow- is located on the left B-pillar.

rrectne
Note
ss o
Vehicles for certain export countries have no type plate.

cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
3.11 Severe operating conditions

r
fo
en
ng
t.
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op
If the vehicle is used under severe operating conditions some jobs C py
t. rig
will have to be performed before the next service due or at shorter
gh ht
pyri by
service intervals.
co Vo
by lksw
cted agen
Prote AG.
Sharan 1996 ➤
Severe operating conditions

• Regular short trips or stop and go operation in urban traffic
• High percentage of cold starts
• Vehicle is used in areas with winter temperatures over a long
period
• Regular long periods of idling (e.g. taxis)
• Vehicle is often driven at full throttle with high payload or whilst
towing a trailer
• Using diesel with elevated sulphur content
• Regular operation in areas with high levels of dust
3.12 “Countries with hot climate” includes

Afghanistan Egypt Algeria
Angola Equatorial Guinea Ethiopia
Australia Bahrain (AGCC) Benin (Dahomey)
Botswana Brunei Burkina Faso (Upper Volta)
satelettronica
Burundi China Dem. Rep. Congo
Djibouti Dubai (AGCC) Ivory Coast
Eritrea Gabon Gambia
Ghana Guinea Guinea-Bissau
India Indonesia / (Borneo) Iraq
Iran Israel Japan
Yemen (AGCC) Jordan Cameroon
Qatar (AGCC) Kenya Congo
Kuwait (AGCC) Lesotho Lebanon
Liberia Libya
. Volkswagen AG
Madagascar
gen AG d
Malawi olks
wa
Malaysia oes not Mali
byV gu
ara
Morocco rise
d Mauritania nte Mauritius
tho eo
Mexico s au Mozambique ra
c Namibia
s
Niger Nigeria Oman (AGCC)
ce
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un
pt
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d
Palestine Puerto Rico Rwanda

itte
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erm
ab
Zambia Saudi Arabia (AGCC) Senegal

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Sierra Leone Zimbabwe Singapore

wit
is n
h re
Somalia South Africa Sudan

ole,
spec
Swaziland Syria Tanzania

t to the co
Thailand Togo Chad

Tunisia Turkey Uganda
rrectne
United States of America United Arab Emirates / Abu Dhabi West Sahara
(AGCC)
ss
Central African Republic

o
cial p
f inform
mer
atio
om
n
c
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n thi
te
sd
iva
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cum
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fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Sharan 1996 ➤
4 Descriptions of work:
♦ Removable towing bracket: checking and cleaning if neces‐
sary ⇒ page 45
♦ Additive container: Extract and replenish new additive
⇒ page 47
♦ Rear final drive: Check oil level ⇒ page 53
♦ Swivel joints and axle mountings: inspecting ⇒ page 53
♦ Automatic gearbox: Check oil level of front wheel drive
AG. Volkswagen AG d
⇒ page 55 kswagen oes
n ol ot g
yV ua
♦ Automatic gearbox: checking
ise
ATF
db level ⇒ page 55 ran
r tee
ho
♦ Automatic gearbox: changing
sa
ut ATF ⇒ page 55 or
ac
s
♦ Automatic gearbox: Change ATF strainer ⇒ page 55
ce
le
un
pt
an
d
itte
♦ Battery: checking battery terminal clamps for secure seating
y li
rm
ab
⇒ page 56
pe
ility
satelettronica
ot
wit
♦ Battery: Check using battery tester with printer VAS 5097A or
, is n
h re
VAS 6161 ⇒ page 57
hole
spec
♦ Tyres: checking condition, wear pattern, tyre pressure and
es, in part or in w
t to the co
tread depth ⇒ page 57
♦ Brake fluid: changing ⇒ page 60
rrectness of i
♦ Brake fluid level: checking ⇒ page 64
l purpos
♦ Brake system and shock absorbers: inspecting for leaks and

damage ⇒ page 64
nform
ercia
♦ Brakes, front and rear: checking thickness of brake pads and

condition of brake discs ⇒ page 65
m
a
com
tio
♦ Diesel particulate filter: Read ash loading level ⇒ page 55

n in
r
te o
thi
♦ Diesel fuel filter: renewing ⇒ page 72

s
iva
do
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rp
cum
♦ Diesel fuel filter: Drain water (not TDI PD diesel engine)

fo
en
g
⇒ page 73
n
t.
yi Co
Cop py
♦ Renewing diesel particulate filter ⇒ page 68
t. rig
gh ht
pyri by
Vo
o
♦ Window regulators: checking positioning (open and close
by c lksw
cted agen
functions) ⇒ page 68
Prote AG.
♦ Carrying out vehicle system test ⇒ page 68

♦ Front passenger airbag: checking key switch and “On/Off
function” ⇒ page 54
♦ Protective bellows: inspecting ⇒ page 70
♦ Haldex coupling: Renew oil filter ⇒ page 70
♦ Haldex coupling: Changing oil ⇒ page 70
♦ Interior and exterior body: inspecting for corrosion when doors
and flaps are open ⇒ page 73
♦ Poly V-belt: checking condition ⇒ page 70
♦ V-belt: Check condition and tension (vehicles with 4-cylinder
engine) ⇒ page 71
♦ Cooling system: checking frost protection and coolant level
⇒ page 74
4. Descriptions of work: 43
Sharan 1996 ➤
♦ Air filter: cleaning housing and renewing filter element

⇒ page 76
♦ Oil level: checking ⇒ page 82
♦ Engine oil: Drain or extract and top up; Renew oil filter
⇒ page 82
♦ Engine and components in engine compartment: inspecting
for leaks and damage (from above and below) ⇒ page 86
♦ Engine cover panel -top-: Removing and installing
⇒ page 87
♦ Engine cover -bottom- (noise insulation): Removing and in‐
stalling ⇒ page 88
♦ Road test (performance, handling, noises, air conditioner etc.):
carrying out ⇒ page 89
♦ Radio/navigation system: Entering PIN of anti-theft coding and
store local radio stations to station buttons ⇒ page 89
♦ Wheel securing bolts: tightening to specified torque
⇒ page 90
♦ Tyre repair set ⇒ page 93
satelettronica
♦ Manual gearbox/final drive: Check oil level ⇒ page 103
♦ Window wash/wipe system and headlight washer system:
checking function ⇒ page 93
♦ Checking wiper blade setting angle: if wiper blades judder
⇒ page 99 wage
e ks s no
Vol t gu
♦ Wiper blade protection: removing ⇒ page 101 ed by ara
ris nte
♦ Wiper blades: Check park position ⇒ page 101utho eo
ra
a c
ss
♦ Checking/adjusting headlight setting ⇒ page 127
ce
e
nl
pt
du
an
♦ Sunroof: checking function, cleaning and lubricating guide
itte
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rails ⇒ page 103
erm
ab
ility
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♦ Track rod ends: checking clearance, security and boots

wit
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⇒ page 104
h re
hole
♦ Service interval display: recoding ⇒ page 104 spec

es, in part or in w
t to the co
♦ Service interval display: resetting ⇒ page 111
♦ Power assisted steering: checking fluid level ⇒ page 126
rrectness of i
♦ Door arrester: lubricating ⇒ page 132

l purpos
♦ Dust and pollen filter: Renew filter element ⇒ page 133

♦ Underseal: inspecting for damage to underseal, underbody
nform
ercia
cladding, routing of lines and plugs ⇒ page 133

m
at
om
♦ Clock: setting to correct time ⇒ page 134

ion
c
in t
or
♦ Camshaft drive toothed belt: Renew (TDI diesel engine)

his
ate
⇒ page 134
do
priv
cum
or
♦ Camshaft drive toothed belt and tensioning roller: Renew (PD

f
en
ng
t.
yi
TDI diesel engine) ⇒ page 135
Co
Cop py
t. rig
♦ Camshaft drive toothed belt: Renew (4-cylinder petrol engine,
gh ht
pyri by
5-valve) ⇒ page 135
co Vo
by lksw
cted agen
Prote AG.
♦ Toothed belt: Check for wear (diesel engine) ⇒ page 135
♦ Camshaft drive toothed belt: Check (4-cylinder petrol engine)
⇒ page 136
♦ Spark plugs: renewing ⇒ page 136
44 4. Descriptions of work:
Sharan 1996 ➤
4.1 Removable towing bracket: checking

and cleaning if necessary
This chapter describes how to check and repair a removable tow‐
ing bracket.
Note
Note that checking towing bracket is included in the respective

AG. Volkswagen AG d
service. However, a repair is charged separately
lkswand must be re‐
agen oes
not
quired by the customer. d byV
o gu
ar
e an
ris tee
tho or
Check procedure au ac
ss
ce
e
– Detach cover -1-.

nl
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ab
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wit
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hole
spec
es, in part or in w
satelettronica
t to the co
rrectness of i
l purpos
– Pull off protective cap -1- from ball head mounting -2-.
nf
ercia
or
– Insert ball head into mounting.
m
m
atio
om
n in
or c
thi
te
sd
iva
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f
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t.
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Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.
After ball head has been inserted, green mark on hand wheel
must be aligned with white mark on ball head. Hand wheel must
be entirely in contact. Afterwards, it must be possible to close the
towing bracket lock by removing the key. If this is not possible,
the following repair procedure must be performed.
Note
If a repair has to be performed, it has only to be in agreement with

the customer. A repair must be charged separately.
Repair procedure:
Sharan 1996 ➤
– Check contact surfaces -arrows- of ball head mounting for

corrosion.
– If contact surfaces are corroded, eliminate corrosion with a tri‐
angular scraper and clean the treated areas with silicone
remover.
– Apply a thin coat of lubricating paste G 000 650 or G 000 150
on cleaned surfaces.
– Check contact surfaces -arrows- of ball head for corrosion.

– If contact surfaces are corroded, eliminate corrosion with a tri‐
angular scraper and clean the treated areas with silicone
remover.
– Apply a thin coat of lubricating paste G 000 650 or G 000 150
on cleaned surfaces.
– Check again ball head seat in mounting ⇒ page 45 .
satelettronica
olkswagen AG
en AG. V
– After checking, fit protective cap -1- into ballkswhead mounting
ag does
not
Vol
-2-. ed
by gu
ara
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Note ss
ce
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nl
pt
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If protective cap is damaged or not available, a new protective

y li
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cap must be fitted to protect ball head mounting against corrosion.

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⇒ ETKA
wit
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
– Insert cover -1-.

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om
n in
or c
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Sharan 1996 ➤
4.2 Additive container: Extract and replen‐

ish new additive
♦ Engine and gearbox jack - VAG 1383 A-
4.2.1 Safety measures and handling instruc‐

tions when working on additive contain‐
satelettronica
er system
AG. Volkswagen AG d
agen oes
lksw not
WARNING d byV
o gu
ara
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or eo
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Please note the following for all procedures: s aut ra
c
s
♦ The diesel additive fluid is hazardous to health.
ce
le
un
pt
an
d
itte
♦ Read safety instructions on new additive fluid container!
y li
erm
ab
ility
♦ Information concerning storage and disposal ⇒ Service‐
ot p
Net → Environmental protection → Workshop disposal !
wit
is n
h re
Ask your importer about country-specific information on
ole,
storage and disposal.
spec
t to the co
♦ Before starting work, place extraction hose of switched on
exhaust gas extraction system near the connections of
additive container, to ensure the released additive emis‐
sions are extracted.
rrectne
♦ If no exhaust extraction system is available, a centrifugal
s
fan (motor outside air stream) with a delivery volume of
more than 15 m3/h can be used. s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Sharan 1996 ➤
WARNING
Please note the following for all procedures:

♦ For all assembly work on the additive container system
always wear eye protection and fuel resistant protective
gloves (avoid additive contact with skin)!
AG. Volkswagen AG d
agen oes
♦ Always perform assembly work on open system iny Vwell
olks
w not
gu
ventilated rooms! ise
d b ara
nte
r
ho eo
♦ Do not inhale vapours of additive fluid! aut ra
c
ss
♦ Keep additive fluid away from heat, sparks and open
ce
le
un
pt
flame.
an
d
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♦ The fluid vapours in combination with air can create an
pe
ility
explosive mixture.
ot
wit
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h re
♦ Vapours are heavier than air and can spread to igniting
hole
sources near ground level.
spec
es, in part or in w
t to the co
satelettronica
WARNING
rrectness of i
Please note the following for all procedures:
l purpos
♦ The diesel additive must not drain into sewerage and not
soak into the soil. If leaks occur, immediately bind and
nform
ercia
eliminate.
m
a
com
ti
♦ The additive container is under pressure! Before opening
on in
the system, place a cloth around the connection, and re‐
r
te o
thi
duce pressure by carefully loosening the connection!
s
iva
do
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rp
c
♦ Collect fluid in a container e.g. when lines are drained
um
fo
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empty etc.!
n
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Cop py
♦ Route lines of all types, e.g. fuel lines, additive lines as
t. rig
gh ht
yri
well as electrical wires, so that the cable guide is in original p by
co Vo
condition.
by lksw
cted agen
Prote AG.
♦ Make sure that there is sufficient clearance to all moving

or hot components.
4.2.2 General information
Note
♦ The additive container with connections is located underneath

the vehicle on rear right of floor pan.
♦ The additive container has a capacity of 4.0 litres.
♦ Only use new additive fluid.
♦ The part number of the 1.0 litre container is -G 052 143 A2- .
♦ If the residual capacity in the additive container is less than 0.3
litre, this is shown on display in the dash panel insert.
Sharan 1996 ➤
4.2.3 Removing sealing plug

– Unscrew bolts -arrows A- and -arrows B- from fuel additive
container bracket -1- and lower container downwards hori‐
zontally using engine and gearbox jack - VAG 1383 A- .
The connections of the fuel additive container can be seen
-arrows A + B-.
Note
Always note safety measures when working on additive contain‐

er! G. Volkswagen
nA AG do
wage es n
Volks ot g
– First pull sealing plug offedVENTILATION -arrow A-
by ua
ran
⇒ page 49 ! thoris tee
u or
a ac
– Then pull sealing splug
s off EXTRACTION/FILLING -arrow B-
ce
⇒ page 49
e
nl
pt
du
an
itte
– Before opening the system, place a cloth around the connect‐
y li
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ab
ing location and reduce pressure by carefully loosening the
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connecting location!
satelettronica
wit
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h re
Pull off sealing plug as follows:
hole
spec
es, in part or in w
-Arrow A- round connector side.
t to the co
-Arrow B- flat connector side.
rrectness of i
– Push securing ring in at round side of connector -arrow A- by
hand or with a suitable tool and pull connector off.
l purpos
nf
ercia
orm
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4.2.4 Connections for fuel additive container

t.
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t. rig
VENTILATION -arrow A- (smaller connection diameter). gh ht
pyri by
Vo
co lksw
by
EXTRACTION/FILLING -arrow B- (larger connection diameter) Prote
cted AG.
agen
Sharan 1996 ➤
4.2.5 Extracting and replenishing with fluid

Special tools, testers, measuring instruments and auxiliary items
required
♦ Extraction unit - VAS 6277/1-

♦ Filling device - VAS 6277/2-
♦ Overflow protection - VAS 6277/3-
♦ Hose clamp - 3094-
Extracting fluid:
satelettronica
Note AG. Volkswagen AG d
agen oes
olksw not
V
Observe instruction manual
ed by for extraction unit - VAS 6277/1-
gu
ara .
nte
ris
ho eo
aut ra
ss c
ce
e
– Push connector -4- of extraction unit - VAS 6277/1- onto con‐

nl
pt
du
nection for EXTRACTION/FILLING; respective connections

an
itte
y li
⇒ page 49 .
erm
ab
ility
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wit
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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
om
n in
or c
thi
te
sd
iva
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rp
cu
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m
f
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Sharan 1996 ➤
– Connect compressed air supply -2- to extraction unit - VAS

6277/1- .
– Extract fluid by carefully pulling metering lever -3-.
WARNING
♦ Turn ventilation -1- in direction of the well ventilated room,

do not inhale emitting vapours.
♦ Ensure the extraction container of the extraction unit - VAS
6277/1- is not overfilled during extraction process. A dan‐
ger of overflowing exists.
♦ Finish extraction process when the container is approx.
2/3 full, see -arrow 5-.
♦ If necessary repeat extraction process.
♦ Do not reuse extracted (used) additive fluid.
♦ Dispose of extracted (used) additive fluid according to op‐
erating instructions ⇒ ServiceNet, Genuine parts, Product
information, Safety data sheets and operating instruc‐
tions; Additive or ask your importer.
satelettronica
– If the total quantity of fluid has been extracted, separate com‐
pressed air supply.
Replenishing fluid:
– Bolt container with new additive fluid -1- to filling device - VAS
6277/2- .
– Connect filling device - VAS 6277/2- and overflow protection
- VAS 6277/3- with connections -3- and -4- to respective con‐
nections ⇒ page 49 .
– Additionally secure hose clamp e.g. hose clamp - VAS 6277/2-n AG. Volkswagen AG
on hose end of filling device - 3094- olks
wage does
no
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db ara
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tho eo
Note au ra
c
ss
ce
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un
The hose clamp prevents that after filling and when pulling off
pt
an
d
hose, fluid is drained from filling hose.

itte
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rm
ab
pe
ility
ot
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– Open valve -2- and drain fluid (4 x 1.0l container) into additive
h re
container, until fluid is visible on hose of overflow protection -

hole
spec
VAS 6277/3- .
es, in part or in w
t to the co
The additive container has a capacity of 4.0 litres.

– Seal valve -2-, and clamp off filler hose using e.g. hose clamp
- 3094- .
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
51
Prote AG.
Sharan 1996 ➤
– Separate filling device - VAS 6277/2- and overflow protection

- VAS 6277/3- from additive container connections
-arrows A + B-.
– Connect both sealing plugs onto connections.
– Push bracket -1- upwards and tighten bolts -arrows A- and

-arrows B- to 25 Nm.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
4.2.6 Final checks ise
d by V gu
ara
nte
or eo
h
– Unscrew additives a container from filling device - VAS 6277/2- .
u t ra
c
s
– Drain all fluid from filling device - VAS 6277/2- , so that no
ce
e
nl
pt
du
residual fluid will remain in the hose or cut-off valve.

an
itte
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erm
ab
ility
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Note
wit
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hole
Residual fluid crystallises in combination with oxygen.

spec
es, in part or in w
t to the co
Caution
rrectness of i
Crystallised fluid may cause malfunctions in the additive sys‐

l purpos
tem.
nform
mercia
WARNING
at
om
ion
c
in t
r
Remove spilt fluid with absorbing, non-flammable material

o
his
te
(binding agent).
a
do
priv
cum
or
Dispose of materials which are soaked with fluid, e.g. cloths or

f
en
ng
binding agents, in a suitable container which can be closed,

t.
yi Co
op
observe hazardous material regulations! C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
– If fluid has been extracted from the additive container system,
Prote AG.
fill used fluid of extraction unit - VAS 6277/1- into empty orig‐
inal container of new fluid. Observe hazardous material regu‐
lations!
Sharan 1996 ➤
WARNING
Always store additive fluid in the original container in a dry and

well ventilated area.
4.3 Rear final drive: Check oil level

• Only valid for Sharan ►1996 syncro and 4motion
»Power transmission; Automatic gearbox« ⇒ Rep. gr. 39 ;
»Checking gearbox oil in rear final drive«.
4.4 Swivel joints and suspension link

mountings: inspecting
– Check swivel joint boots -arrow- for leaks and damage.
satelettronica
– Check also suspension link mountings -arrow- for following
damage:
♦ Large cracks, perforating cracks or cuts in rubber material.
. Volkswagen AG
♦ Complete separation of rubber
swa
geand
n AGmetal parts. does
k not
Vol g
♦ Large play betweensemounting
db
y
and suspension link, whichuhas
ara
nte
a considerably negative
thori
effect on the function of the mounting. eo
au ra
c
ss
ce
le
un
Note
pt
an
d
itte
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rm
ab
♦ Superficial cracks and cuts as well as minor separations of the

pe
ility
rubber element from the metal part do not significantly affect

ot
wit
, is n
the operation of the elasto-kinematic mounting and do not

h re
constitute a basis for a complaint.

hole
spec
es, in part or in w
♦ Damage to the thin rubber skin over cavities due to construc‐

t to the co
tion is also permissible.

♦ Play between bearing and axle component is permissible as
rrectness of i
long as there is no negative effect on the function of the bear‐

ing.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Sharan 1996 ➤ horis nte
eo
Maintenance - Edition 03.2018 aut ra
ss c
ce
e
nl
pt
4.5 Front passenger airbag: checking key
du
an
itte
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switch and “On/Off function”
erm
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ility
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h re
Note
hole
spec
es, in part or in w
t to the co
The “Airbag ON/OFF” switch is located in the stowage compart‐
ment in centre of dash panel.
rrectness of i
Front passenger airbag: Check key switch and “On/Off function”
l purpos
– Using vehicle key, turn key switch to position “Airbag Off”.
nform
ercia
– Switch on ignition.
m
– Warning lamp “Passenger airbag off” -arrow- must also light
at
om
io
up after self-test (passenger airbag deactivated).
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
satelettronica
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Switch off ignition.

– Using vehicle key, turn key switch to position “Airbag ON”.
– Warning lamp “Passenger Airbag Off” -arrow- goes out after
self-test (passenger airbag activated).
Sharan 1996 ➤
4.6 Diesel particulate filter: Reading ash

loading level
Note
♦ When checking the diesel particulate filter the ash loading limit
value is read.
♦ Only applies to engines with engine codes BRT, BVH
– Connect vehicle diagnostic tester . ⇒ page 36

– Select “Guided Function” mode on display.
– Carry out identification of vehicle.
– Select vehicle system “Engine”. n AG. Volkswagen AG do
lkswage es n
– Then, check “ash loading of diesel particulate
d by V filter”.
o ot g
ua
ran
ir se tee
Follow instructions on display. tho
or
satelettronica
au ac
ss
4.7 Automatic gearbox: changing ATF (099
ce
le
un
pt
gearbox)
an
d
itte
y li
rm
ab
Affected countries ⇒ page 42 .
pe
ility
ot
wit
, is n
Carry out the following procedure:
h re
hole
spec
»Power transmission; Automatic gearbox«; ⇒ Rep. gr. 37 ,
es, in part or in w
»Changing ATF«
t to the co
4.8 Automatic gearbox: Change ATF strain‐
er (099 gearbox)
rrectness of i
l purpos
Affected countries ⇒ page 42 .

»Power transmission; Automatic gearbox« ⇒ Rep. gr. 38 »Re‐
nform
ercia
moving and installing valve body; Changing ATF strainer«

m
Countries with hot climate

a
com
tion in
Jordan Egypt Qatar

r
te o
thi
s
iva
Syria Kuwait United Arab Emirates

do
r
rp
cum
Lebanon Bahrain Yemen

fo
en
ng
t.
yi Co
Palestine Saudi Arabia
t. Cop Iran py
rig
Iraq Tunisia Morocco
gh ht
pyri by
Vo
co lksw
by
Afghanistan Turkey Prote
cted AG. Israelagen
4.9 Automatic gearbox: Check oil level of

front wheel drive (099 gearbox)
»Power transmission; Automatic gearbox«; ⇒ Rep. gr. 39 ;
»Checking gear oil in front final drive«
4.10 Automatic gearbox: check ATF level.

»Power transmission; Automatic gearbox« ⇒ Rep. gr. 37
»Checking ATF level and topping up«
AG. Volkswagen AG d
agen oes
olksw not
V
Sharan 1996 ➤ d by gu
ara
ise nte
thor eo
au ra
ss c
4.11 Battery: checking battery terminal
ce
e
nl
pt
du
an
clamps for secure seating
itte
y li
erm
ab
ility
ot p
wit
, is n
♦ Torque wrench - V.A.G 1331-
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
c
Note
um
for
en
ng
satelettronica
t.
yi Co
op
♦ The battery is located in engine compartment.
C py
t. rig
gh ht
yri by
♦ The second battery is located below the front passenger seat. cop Vo
by lksw
cted agen
Prote
♦ A securely seated battery clamp ensures trouble free function
AG.
and long service life of the battery.
– Battery installation position: »Electrical system« ⇒ Rep. gr.

27 »Battery«
– Switch off ignition and all electrical consumers and remove
ignition key.
After waiting 60 seconds:
– Check if battery clamps -3- and -4- are seated securely on
battery terminals by moving battery positive cable -1- and bat‐
tery negative cable -2- back and forth.
WARNING
If the battery clamp is not seated securely on the positive ter‐

minal, first disconnect battery clamp from battery negative
terminal to prevent possible accidents.
If the battery clamp is not seated securely on positive terminal:

– Disconnect battery terminal clamp -4- from battery negative
terminal first.
– Tighten battery clamp -3- on battery positive terminal to 6 Nm.
– Reconnect battery clamp -4- to battery negative terminal and
tighten to 6 Nm.
If the battery clamp on negative terminal is not seated securely:
Sharan 1996 ➤
– Tighten battery clamp -4- on battery negative terminal to 6 Nm.

AG. Volkswagen AG d
agen oes
lksw not
Note d by Vo gu
ara
rise nte
ho eo
If the battery has been reconnected,
s aut
observe procedures descri‐ ra
c
bed in: »Electrical system«
s ⇒ Rep. gr. 27 »Disconnecting and
ce
e
connecting battery«. 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
4.12 Battery: Check using battery tester with
t to the co
printer VAS 5097A or VAS 6161
rrectness of i
Procedure: »Electrical system general information« ⇒ Electrical
system general information; Rep. gr. 27 ; Checking battery
l purpos
»Checking battery«
4.13 Tyres: checking condition, wear pattern,
nf
ercia
satelettronica
r
tyre pressure and tread depth
m
m
atio
om
n in
c
Checking condition of tyre ⇒ page 57 .

or
thi
te
sd
a
Checking wear pattern ⇒ page 58

iv
o
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rp
cu
o
m
Tread depth (including spare wheel): check ⇒ page 58 .
f
en
ng
t.
yi Co
op
General notes ⇒ page 58 C py
t. rig
gh ht
yri
Tyre pressure: check, correct if necessary ⇒ page 59
p by
co Vo
by lksw
cted agen
Prote AG.
♦ Tyre inflator - VAS 5216-
4.13.1 Tyres: checking condition
WARNING
If damage is determined, always check to see if a new tyre

should be fitted.
Tests at delivery inspection

– Check tyre treads and side walls for damage and remove for‐
eign bodies such as, for example, nails or glass splinters.
Tests at inspection service
– Check tyre treads and side walls for damage and remove for‐
eign bodies such as, for example, nails or glass splinters.
Sharan 1996 ➤
– Check tyres for cupping, one-sided wear, porous side walls,

cuts and punctures.
4.13.2 Wear pattern: checking

The wear pattern on the front tyres will indicate, for example, if
toe and camber settings should be checked:
♦ Feathering on tread indicates incorrect toe setting.
♦ One-sided tread wear is mainly attributed to incorrect camber.
When wear of this nature is detected, determine cause by check‐
ing alignment (repair measure).
4.13.3 Tyre tread depth: Check and enter

– Check tyre tread depth.
Minimum tread depth: 1.6 mm
Note
♦ This figure may vary according to legislation in individual coun‐
satelettronica
tries.
♦ The minimum tread depth is reached when the tyres have
worn down level with the 1.6 mm high tread wear indicators
-arrows- positioned at intervals around the tyre.
♦ If the tread depth is approaching the minimum allowed depth,
G. Volkswage
inform the customer. lksw
agen
A n AG d
oes
not
o
yV gu
db ara
rise nte
tho eo
4.13.4 General information ss au ra
c
ce
le
un
pt
WARNING an
d
itte
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rm
ab
pe
ility
♦ For safety reasons, only tyres of same type and tread pat‐
ot
wit
tern should be fitted on a vehicle! Approved wheel and tyre
, is n
h re
combinations, e.g. ⇒ Running gear; Rep. gr. 44 ; Sharan

hole
from model year 1996

spec
es, in part or in w
t to the co
♦ On four-wheel drive vehicles, tyres of the same type and

tread pattern must be used. Otherwise the centre differ‐
ential may be damaged.
rrectness of i
l purpos
Note
nform
ercia
♦ Tyre pressures for the relevant model can also be found on a

m
a
com
sticker. It is attached to the inside of tank flap or to B-pillar.

ion in
r
te o
♦ The pressures on the sticker apply to cold tyres. Do not reduce

thi
s
iva
increased pressures of warm tyres.

do
r
rp
cum
fo
♦ Adjust the tyre pressure to suit the vehicle load.

en
ng
t.
yi Co
op
♦ The spare wheel should have the highest tyre pressure deter‐
C py
t. rig
mined for the vehicle.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Sharan 1996 ➤
M+S tyres
Note
♦ Important information on recommended winter tyres can be

found in Wheels and Tyres Guide - Standard → ⇒ Running
gear; Rep. gr. 44 ; Recommended winter tyres → Recom‐
mended winter tyres.
♦ If winter tyres are fitted, a sticker, visible for the customer and
indicating the speed limit, must be applied in the in interior of
the vehicle.
♦ For winter tyres, the tyre pressure does not have be increased.
However, this applies only if the winter tyre used corresponds
exactly to the standard summer tyre size and the speed index
is no higher than “H”. If this is not the case, please refer to the
recommendation of the tyre manufacturer.
Note
satelettronica
4.13.5 Tyre pressure: checking and correcting

if necessary
Note agen
AG. Volkswagen AG d
oes
olksw not
V gu
by ara
The mandatory tyre pressures for the respectiveormodel
ised
can be nte
found on a sticker attached to the inside of tankaut flap or to the B-
h eo
ra
pillar. ss c
ce
le
un
pt
an
d
Check tyre pressure using tyre inflator - VAS 5216- , correct if

itte
y li
necessary.
rm
ab
pe
Tyre inflation pressures for all factory fitted tyre sizes. ility
ot
wit
, is n
h re
Tyre inflation pressure table for summer tyres or all-season tyres.
hole
spec
es, in part or in w
Half load Full load

t to the co
bar bar
Tyre size Front Rear Front Rear
rrectness of i
195/65 R15 2.6 2.4 2.7 3.1

l purpos
195/55 R16 98/96 2.9 2.7 3.1 3.6

195/55 R16 C
nform
ercia
99/97 T
195/55 R16 C 3.2
m
2.9 3.3 3.6

a
com
ti
99/97 H
on in
r
te o
205/60 R15 2.7 2.5 2.9 3.3

thi
s
iva
do
205/55 R16 C98/96 3.3 3.0 3.5 3.8

r
rp
cum
H
fo
en
ng
t.
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215/60 R15 2.3 2.2 2.5 2.9
Co
Cop py
t. rig
215/55 R16 95 H 2.8 2.6 3.0 3.2
gh ht
pyri by
Vo
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by c
215/55 R16 95 W
lksw
cted agen
Prote AG.
215/55 R16 97 H
215/55 R16 97 W
Sharan 1996 ➤
Half load Full load

bar bar
Tyre size Front Rear Front Rear
AG. Volkswagen AG d
225/45 R17 2.9 agen 2.9
not 3.1 3.4
oes
olksw
y V gu
d b ara
rise nte
tho eo
au ra
Spare wheel with standard tyres ss c
ce
e
nl
pt
du
The spare wheel should have the highest tyre pressure deter‐
an
itte
mined for the vehicle.
y li
erm
ab
ility
ot p
4.14 Changing brake fluid
wit
, is n
h re
Instructions for use and safety ⇒ page 60 .
hole
spec
es, in part or in w
Brake fluid specification ⇒ page 60 .
t to the co
Procedure, changing brake fluid ⇒ page 60 .
4.14.1 Operation and safety notes
rrectness of i
l purpos
satelettronica
Note
nf
ercia
or
♦ From model year 2006 a new brake fluid is used.
m
m
atio
om
♦ The new brake fluid can also be used for older vehicles.
n in
or c
thi
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♦ For this purpose it can be mixed with the previous brake fluid.
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t.
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WARNING
Co
Cop py
t. rig
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♦ Never allow brake fluid to come into contact with fluids that cop Vo
by lksw
contain mineral oils (e.g. oil, petrol, cleaning agents). Min‐ cted agen
Prote AG.
eral oils damage the seals and boots in the brake system.
♦ Brake fluid is poisonous. In addition, due to its corrosive
nature, it must not come into contact with paint.
♦ Brake fluid is hygroscopic, which means it absorbs mois‐
ture from the ambient air and should therefore always be
stored in air-tight containers.
♦ Rinse off spilled brake fluid using plenty of water.
♦ Do not reuse extracted (used) brake fluid.
♦ Observe relevant disposal regulations.
4.14.2 Brake fluid specification

Permissible brake fluid specifications
♦ Brake fluid conforming to US standard FMVSS 116 DOT 4
(previous brake fluid)
♦ Brake fluid conforming to VW standard, VW 501 14 (new brake
fluid).
4.14.3 Procedure, changing brake fluid

Sharan 1996 ➤
♦ Brake filling and bleeding equipment - VAS 5234-
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
♦ Brake bleeding wrench - VAS 5519-
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
ercia
♦ Brake bleeding tool - VAS 6564-

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
o
by c lksw
cted agen
Prote AG.
♦ Bleeder T spanner 11 mm - VAS 3237-
Please note the following:

• The strainer in brake fluid reservoir must remain in place.
Sharan 1996 ➤
For vehicles with ABS/EDL, ABS/EDL/TCS, ABS/EDL/TCS/ESP

note the following:
WARNING wage
es n
olks ot g
byV ua
When changing the brake fluid using the ir se brake filling and
d ran
tee
bleeding equipment - VAS 5234- , make u sure that the filling
tho
or
a ac
pressure of 1 bar is not exceeded. ss
ce
e
nl
pt
du
an
itte
y li
Therefore the brake fluid pressure on the brake filling and bleed‐
erm
ab
ing equipment - VAS 5234- must be reduced to 1 bar ⇒ Operating
ility
ot p
instructions for brake filling and bleeding equipment - VAS 5234- .
wit
, is n
h re
Continued for all vehicles:
hole
spec
es, in part or in w
– Unscrew cap -1- from brake fluid reservoir.
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
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– Extract as much brake fluid as possible from brake fluid res‐
f
en
ng
t.
yi
ervoir, using suction hose -1- from brake filling and bleeding
Co
op py
equipment - VAS 5234- . t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
WARNING Prote AG.
Do not reuse extracted (used) brake fluid.
– Screw adapter - 5234/1- -1- or adapter - 1869/1 A- onto brake

fluid reservoir.
– Connect filling hose from brake filling and bleeding equipment
- VAS 5234- to adapter.
Vehicles with manual gearbox:
– Pull cover cap off clutch slave cylinder bleeder screw.
Sharan 1996 ➤
– Connect bleeder hose -arrow- using bleeder T spanner 11 mm

- 3237- on clutch slave cylinder.
– Open bleed screw and allow approx. 0.1 litre to flow out. Close
bleed screw.
– Operate clutch pedal several times.
Continued for all vehicles:
– Remove caps from bleeder screws of wheel brake cylinders
and brake calipers.
– Push collector bottle bleeder hose -1- onto rear bleeder screw
1)
, open bleeder screw and let appropriate quantity of brake
fluid (see table) run out. Close bleed screw. Torque: »Running
gear, brake systems« ⇒ Running gear, brake systems; Rep.
gr. 47 ; Repairing rear brake caliper »Repairing rear brake
caliper«
1) Start at rear right of left-hand drive vehicles and at rear left of right-hand drive
vehicles.
satelettronica
Repeat procedure on other side of vehicle at rear.
– Push collector bottle bleeder hose -1- onto front bleeder screw
2)
, open bleeder screw and let appropriate quantity of brake
fluid (see table) run out. Close bleed screw. Torque: »Running
gear, brake systems« ⇒ Running gear, brake systems; Rep.
gr. 47 ; Repairing front brake caliper »Repairing front brake
caliper«
2) Start at front right of left-hand drive vehicles and at front left of right-hand drive
vehicles.
Repeat procedure on other side of vehicle at front.

Table – Sequence and quantity of brake fluid lkswage es n
o ot g
byV ua
ed ran
Sequence: Brake fluid quantity
thoris
which must tee
or
Brake calipers flow out ofs abrake
u calipers: ac
(LHD vehicles) s
ce
e
nl
pt
du
Rear right 0.5 l

an
itte
y li
erm
Rear left 0.5 l

ab
ility
ot p
Front right 0.5 l

wit
, is n
h re
Front left 0.5 l

hole
spec
es, in part or in w
Total quantity3): 2 litres

t to the co
3) Includes quantity of brake fluid extracted from brake fluid reservoir and quantity
used changing hydraulic clutch mechanism fluid
rrectness of i
– Fit cover caps on wheel brake cylinder and brake caliper

bleeder screws.
l purpos
– Move fill lever of brake filling and bleeding equipment - VAS

5234- to position B.
nf
ercia
or
– Take filler hose off adapter.

m
m
atio
om
– Unscrew adapter from brake fluid reservoir.

n in
or c
thi
e
– Check brake fluid level and correct if necessary.

t
sd
iva
o
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cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
63
co Vo
by lksw
cted 4. Descriptions of work:
agen
Prote AG.
Sharan 1996 ➤
– Screw on cap -1- of brake fluid reservoir.

– Check pressure and free travel of brake pedal:
Free play: max: 1/3 of pedal travel.
4.15 Brake fluid level: checking

Instructions for use and safety ⇒ page 60 .
Brake fluid specification ⇒ page 60 .
Procedure, brake fluid level (dependent upon lining/pad wear):
check ⇒ page 64 .
4.15.1 Procedure, brake fluid level (dependent
satelettronica
upon lining/pad wear): checking
Brake fluid level at delivery inspection: agen
AG. Volkswagen AG d
oes
olksw not
For delivery inspection fluid level must bed baty V MAX. marking. gu
ara
ise nte
or eo
h
aut ra
s c
Note s
ce
le
un
pt
an
d
To prevent that brake fluid flows out of reservoir, the MAX marking
itte
y li
rm
must not be exceeded. ab

pe
ility
ot
wit
, is n
Brake fluid level at inspection service:

h re
hole
spec
The fluid level must always be judged in conjunction with lining/

es, in part or in w
pad wear.
t to the co
When vehicle is in use, fluid level tends to drop slightly due to

lining/pad wear and automatic adjustment.
rrectness of i
• Recommended brake fluid level, if brake pads are almost at

l purpos
wear limit:
“At MIN. marking or just above” “REPLENISHING IS NOT RE‐

nform
ercia
QUIRED”.
m
a
com
ti
• Recommended brake fluid level when brake pads are new or

on in
well within wear limit:

r
te o
thi
s
iva
do
“Between MIN and MAX marking”.

r
rp
cum
fo
en
ng
t.
yi
WARNING
Co
Cop py
t. rig
gh ht
yri by
If the fluid level is below MIN. marking, the brake system must op Vo
by c lksw
be checked before fluid is topped up “repair measure”. cted agen
Prote AG.
4.16 Brake system and shock absorbers: in‐

specting for leaks and damage
Check following components for leaks and damage:
♦ Brake master cylinder
Sharan 1996 ➤
♦ Brake servo (for anti-lock brake system: hydraulic unit)

♦ Brake pressure regulator and
♦ Brake caliper
♦ Shock absorbers (during inspection only)
♦ Presence of dust caps on brake fluid bleeder valves
– Ensure that brake hoses are not twisted.
– Additionally ensure that brake hoses do not touch any vehicle
components when steering is at full lock.
– Check brake hoses for porosity or brittleness.
– Check brake hoses and lines for chafing.
– Check brake connections and fastenings for correct seating,
leaks and corrosion.
WARNING
Faults found must always be rectified (repair measure).
satelettronica
4.17 Brakes, front and rear: checking thick‐
ness of brake pads and condition of
brake discs
Front disc brake pads: checking thickness ⇒ page 66
Rear disc brake pads: checking thickness ⇒ page 67 olkswage es n
ot g
yV ua
db
Brake discs: checking condition ⇒ page 67 rise
ran
tee
tho or
ss
au ac
ce
le

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f in
♦ Pliers - 3314-
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
o
by c lksw
cted agen
Prote AG.
♦ Electric hand torch and mirror
AG. Volkswagen AG d
agen
Sharan 1996 ➤ Volksw
oes
not
by gu
Maintenance - Edition 03.2018 ised ara
nte
or eo
h
ut ra
♦ The puller hooks to remove the wheel trims are located
ss a
in the c
vehicle tool kit.
ce
e
nl
pt
du
an
♦ The adapter to loosen and tighten the anti-theft wheel bolts
itte
y li
erm
can be found in the vehicle tool kit.
ab
ility
ot p
wit
, is n
h re
4.17.1 Front brake pads:
hole
spec
es, in part or in w
t to the co
– For better evaluation of remaining pad thickness, use a test
mirror and, if necessary, remove the wheel on the side where
the brake pad wear indicator is installed.
rrectness of i
– If necessary, pull wheel bolt covers off with pliers - 3314- or
pull full sized wheel trim off. l purpos
– Mark position of wheel relative to brake disc.
nform
ercia
– Unbolt wheel bolts and remove wheel.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
satelettronica
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Measure thickness of inner and outer pads. Prote
cted AG.
agen
-a- Pad thickness “without” backplate

Wear dimension: 2 mm
The brake pads have reached their wear limit at a pad thickness
of 2 mm (without backplate) and must be renewed (repair meas‐
ure). Inform customer!
Note
When replacing brake pads, always check brake discs as well for
wear. Checking and if necessary replacing the brake discs is a
repair measure.
– Check brake disc for wear »Brake systems« ⇒ Rep. gr. 46

»Repairing front brakes«.
– Install wheel in marked position.
– Tighten wheel bolts diagonally and alternately to following
specified torque:
Specified torque:
Wheel bolt to wheel hub for all vehicles: 170 Nm
– Place adapter in vehicle tool kit after completing work.
– Fit wheel bolt covers if necessary .
Sharan 1996 ➤
– Install full sized wheel trim so that the tyre filler valve is guided
through the cut-out provided -arrow-.
4.17.2 Rear brake pads:

– Remove full-sized wheel trim if necessary.
– Illuminate area behind hole in wheel using an electric hand
torch.
– Determine the pad thickness by visual check.
– Illuminate inner pad with an electric hand torch and mirror.
satelettronica
-a- Inner and outer pad thickness without packing plate
Wear dimension: 2 mm
The brake pads have reached their wear limit at a pad thickness
of 2 mm (without backplate) and must be renewed (repair meas‐
ure). Inform customer!
Note
AG. Volkswagen AG d
agen oes
olksw not
When replacing brake pads, d b always check brake discs as well
y V gu for
ara
wear. Checking and hifornecessary
ise replacing the brake discs is a ntee
repair measure. s aut or
ac
s
ce
le
un
– Check brake disc for wear »Brake systems« ⇒ Rep. gr. 46

pt
an
d
itte
»Repairing rear brakes«.

y li
erm
ab
ility
ot p
– Install full sized wheel trim so that the tyre filler valve is guided
wit
is n
through the cut-out provided -arrow-.

h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
4.17.3 Brake discs: checking condition

i
or
n thi
te
sd
va
Check all brake discs for the following damage pattern:

i
o
pr
cum
r
fo
en
♦ Cracks
ng
t.
yi Co
op py
♦ Scoring t. C rig
gh ht
pyri by
Vo
♦ Rust (no surface rust)
co lksw
by
cted agen
Prote AG.
♦ Degree of wear at the ridge along the circumference
Sharan 1996 ➤
Note
Inform customer if brake disc damage is similar to these damage

patterns. Renewing the brake discs is a repair measure.
4.18 Renewing diesel particulate filter

Installation position of diesel particulate filter, see vehicle under‐
side, component -A-.
– Removing and installing diesel particulate filter
agen
AG.»4-cylinder
Volkswagen AG
do
diesel engine« ⇒ Rep. gr. 26 »Removing
Volksw and installing parts es not
gu
of the exhaust system« ed
by ara
n ris tee
ho
aut or
ac
ss
Note
ce
e
nl
pt
du
an
itte
Every time the diesel particulate filter is changed, the ash mass
y li
erm
ab
comparison adaption must be set to »0«, diagnostic tester
ility
ot p
wit
, is n
h re
satelettronica
hole
4.19 Electric windows: checking positioning
spec
es, in part or in w
(open and close functions)
t to the co
WARNING
rrectness of i
The automatic opening and closing features for the electric
l purpos
windows do not function after disconnecting and reconnecting

the vehicle battery. Severe pinching injuries could result!
nform
mercia
at
om
ion
c
in t
or
Note
his
ate
do
priv
♦ The automatic opening and closing features for the electric

um
for
en
windows do not function after disconnecting and reconnecting

ng
t.
yi Co
the vehicle battery. t. Cop py
rig
gh ht
♦ Therefore, with immediate effect, before a new vehicle is de‐ pyri by
Vo
o
by c
livered, the window regulators must be reactivated.
lksw
cted agen
Prote AG.
♦ Once the windows have been repositioned, the batteries must
not be disconnected again.
Carry out the following procedure to reactivate the automatic

functions of the window regulators:
– Close all doors and windows completely.
– Lock vehicle from outside at driver door or front passenger
door.
– Unlock vehicle.
– Lock vehicle again from outside at driver door or front pas‐
senger door. Hold key in lock position for at least 1 second.
The opening and closing features for the electric windows are
ready for use again.
4.20 Carry out vehicle system test

– Connect vehicle diagnostic tester ⇒ page 36 .
Sharan 1996 ➤
– Select operating mode “Guided fault finding” on display.

– Then perform vehicle identification on vehicle diagnostic test‐
er .
The programme now automatically performs a vehicle system test
and reads all control units available for this vehicle type.
– Press > button.
Now all faults are listed.
Note
♦ At this point it is useful to change to operating mode guided

functions to carry out further operations with vehicle diagnostic
tester and to prevent a second vehicle identification on vehicle
diagnostic tester .
♦ To do this, press button operating mode and then guided func‐
tions.
♦ For further procedure see respective work descriptions.
♦ To return to guided fault finding, press button operating mode
satelettronica
and then guided fault finding.
Caution
The vehicle must always be delivered to the customer with

event memory cleared.
Static faults n AG. Volkswagen AG do

lk swage es n
o ot g
yV ua
If one or more static faults are found in the fault memory,
ir se
d b we rec‐ ran
ommend in agreement with the customer to rectify utho these faults tee
or
using guided fault finding. ss
a ac
ce
e
Sporadic faults
nl
pt
du
an
itte
y li
If only sporadic faults or notes are stored in the event memory
erm
and the customer has no complaints regarding the electronic ve‐ ab

ility
ot p
hicle system, erase event memory. wit

, is n
h re
– Press > button again to reach the test plan.
hole
spec
es, in part or in w
– Now finish guided fault finding using GoTo button and then
t to the co
End.
All event memories are read again.
rrectness of i
Now it is confirmed on display that all sporadic faults have been

l purpos
cleared.
Then the diagnostic log is sent “online” or stored on the vehicle
nform
ercia
diagnostic tester .
m
at
om
ion
Note
c
in t
or
his
ate
do
riv
♦ If the diagnostic tester is not connected to the network, the

p
cum
diagnostic log is stored and will be sent when the diagnostic

for
en
g
tester is connected to the network.

n
t.
yi Co
Cop py
♦ Logs stored and which are more than 40 days old will be
t. rig
gh ht
yri
cleared automatically.
p by
co Vo
by lksw
cted agen
Prote AG.
The vehicle system test is completed.
Sharan 1996 ➤
4.21 Boots: inspecting

– Check outer boots -2- and inner boots -1- for leaks and dam‐
age.
Note
For vehicles with four-wheel drive, also check bellows on rear

axle.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut
4.22 Haldex coupling: Renew oil filter ss a ra
c
ce
e
nl
pt
du
an
Caution
itte
y li
erm
ab
satelettronica
ility
ot p
The drain plug of Haldex coupling is available in two different
wit
, is n
versions:
h re
hole
♦ 1) drain plug with captive seal (drain plugs of this type
spec
es, in part or in w
must always be renewed).
t to the co
♦ 2) drain plug with removable seal (here, the seal must al‐
ways be renewed).
rrectness of i
l purpos
Procedure: »Power transmission; 6-speed manual gearbox 02N

four-wheel drive« ⇒ Rep. gr. 39 »Checking oil level in Haldex
coupling or change oil; Changing oil filter for Haldex coupling«
nform
ercia
4.23 Haldex coupling: Change oil

m
at
om
ion
c
in t
or
his
e
Caution
at
do
priv
cum
or
The drain plug of Haldex coupling is available in two different

f
en
ng
t.
yi
versions:
Co
Cop py
ht. rig
♦ 1) Drain plug with captive seal (drain plugs of this type rig ht
py by
must always be renewed).
co Vo
by lksw
cted agen
Prote AG.
♦ 2) drain plug with removable seal (here, the seal must al‐
ways be renewed).
Procedure: »Power transmission; 6-speed manual gearbox 02N

four-wheel drive« ⇒ Rep. gr. 39 »Checking oil level in Haldex
coupling or change oil«
4.24 Poly V-belt: checking condition

Sharan 1996 ➤
– Crank engine at vibration damper/belt pulley -arrow- using a

socket.
– Raise vehicle and check poly V-belt -1- from below for:
♦ Sub-surface cracks (cracks, core ruptures, cross sectional
breaks)
♦ Layer separation (top layer, cord strands)
♦ Base break-up
♦ Frayed cord strands
♦ Flank wear (material wear, frayed flanks, flank brittleness -en AG. Volkswagen AG
glassy flanks-, surface cracks) olks
wag does
no
yV t gu
db ara
♦ Traces of oil and grease rise nte
tho eo
au ra
c
ss
ce
Note
le
un
pt
an
d
itte
y li
If faults are found, it is essential for the poly V-belt to be renewed.
rm
ab
pe
This can avoid breakdowns and malfunctions. The replacement
ility
ot
of a poly V-belt is a repair measure.
wit
, is n
h re
satelettronica
hole
spec
es, in part or in w
4.25 V-belt: Check condition and tension (ve‐
t to the co
hicles with 4-cylinder engine)
Checking V-belt condition
rrectness of i
– Check the V-belt of the power assisted steering vane pump
l purpos
for:
♦ Sub-surface cracks (cracks, core ruptures, cross sectional
nform
ercia
breaks)
m
a
com
ti
♦ Layer separation (top layer, cord strands)
on in
r
te o
thi
♦ Base break-up
s
iva
do
r
rp
c
♦ Frayed cord strands
um
fo
en
ng
t.
♦ Flank wear (material wear, frayed flanks, flank brittleness -
yi Co
op
glassy flanks-, surface cracks)
C py
t. rig
gh ht
yri by
♦ Traces of oil and grease
op Vo
by c lksw
cted agen
Prote AG.
Note
If faults are found, it is absolutely necessary to renew the V-belt.

This can avoid breakdowns and malfunctions. The replacement
of a V-belt is a repair measure.
Checking V-belt tension

The V-belt must be checked at the central point between the two
pulleys that are the greatest distance apart from one another by
using strong thumb pressure.
– Check V-belt tension by strong thumb pressure (deflection ap‐
prox. 5 mm) and adjust if necessary.
»Running gear; Steering« ⇒ Rep. gr. 48 ;»Vane pump, reservoir,
hydraulic lines; Tensioning V-belt«
Sharan 1996 ➤
4.26 Diesel fuel filter: Renewing
Note
♦ Ensure that no diesel fuel contacts coolant hoses. Clean ho‐

ses immediately if soiled.
♦ Please observe disposal instructions!
Removing:
– Pull off retaining clip -1-.
– Remove control valve -2- with fuel hoses connected.
– Open hose clips -3- and -4- and pull fuel hoses off hose con‐
nections.
– Loosen cross head bolt -5- on clamp and take out filter up‐
wards.
Installing:
– Fit new O-ring to seal regulating valve.
satelettronica
– Fill new filter with clean Diesel. This allows the engine to start
quicker.
– Fit new filter and secure by tightening the cross head bolt
agen
AG. Volkswagen AG d
-5-. Volksw
oes
not
g y ua
db ran
– Push fuel hoses over hose connections and secure
ris
e
hoses with tee
new hose clips. utho or
a ac
ss
ce
le
un
pt
an
d
Note
itte
y li
rm
ab
pe
ility
Fuel flow direction is marked by arrows (do not interchange con‐
ot
wit
nections).
, is n
h re
hole
spec
es, in part or in w
t to the co
– Install control valve -2- with fuel lines connected.

– Fit retaining clip -1-.
rrectness of i
– Start engine and check fuel system for leaks (visual check).
l purpos
– Operate throttle several times to bleed fuel system.

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.
AG. Volkswagen AG d
agen oes
olksw not
d byV gu
ara Sharan 1996 ➤
e
horis nte
eo Maintenance - Edition 03.2018
aut ra
ss c
4.27 Diesel fuel filter: Drain water (not TDI
ce
e
nl
pt
du
unit injector engine)
an
itte
y li
erm
ab
ility
ot p
Caution
wit
, is n
h re
hole
Ensure that no diesel fuel contacts coolant hoses. Clean hoses
spec
es, in part or in w
immediately if soiled.
t to the co
Please observe disposal instructions!
rrectness of i
– Pull off retaining clip -1-.
l purpos
– Remove control valve -2- with fuel hoses connected.
nform
ercia
– Open hose clips -3- and -4- and pull fuel hoses off hose con‐
nections.
m
at
om
io
– Loosen cross head bolt -5- on clamp and take out filter up‐
n
c
in t
r
wards.
o
his
ate
do
riv
– Open drain screw of fuel filter (the drain screw is located below
p
cum
or
the fuel filter).

f
en
g
satelettronica
n
t.
yi Co
– Drain approx. 0.1 l fluid via water drain plug.
Cop py
ht. rig
rig ht
– Tighten drain screw of fuel filter.
py by
co Vo
by lksw
cted agen
Prote AG.
– Fit filter and secure by tightening the cross head bolt -5-.
– Push fuel hoses over hose connections and secure hoses with
new hose clips.
Note
Fuel flow direction is marked by arrows (do not interchange con‐

nections).
– Install control valve -2- with fuel lines connected.

– Fit retaining clip -1-.
– Start engine and check fuel system for leaks (visual check).
– Operate throttle several times to bleed fuel system.
4.28 Interior and exterior body: inspecting for

corrosion with doors and flaps open
Test locations
♦ Sliding roof frame
♦ Inner and outer door frame
♦ Area around trim strips
♦ Windscreen roof edge
♦ Outer and inner A-pillar
♦ Bonnet
♦ Wheel arches
♦ Inner and outer tailgate
Sharan 1996 ➤
4.29 Cooling system: checking Vol
ksw frost protec‐
age es n
ot g
tion and coolant olevel by ua
ed ran
ris tee
th or
s au ac
s
ce
Note
le
un
pt
an
d
itte
y li
♦ The water used for mixing has a major influence on the effec‐
rm
ab
pe
tiveness of the coolant. Because the water quality differs from
ility
ot
country to country and even from region to region, the quality
wit
, is n
of the water to be used in the cooling system has been speci‐
h re
hole
fied by Volkswagen. Distilled water fulfils all requirements.
spec
Therefore, only ever use distilled water when mixing coolant
es, in part or in w
t to the co
for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
rrectness of i
reduce corrosion protection substantially. The resulting dam‐
l purpos
age could lead to loss of coolant and subsequent severe

damage to the motor.
nform
ercia
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐

rosion damage as well as scaling. Furthermore, the boiling
m
a
point is raised. For these reasons, the cooling system must be
com
tio
satelettronica
n in
filled all year round with a coolant additive.
r
te o
thi
♦ Because of its high boiling point, the coolant improves engine
s
iva
do
reliability under heavy loads, particularly in countries with trop‐
r
rp
cum
fo
ical climates.
en
ng
t.
yi Co
op
♦ Use ONLY refractometer - T10007A- for determining current C py
t. rig
anti-freeze value.
gh ht
pyri by
Vo
co lksw
by
♦ Frost protection must be guaranteed down to -25°C as a min‐ cted agen
Prote AG.
imum and, in countries with arctic conditions, down to approx.
-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐
ever, be increased only to a maximum of -48°C. Otherwise,
the cooling effect will be impaired.
♦ Do not reduce the coolant concentration by adding water even
in the warm season or in hot countries. Frost protection must
be guaranteed down to at least -25°C.
♦ Read anti-freeze figures from the respective scale for type of
anti-freeze added.
♦ The temperature read off the refractometer - T10007A- corre‐
sponds the »ice flocculation point«. Flakes of ice may start
forming in the coolant at this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
4.29.1 Frost protection: checking, replenishing

coolant additive if necessary
Sharan 1996 ➤
♦ Refractometer - T10007 A-
Note
Read precise value for the following tests at light/dark boundary.

Using a pipette, place a drop of water on the glass to improve the
readability of the light/dark boundary. The bright/dark boundary
can be clearly recognised on the “WATERLINE”.
satelettronica
olkswagen AG
– Check concentration of coolant additive using refractometer - en AG. V
wag does
T10007 A- (refer to operating instructions). Volks not
gu
by d ara
se nte
The scale -1- of the refractometer is calibrated for tcoolant
ho
ri addi‐ eo
tives G12; G12 Plus, G12 Plus Plus and G11. s a u ra
c
s
ce
le
The scale -2- is only calibrated for coolant additive G13.

un
pt
an
d
itte
y li
– If frost protection is too low, drain some coolant and add cool‐
erm
ab
ant additive.
ility
ot p
wit
is n
h re
ole,
Note
spec
t to the co
♦ If the currently used coolant additive cannot be determined
precisely, use the scale -2- for coolant additive G13.
rrectne
– Check coolant additive concentration after road test again.
ss o
cial p
4.29.2 Coolant level: checking, replenishing f inform

mer
coolant if necessary
atio
om
n
c
i
or
– Check coolant level on expansion tank with engine cold.

thi
te
sd
va
♦ Delivery inspection: Coolant level at max. marking.

i
o
pr
cum
r
fo
en
ng
♦ Inspection service: Coolant level between max. and min.

t.
yi Co
markings. Cop py
t. rig
gh ht
yri
– If coolant is too low, add required amount according to mixture p by
co Vo
lksw
ratio.
by
cted agen
Prote AG.
Note
If fluid loss is greater than can be expected through normal use,

determine source and rectify (repair measure).
Sharan 1996 ➤
4.29.3 Mixing ratio:
Caution
Use only distilled water for mixing coolant additives. The use
of distilled water ensures optimum protection against corro‐
sion.
Frost protection to Coolant additive Distilled water

portion
-25 °C approx. 40% approx. 60 %
-36 °C approx. 50 % approx. 50 %
4.30 Air filter: cleaning housing and renewing

filter element
Diesel engine 1.9 l TDI ⇒ page 79 .
satelettronica
Petrol engine 1.8 l ⇒ page 80 .
Petrol engine 2.0 l (2-valve engine) ⇒ page 78 .
Petrol engine 2.0 l (without intermediate shaft) ⇒ page 81 .
VR6 engine ⇒ page 77 .
♦ Spring-type clip pliers - VAS 5024A-
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
Air filter housing with snow screen

t to the co
rrectne
Note
Depending on equipment level a strainer is installed in area of

ss
intake duct in the lower part of filter housing.

o
cial p
f inform
mer
This strainer is designed to catch snow and ice in the winter

atio
m
months so that the filter is not blocked.

o
n
c
i
or
– If the strainer is visible after removing the filter element, pro‐

thi
te
sd
a
ceed as follows:
iv
o
pr
cum
r
fo
– Remove strainer, remove main debris and blow through with

en
ng
t.
compressed air.
yi Co
Cop py
ht. rig
– Reinstall strainer in reverse order. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Sharan 1996 ➤
4.30.1 VR6 engine

Removing:
– Pull cover out upwards -arrow- if necessary.
– Release spring retainers -1-.
– Loosen spring retainers -2- (above and below) and pull off air
intake hose.
Note
The 6-cylinder 4-valve engine has securing

n AGbolts
. Volksinstead
wagen AGof spring
retainers, which are tightened to 6
l wagewhen installing. does n
ksNm
Vo ot g
by ua
ed ran
ris tee
– Loosen hose clip -3-uthand pull
o off hose. or
a ac
ss
– Lift filter housing upper part on right and take out upwards.
ce
le
un
pt
an
d
itte
y li
– Take out used filter element -1-.
erm
ab
ility
ot p
– Check if a snow screen is fitted ⇒ page 76 .
satelettronica
wit
is n
h re
ole,
spec
Note
t to the co
rrectne
Installing:
– Clean filter housing and install new filter element.
ss o
cial p
f inform
mer
– Fit filter housing upper part. The plastic lugs -1- must fit in the
atio
mounting recesses -2-.

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.
– Secure spring retainers -1-.

– Fit intake hose, and secure it with spring retainers -2-.
– Fit hose and secure with hose clip -3-.
– Install cover -arrow- if necessary.
Sharan 1996 ➤
4.30.2 Petrol engine, 2.0 l (2-valve engine)

Removing:
– Press hose clip -2- together with spring-type clip pliers - VAS
5024A- and pull off air intake hose.

satelettronica
Note
Please observe disposal instructions!swagen AG. Vo

lkswagen AG
does
k not
Vol gu
d by ara
Installing: ris
e nte
utho eo
ra
a
– Clean filter housing and
ss install new filter element. 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
– Fit intake hose, and secure it with hose clip -2-.

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 ➤
4.30.3 Diesel engine, 1.9 l TDI

Removing:
– Press hose clip -2- together with spring-type clip pliers - VAS
5024A- and pull off air intake hose.
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
satelettronica
t to the co
Note
rrectne
Installing:
ss o
cial p
f inform
mer
atio
m
o
n
c

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 ➤
4.30.4 Petrol engine, 1.8aglen AG. Volkswagen AG do

ksw es n
Vol ot g
Removing: ed by ua
ran
ris tee
– Pull cover out upwards
au
tho -arrow- if necessary. or
ac
ss
– Unscrew cross-head bolts -1-.
ce
e
nl
pt
du
an
– Loosen locking device and pull hose off -2-.
itte
y li
erm
ab
– Pull off connector -3-.
ility
ot p
wit
, is n
– Loosen hose clip -4- and pull off hose.
h re
hole
– Lift filter housing upper part and remove upwards.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
satelettronica
Note
om
ion
c
in t
or
his
ate
do
priv
cum
or
Installing:
f
en
ng
t.
yi Co
op
– Clean filter housing and install new filter element. C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Tighten cross-head bolts -1- to 6 Nm.

– Push on connector -3-.
– Connect hose -2- and lock.
– Install cover -arrow- if necessary.
Sharan 1996 ➤
4.30.5 Petrol engine, 2.0 l (without intermediate

shaft)
Removing:
– Remove cross-head bolts -arrows-.
– Lift filter housing upper part -1-.

swage es n
– Check if a snow screen is fitted ⇒ page 76 . byV
olk ot g
ua
d ran
ir se
satelettronica
o tee
th or
au ac
Note ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ For a better overview the filter housing upper part is not illus‐
ility
ot p
trated. When changing the filter it is not necessary to remove
wit
, is n
the upper part.
h re
hole
spec
Installing:
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
o
– Tighten cross-head bolts -arrows- to 6 Nm.
c by lksw
cted agen
Prote AG.
Sharan 1996 ➤
4.31 Engine oil level: checking

Please note the following:
After shutting off engine, wait at least 3 minutes so that the oil can
flow back into the sump.
– Pull out dipstick, wipe with a clean cloth and push dipstick in
again to limit stop.
Note

♦ Oil level must always be in area A for the delivery inspection.
– Pull dipstick out again and read oil level.

AG. Volkswagen AG d
A - Do not top up oil. lksw
agen oes
not
Vo gu
y
B - Oil can be replenished up to area -A-. ise
d b ara
nte
or eo
th
C - Oil must be replenished. Oil levelsmust
au then be at least in upper ra
c
third of measuring area -B-. s
satelettronica
ce
e
nl
pt
du
– If oil level is above marking -A-, drain or extract excess oil to
an
itte
y li
prevent damage to catalytic converter.
erm
ab
ility
ot p
– If oil level is below marking -C-, replenish oil to marking -A-.
wit
, is n
Oil specification ⇒ page 4
h re
hole
spec
es, in part or in w
t to the co
4.32 Engine oil: Draining or extracting and re‐
plenishing; renewing oil filter
rrectness of i
Engine oil: Draining or extracting and replenishing ⇒ page 82 .
l purpos
Renew oil filter ⇒ page 84 .

Replenishing engine oil ⇒ page 86 .
nf
ercia
orm
4.32.1 Engine oil: draining or extracting

m
atio
om
n in
c

or
thi
te
sd
a
♦ Used oil collection and extraction unit - V.A.G 1782-

iv
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.
lkswage es n
o ot g
byV ua
ir se
d Sharan ran 1996 ➤
tee
o
auth Maintenance - Edition 03.2018 or
ac
ss
ce
e
♦ Used oil collection and extraction unit - VAS 6622-
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
♦ Oil spill cloth - VAS 6204/1-

m
Engine oil: draining or extracting
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
Note
f
en
ng
t.
yi Co
satelettronica
op py
♦ For engines with standing oil filter, the oil filter must be re‐ t. C rig
gh ht
newed before changing the engine oil. When removing the pyri by
Vo
co
filter element a valve is opened, the oil in the filter housing
by lksw
cted agen
Prote
automatically flows into crankcase.
AG.
♦ If the engine oil is drained and not extracted with a used oil
collection and extraction unit, renew the oil drain plug. This
prevents leaks.
– Extract engine oil using used oil collection and extraction unit
- V.A.G 1782- .
or
– Extract engine oil using used oil collection and extraction unit
- VAS 6622- .
or
– Remove oil drain plug.
– Let engine oil drain.
Note
♦ If the oil drain plug is fitted with a secure seal, the oil drain plug
must always be renewed. ⇒ Electronic Parts Catalogue ETKA
♦ If the oil drain plug is fitted with a removable seal, clean the oil
drain plug and fit a new seal. ⇒ Electronic Parts Catalogue
ETKA
– Screw in oil drain plug together with seal hand-tight and then
tighten to specified torque.
– Replenish engine oil, specification ⇒ page 4 .
Engine oil capacity ⇒ Rep. gr. 17 or ⇒ Maintenance table .
Specified torques for oil drain plug:
♦ M26: 40 Nm
Sharan 1996 ➤
♦ M14: 30 Nm
WARNING
♦ Torque specifications must not be exceeded.

♦ Excessive torque can cause leaks in the area of the oil
drain plug or even damage.
4.32.2 Oil filter: renewing
Note
♦ Prevent engine oil from dripping onto components in engine

compartment.
♦ Oil new O-rings before installing.
satelettronica
Renewing oil filter, 6-cylinder engines ⇒ page 84 .
Renewing oil filter, 4-cylinder petrol engines and TDI diesel en‐
gines ⇒ page 84 . olks
wage es n
o V t gu
by
Renewing oil filter, PD TDIrisengines
ed ⇒ page 85 . ara
nte
tho eo
Renewing oil filter, 6-cylinder
sa
u engines ra
c
s
ce
e
nl
pt
du
an
itte
Note
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erm
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ility
ot p
Before draining or extracting release threaded cap, so that the

wit
, is n
engine oil can flow out of filter housing.

h re
hole
spec
– Drain oil via plug -1-.

es, in part or in w
t to the co
– Unscrew filter lower part -2-.

– Take out used filter element.
rrectness of i
– Moisten new O-ring of filter lower part with oil.

l purpos
– Insert new filter element and new O-ring.

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Tighten filter lower part -2- to 30 Nm.

f
en
ng
t.
yi Co
– Moisten new O-ring of drain plug with oil. Cop py
t. rig
gh ht
yri
– Fit drain plug -1- with O-ring and tighten to 10 Nm. p by
o Vo
by c lksw
cted agen
Renewing oil filter, 4-cylinder petrol engines and TDI diesel en‐ Prote AG.
gines
Sharan 1996 ➤
♦ Oil filter tool - VAS 3417-
– Loosen oil filter -arrow- from below with oil filter tool - 3417- ,
and remove oil filter. . Volkswage
n AG n AG d
wage oes
– Clean engine sealing surface. Volks not
gu
by ara
ed
– Oil rubber seal lightly on new filter. Thushoristhe oil filter can ad‐ nte
eo
here better when tightening, which assures
sa
ut best possible seal‐ ra
c
ing. s
ce
e
nl
pt
du
– Screw in filter and tighten hand-tight.
satelettronica
an
itte
y li
erm
ab
Renew oil filter, PD TDI engines .
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
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sd
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o
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f
en
ng
t.
yi Co
Cop py
. rig
– Unscrew sealing cap -arrow- and remove used oil filter ele‐
ht ht
rig by
py
ment. co Vo
by lksw
cted agen
Prote AG.
Sharan 1996 ➤
– Renew O rings -2- and -3- as well as oil filter element -4-.
Note
– Tighten cover cap -1-.

Cover cap torque setting: 25 Nm
4.32.3 Engine oil: replenishing
satelettronica
Oil specifications ⇒ page 6
Engine oil capacity ⇒ Rep. gr. 17 or ⇒ Maintenance table .
General information
Note
Please observe disposal instructions! agen

AG. Volkswagen AG d
oes
olksw not
V gu
by ara
– After replenishing with oil, wait at least 3 minutes and thenrised
nte
check oil level. ut
ho eo
ra
s a c
s
– Pull out dipstick, wipe with a clean cloth and push dipstick in
ce
le
un
again to limit stop.
pt
an
d
itte
y li
– Pull dipstick out again and read oil level.
rm
ab
pe
ility
A - Do not top up oil.
ot
wit
, is n
h re
B - Oil can be replenished up to area -A-.
hole
C - Oil must be replenished. Oil level must then be at least in upper spec
es, in part or in w
third of measuring area -B-. t to the co
– If oil level is above marking -A-, drain or extract excess oil to

prevent damage to catalytic converter.
rrectness of i
– If oil level is below marking -C-, replenish oil to marking -A-.

l purpos
Oil specification ⇒ page 4

nform
mercia
4.33 Engine and components in engine com‐

a
com
tion in
partment: inspecting for leaks and dam‐

r
te o
thi
age (from above and below)

s
iva
do
r
rp
cum
fo
Inspect as follows:
en
ng
t.
yi Co
op
– Check engine and components in engine compartment for C py
t. rig
leaks and damage.
gh ht
pyri by
Vo
o
by c lksw
– Check lines, hoses and connections of: cted agen
Prote AG.
♦ Fuel system
Sharan 1996 ➤
♦ Cooling and heating system

♦ And brake system
for leaks, abrasions, porosity and brittleness.
Note
♦ Arrange for defects to be rectified as repair measures.

♦ If fluid loss is greater than can be expected through normal
use, determine source and rectify (repair measure).
4.34 Engine cover panel -top-: Removing and

installing
Removing and installing engine cover -top-: 1.8 l engine
⇒ page 87
⇒ page 87
Volkswagen AG
Removing and installing engine cover -top-: PD diesel
wage engines
n AG.
satelettronica
does
⇒ page 87 Volks not
gu
by ara
ed nte
ris
tho eo
Caution ss
au ra
c
ce
le
un
pt
♦ Do not push with the fist or a tool on the engine cover panel
an
d
itte
when it is installed or engaged at securing points, it could
y li
erm
ab
be damaged.
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is n
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ole,
spec
Removing:
t to the co
– Remove cover caps, loosen flange nuts below -arrows- and
take engine cover out upwards.
rrectne
Installing
s
– Tighten flange nut -arrows- to 7 Nm.
s o
cial p
f i
– Seal flange nuts with cover caps.

nform
mer

atio
om
n
c
i
or
n thi
te
sd
a
Removing:
iv
o
pr
cum
r
fo
– Pull out oil dipstick -1-.

en
ng
t.
yi Co
op
– Lift engine cover -arrows- and disengage.
C py
t. rig
gh ht
yri by
Installing: cop Vo
by lksw
cted agen
Prote AG.
– Fit engine cover onto securing point -arrows- and engage no‐
ticeably.
– Reinsert dipstick -1-.
Removing and installing engine cover -top-: PD diesel engines
Removing:
Sharan 1996 ➤
– Disengage engine cover panel at securing points -arrows B-,

and raise it.
– Then pull out of bracket -arrow A-,
Installing:
– First push engine cover with lugs -arrows B- into bracket -2-.
satelettronica
– Then fit engine cover at the other securing points -arrows B-
and press on, until they noticeably engage.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
4.35 Engine cover -bottom- (noise insula‐

un
pt
an
d
itte
tion): Removing and installing

y li
rm
ab
pe
ility

ot
wit
, is n
h re
Removing:
hole
spec
es, in part or in w
– Remove hexagon bolts -arrows- with cordless power driver 12

t to the co
V / 2.0 Ah - VAS 5826- .

– Hold noise insulation and unscrew cap nuts -1-.
rrectness of i
– Swing noise insulation down and remove.

l purpos
Installing:
– Push noise insulation forwards and hold.
nform
ercia
– Tighten cap nuts -1- and hexagon bolts -arrows-.

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
88
by lksw
cted agen
4. Descriptions of work: Prote AG.
Sharan 1996 ➤
4.36 Road test: performing (driving behav‐

iour, noises, air conditioner etc.)
Which of the following can be checked depends on vehicle equip‐
ment and local conditions (urban/country).
Check the following during a road test:
♦ Engine: output, misfiring, idling speed, acceleration
♦ Clutch: pulling away, pedal pressure, odours
. Volkswage n AG d n AG
oes wage
♦ Gear selection: ease of operation,
yV
olksstick position not
gu
d b ara
♦ Automatic gearbox: selector rise lever position, shift lock/ignition nte
ho eo
key removal lock, shift
s a behaviour, dash panel insert display.
ut ra
c
s
♦ Foot brake and handbrake: function, free travel and effective‐
ce
e
nl
pt
du
ness, pulling to one side, juddering, squeal
an
itte
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erm
ab
♦ ABS function: Pulsing must be felt at the brake pedal during
ility
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ABS-regulated braking.
wit
, is n
h re
♦ Steering: function, steering free clearance, steering wheel
hole
centred when vehicle is travelling straight ahead
spec
es, in part or in w
satelettronica
t to the co
♦ Tilting roof: function
♦ Radio/radio navigation system: Function, reception, GALA, in‐
terference noise
rrectness of i
♦ Multi-function indicator (MFI): functions
l purpos
♦ Air conditioner: Check function (at low temperatures the func‐

tion of air conditioner must be checked in a workshop)
nf
ercia
orm
♦ Vehicle: pulling to one side when travelling straight-ahead
m
atio
m
(level road)
o
n in
or c
♦ Imbalance: wheels, drive shafts, propshaft

thi
te
sd
iva
♦ Wheel bearings: noises

r
rp
cu
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f
en
ng
♦ Engine: hot starting behaviour

t.
yi Co
Cop py
4.37 Radio/navigation system: entering PIN

t. rig
gh ht
pyri by
Vo
o
of anti-theft coding and storing local ra‐
c by lksw
cted agen
Prote AG.
dio stations to station buttons
The anti-theft coding electronically prevents unauthorized per‐
sons from operating the unit after it has been removed from
vehicle. The anti-theft codes are also called radio codes or se‐
curity codes. Security code means that each unit with an anti-theft
coding is programmed with its own code number. This security
code is not active when leaving the factory. The security code is
found on the unit card, if fitted. If the unit card is not fitted, the
security code can be read using vehicle diagnostic tester of a
central database.
Note
If an incorrect code number is entered when releasing the elec‐

tronic lock, the whole procedure can be repeated once. If an
incorrect code number is entered again, the unit is locked for
about one hour. That means, it cannot be used. After one hour,
during which time the unit must remain switched on, the display
extinguishes. The electronic lock can be released as described
above. The cycle two attempts, one hour lock applies again.
Sharan 1996 ➤
Procedure
Vehicle electrics → Communication ⇒ Rep. gr. 91 → e.g. radio
system "RCD 500" → Anti-theft coding → Deactivating anti-theft
coding
cedure manually in the information. AG. Volkswagen AG d
agen oes
lksw not
4.38 Wheel securing bolts: tightening to Vo gu
d by ara
ise nte
specified torque aut
hor eo
ra
ss c
Removing and installing wheel bolt caps
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
Depending on vehicle equipment, the wheel bolts could be cov‐
h re
ered by the following components:
hole
spec
es, in part or in w
t to the co
♦ Wheel bolt caps
♦ Hub cap
satelettronica
rrectness of i
♦ Wheel trim
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– Remove the respective wheel bolt cover, if fitted.
nf
ercia
or
Note
m
m
atio
om
n in
c
The puller hook to remove the cover caps or the wheel hub trim
or
thi
is located in the vehicle tool kit.
te
sd
iva
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m
Example, removing hub cap
f
en
ng
t.
yi Co
op
– Hook puller hook into one drilling of wheel hub trim and pull off C py
t. rig
in -direction of arrow-.
gh ht
pyri by
Vo
o
by c lksw
Fitting instructions Prote
cted AG.
agen
Note
♦ The cover caps protect the wheel bolts and should be recon‐
nected after the wheel securing bolts have been retightened.
♦ Ensure that on some rims the lug of the wheel hub trim locates
in the groove of the rim.
♦ After completing work, place adapter and puller hooks with
vehicle tool kit.
Sharan 1996 ➤
– On vehicles with full wheel trim install full wheel trim so that
the tyre filler valve is guided through the cut-out provided
-arrow-.
Wheel bolt types
Note
♦ As of the model year 2001, revised wheel bolts are being used.
♦ Dimensions and torque settings of the previously used and
modified wheels bolts are identical.
♦ Notes on modified wheel bolts and permitted wheels »Running
AG. Volkswagen
gear« ⇒ Rep. gr. 44 »Wheels, Tyres«. ksw
agen AG do
es n
y Vol ot g
ua
b
ed ran
oris tee
-1- wheel bolt used ►2000 au
th or
ac
ss
♦ Surface black-finished. Wheel bolt - ET–Nr. 701 601 139 B-
ce
e
nl
pt
du
an
-2- wheel bolt 2001►
itte
y li
erm
ab
♦ Collar -arrow- is not secured firmly to hexagon.
ility
ot p
satelettronica
wit
, is n
♦ Surface coloured silver. Wheel bolt - ET–Nr. 7M3 601 139 B-
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Loosening or tightening anti-theft wheel bolts
nform
ercia
Note
m
at
om
io
♦ The adapter to loosen and tighten the anti-theft wheel bolts
n
c
in t
r
can be found in the vehicle tool kit.

o
his
ate
do
riv
♦ If the adapter to loosen or tighten the anti-theft wheel bolts is

p
cum
or
not available in the vehicle, use the appropriate adapter set for
f
en
g
tamper-proof wheel bolts.

n
t.
yi Co
Cop py
♦ If the adapter is not available, a new replacement adapter can
t. rig
gh ht
yri by
only be obtained via the code number. cop Vo
by lksw
cted agen
Prote AG.

♦ Adapter set for wheel bolts - T10101-
Sharan 1996 ➤
♦ Adapter set for wheel bolts - T10313-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
♦ Adapter set for wheel bolts - T10190- ut
ho eo
ra
s a c
s
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
– Slide adapter into anti-theft wheel bolt onto stop.

– Slide the wheel bolt wrench onto adapter onto stop.
nform
ercia
– Retighten the wheel securing bolts to correct torque setting.

m
at
om
io
Retightening wheel securing bolts
n
c
in t
or
his
e

at
do
priv
c
um
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Ensure that wheel bolts are tightened diagonally and alternately.
Sharan 1996 ➤
Specified torque: 170 Nm
4.39 Tyre repair set

From model 2002 some vehicles are fitted with a tyre repair set
as standard instead of a spare wheel.
Note
♦ The tyre repair set is located in the luggage compartment on

the right-hand side.
♦ It consists of a compressor and a bottle with tyre sealant.
4.39.1 Checking expiry date

The tyre sealant in the bottle has a limited shelf life.
– Check the expiry date.
satelettronica
Therefore the expiry date is indicated on the bottle and on the
housing of the tyre repair set -arrow-.
wage
e ks s no
Vol t
This example shows that the ed
byexpiry date 04/2004 has been ex‐
gu
ara
ceeded, then the bottlehohas to be renewed.
ris nte
e
t or
au ac
ss
Caution
ce
le
un
pt
an
d
itte
y li
Renew tyre sealant if the expiry date has been reached. (The
rm
ab
pe
tyre sealant must not be more than 4 years old.)

ility
ot
wit
, is n
When the bottle has been opened e.g. at a "flat tyre", it has
h re
also to be renewed.
hole
spec
es, in part or in w
t to the co
Note
rrectness of i

l purpos
nform
ercia
4.40 Window wiper and washer system and

m
headlight washer system: Checking

com
tion in
function
r
te o
thi
s
iva
do
Check anti-freeze concentration of Windscreen Clear - G 052

r
rp
cum
164- ⇒ page 93 .
fo
en
ng
t.
yi Co
Window wash/wipe system: Check spray jet settings Cop py
t. rig
⇒ page 95 . opyri
gh by
Vo
ht
by c
Headlight washer system: check spray jet settings ⇒ page 98 .
lksw
cted agen
Prote AG.
4.40.1 Anti-freeze concentration in window

wiper and washer system: Checking
and replenishing fluid if necessary
Sharan 1996 ➤
♦ Refractometer - T10007 A-
Read precise value for the following tests at light/dark boundary.

Using a pipette, place a drop of water on the glass to improve the
readability of the light/dark boundary. The bright/dark boundary
can be clearly recognised on the “WATERLINE”.
G. Volkswagen
– Check concentrationlkofswaanti-freeze additive d
gen A using
AG o
es n refractome‐
ter - T10007 A- .by Vo ot g
ua
ed ran
ris t
The scale -4-uof
tho the refractometer is calibrated for Windscreen
ee
satelettronica
or
Clear - G 052
ss 164- .
a ac
ce
e
nl
Mixing ratio:
pt
du
an
itte
y li
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
Frost protection Windscreen Water

l purpos
to Clear
G 052 164
nf
ercia
In summer 1 part 4 parts

rm
m
atio
m
-16 °C 1 part 2 parts

o
n in
or c
-35 °C 1 part 1 part

thi
te
sd
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-40 °C 2 parts 1 part

iv
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f
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ng
t.
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Cop py
Replenishing fluid:
t. rig
gh ht
pyri by
Vo
o
The fluid reservoir of the window washer system must be filled by c lksw
cted agen
completely.
Prote AG.
Starting immediately, use only Windscreen Clear - G 052 164- all-

year-round when replenishing the window wash/wipe system.
Sharan 1996 ➤
Note
♦ Windscreen Clear - G 052 164- protects the spray jets, fluid

reservoir and connecting hoses from freezing.
♦ For all vehicles having fan-type spray jets, the reservoir must
be filled with “Genuine Volkswagen Windscreen Clear” Wind‐
screen Clear - G 052 164- , as this fluid has a low viscosity at
temperatures below freezing. Otherwise the complicated
spray jet system can become blocked by the crystallised
washer fluid, which affects the spray pattern of the spray jet.
Windscreen Clear - G 052 164- ensures that the fan type spray
jets remain fully functional also at low temperatures.
♦ Replenish genuine Windscreen Clear - G 052 164- also in the
warmer periods of the year. The powerful cleanser removes
wax and oil residue from the glass.
♦ Frost protection must be guaranteed to approx. -25 °C (ap‐
prox. -35 °C in countries with an arctic climate) in the washer
system.
AG. Volkswagen AG d
agen oes
olksw not
4.40.2 Window washer system: Check jet set‐
V
satelettronica
by gu
d ara
rise nte
ting, adjust jets if necessary autho eo
ra
ss c
ce
e
nl
pt
du
an
Note
itte
y li
erm
ab
ility
♦ If the spray field is uneven due to soiling in the spray jet, re‐
ot p
wit
move spray jet »Electrical system« ⇒ Rep. gr. 92 »Wind‐
, is n
h re
screen washer system; Removing and installing spray jets«
hole
spec
and rinse with water opposite to direction of spray.
es, in part or in w
t to the co
♦ Subsequent blowing through with compressed air against the
spraying direction is permitted.
rrectness of i
Caution
l purpos
♦ Never use items to clean the spray jets!

nf
ercia
♦ Never use a needle or a similar object to adjust the spray

rm
m
atio
jets, otherwise the water passages in the spray jet will be

om
damaged!
n in
or c
thi
te
sd
iva
o
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cu
Spray jets for windscreen washer system (vehicles ►05.00)

o
m
f
en
ng
⇒ page 95 . yi
t.
Co
op py
Spray jets for windscreen washer system (vehicles 06.00►... t. C rig
gh ht
yri
►10.03) ⇒ page 96 . p by
co Vo
by lksw
cted agen
Spray jets for windscreen washer system (vehicles 11.03►) Prote AG.
⇒ page 97 .
Spray jet for rear window washer system ⇒ page 97 .
Spray jets for windscreen washer system (vehicles ►05.00)
Sharan 1996 ➤
♦ Adjusting tool - T10127-
AG. Volkswagen AG d
agen oes
ksw
♦ Adjusting tool - T40187-by V ol not
gu
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
satelettronica
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Adjust spray jets so that the water jets spray onto windscreen at rrectness of i
positions shown.
l purpos
Note
nf
ercia
orm
m
atio
Mark the points at which water strikes the window with a water-
om
soluble pin.
n in
or c
thi
te
sd
iva
– Adjust the outer right spray jet to the following dimension:

o
r
rp
cu
o
m
f
en
c - 410 mm
ng
t.
yi Co
op py
d - 620 mm t. C rig
gh ht
pyri by
– Adjust the inner right spray jet to the following dimension:
o Vo
by c lksw
cted agen
Prote AG.
a - 490 mm
b - 200 mm
– Adjust the inner left spray jet to the following dimension:
a - 490 mm
b - 200 mm
– Adjust the outer left spray jet to the following dimension:
c - 410 mm
d - 620 mm
Tolerance for all spray jets: ± 20 mm
Spray jets for windscreen wash/wipe system (vehicles
06.00►10.03) .
The spray jets are preset. However, small differences in height
may be corrected.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
horis Sharan 1996 nt➤
ee
aut Maintenance - Edition 03.2018 r ac
o
ss
ce
le
un
pt
– Check if the spray jet sprays to centre of wiped area and if
an
d
itte
necessary adjust spray direction upwards or downwards as
y li
rm
ab
follows:
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
– Adjust the spray jet upwards or downwards using a slot-head
screwdriver.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
satelettronica
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Spray jets for windscreen washer system (vehicles 11.03►)

The spray jets are preset. However, small differences in height
may be corrected.
– If both spray fields are not at same height, adjust spray direc‐
tion upwards or downwards as follows:
– Adjust spray jet at adjuster -1- by hand upwards or down‐
wards.
Spray jet for rear window washer system
Note
♦ For vehicles ►05.00 the spray jet of the rear window wipe/wash
system is located above the window frame of rear window.
♦ For vehicles 06.00 ► the spray jet of the rear window washer
system is located below a cover in the wiper shaft.
Sharan 1996 ➤
satelettronica
– Check jet setting.
Spray jet must spray to centre of wiped area.
– If necessary, adjust the spray jet using adjusting tool -
T10127- .
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
4.40.3 Headlight washer system: check jet set‐

wit
, is n
h re
ting
hole
spec
es, in part or in w
t to the co
Caution
Only control function of spray jets but do not adjust them.

rrectness of i
l purpos
Headlight washer system: Check jets, vehicles 05.00

nform
mercia
at
Note
om
ion
c
in t
or
The jet adjustment dimensions are for the left-hand headlight

his
ate
(right-hand headlight mirror image)

do
priv
cum
for
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t.
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Cop py
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rig ht
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by lksw
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Prote AG.
Sharan 1996 ➤
The spray jets must be adjusted so that the water jets spray onto
headlight at positions shown.
a - 30 mm
b - 80 mm
c - 15 mm
Washer spray jet: checking settings
– Switch on dipped headlight.
– Operate windscreen washer system.
The headlights are washed if the windscreen wiper lever is held
in “Wipe position” for at least 1.5 seconds.
The spray jet should spray on the headlight lens, as shown in
illustration.
AG . Volkswage
If spray pattern deviates
agen from specifications,
n AG d
oes carry out repair
lksw not
measures. by Vo gu
a
d ran
ise
Headlight
ut
ho washer system: Check jets, vehicles 06.00►
r tee
o
a ra
ss c
ce
le
satelettronica
un
pt
Note an
d
itte
y li
rm
ab
The jet adjustment dimensions are for the left-hand headlight

pe
ility
(right-hand headlight mirror image)

ot
wit
, is n
h re
hole
spec
The spray jets must be adjusted so that the water jets spray onto
es, in part or in w
t to the co
headlight at positions shown.

a - 100 mm
rrectness of i
b - 200 mm
l purpos
c - 75 mm
Washer spray jet: checking settings
nform
ercia
– Switch on dipped headlight.

m
a
com
tio
– Operate windscreen washer system.

n in
r
te o
thi
The headlights are washed if the windscreen wiper lever is held

s
iva
do
in “Wipe position” for at least 1.5 seconds.

r
rp
cum
fo
The spray jet should spray on the headlight lens, as shown in

en
ng
t.
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illustration. t. Cop py
rig
gh ht
If spray pattern deviates from specifications, carry out repair
yri
p by
co Vo
measures.
by lksw
cted agen
Prote AG.
4.41 Checking wiper blade setting angle: if

wiper blades judder
4.41.1 Wiper blades: Check setting angle, ad‐

just if necessary
Note
Check setting angle only if wiper blades judder or make noises.
Sharan 1996 ➤
♦ Wiper setting tool - 3358 B-

– Set wiper arms to rest position.
– Remove wiper blade.
– Insert wiper arm -2- into wiper arm setting device - 3358 B-
and secure with locking screw -3-.
– Check setting angle.
satelettronica
Vehicles ►10.98
Setting angle (specifications) for
LHD vehicles RHD vehicles n AG. Volkswagen AG do
swage es n
Driver -14° by
V-14°
olk ot g
u
side ris
ed
ara
nte
ho e
Front pas‐ +14° au
t +14° or
ac
senger ss
ce
le
side
un
pt
an
d
itte
Rear win‐ -7° -7° y li

erm
dow wiper ab
ility
ot p
Tolerance ± 2° ± 2°
wit
is n
h re
ole,
Vehicles 11.98►
spec
Setting angle (specifications) for

t to the co
LHD vehicles RHD vehicles

Driver side -10° +10°
rrectne
Front passenger +10° -10°

side
ss o
cial p
Rear window wiper -7° -7°

inform
mer
Tolerance ± 2° ± 2°
atio
om
Adjust setting angle to specification, if required, as follows:

n
c
i
or
n thi
te
sd
a
– Fit combination spanner, AF 24 - VAS 5397- -1- on wiper set‐

iv
o
pr
ting tool - 3358 B- , and adjust wiper arm -2- according to

um
r
fo
en
ng
specification -arrows-.
t.
yi Co
op py
– Detach wiper arm -2- from wiper setting tool - 3358 B- , and
t. C rig
gh ht
yri
secure it with locking screw -3- again. p by
co Vo
by lksw
cted agen
– Check setting against table. If necessary, repeat setting and Prote AG.
checking procedure until angle is as specified.
– Remove setting tool, and install wiper blade.
– Make sure that wiper system operates without juddering.

Sharan 1996 ➤
4.42 Wiper blades: Check park position

»Electrical system«, ⇒ Rep. gr. 92 , »Installing windscreen wash/
wipe system, Adjusting wiper blade park position«.
4.43 Wiper blade protection: removing

Currently there are three versions to separate the wiper blade
protection from the wiper blade or to exchange a transport wiper
arm.
Version 1
On this wiper arm the blade protector is secured on the blade with
two securing clips -arrows-.
Perform the following procedure:
lkswage es n
o ot g
satelettronica
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
– Set wipers in service position. This can be done by switching

un
pt
the ignition on and off once with bonnet closed. Then operate
an
d
itte
y li
wiper lever and the wipers will stop in service position.
rm
ab
pe
ility
– Take the right-hand wiper from windscreen and lift.
ot
wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
To prevent damage, ensure that the wiper is only touched at
the wiper joint and do not pull on the wiper blade. rrectness of i
l purpos
– Now remove upper securing clip upwards and lower securing

nform
ercia
clip downwards -arrows-.

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

Sharan 1996 ➤
– Pull blade protector off wiper blade from bottom to top.

– Carefully place wiper arm back onto windscreen.
Carry out the same procedure for the left-hand wiper.
– Switch ignition on and briefly operate the wiper lever to move
the wipers back to park position. Switch ignition off again.
Version 2
This transport wiper arm is fitted without wind deflector.

Perform the following procedure: agen
AG. Volkswagen AG d
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
satelettronica
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
Caution
nf
ercia
o
rm
m
atio
the wiper joint and do not pull on the wiper blade.
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
– Depending on version, turn the wiper arm with lip upwards and
t.
yi Co
op
pull off, or release wiper arm at joint -3- by pushing locking C py
t. rig
device -1- into mounting -2- and pull wiper arm out. gh ht
pyri by
Vo
o
by c lksw
– Slide the new wiper arm into mounting and ensure that it au‐ Prote
cted AG.
agen
dibly engages.
Carry out the same procedure for the left-hand wiper.
Version 3

Sharan 1996 ➤
On this wiper arm the blade protector -arrow- is slid on the wiper
blade. wage
es ks not
Vol gu
Perform the following procedure:ed by ara
nte
ris
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Caution
nf
ercia
orm
satelettronica
m
atio
m
the wiper joint and do not pull on the wiper blade.

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
– Pull blade protector off wiper blade upwards. t. Cop py
rig
gh ht
Carry out the same procedure for the left-hand wiper. yri
p by
co Vo
by lksw
cted
agen
Prote AG.

4.44 Manual gearbox/final drive: Check oil

level
»Power transmission« ⇒ Rep. gr. 34 »Checking gear oil«.
4.45 Sunroof: checking function, cleaning

and greasing guide rails
– Check function of sunroof.

Sharan 1996 ➤
– Clean guide rails -arrows- and grease with special grease G

060 751 A2.
. Volkswagen AG
gen AG
4.46 Track rod oends: checking clearance,
a oes d
lksw not
byV gu
firmhoseating and boots
d ara
e nte
ris e
t or
au ac
Carry out the following
ss procedure:
ce
le
un
– With vehicle raised (wheels hanging free), check play by mov‐
pt
an
d
itte
ing track rods -arrow- and wheels.
y li
erm
ab
Clearance: zero clearance
ility
ot p
satelettronica
wit
is n
– Check attachment.
h re
ole,
spec
– Check boots (right of arrow) for damage and correct seating.
t to the co
rrectness o
cial p
f i
4.47 Service interval display: recoding

nform
mer
atio

om
n
c
i
or
thi
te
sd
va
Indicated on display:
i
o
pr
cum
r
fo
en
– Press button for “Vehicle self-diagnosis” on display -arrow-.

ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Press “17 - Dash panel insert” on display -arrow-.

Sharan 1996 ➤
The control unit identification and coding are displayed -arrow-.
AG. Volkswagen AG d
agen oes
Indicated on display: olksw not
byV gu
ara
ed
– Press “10 - Adaption” on display -arrow-.ho ris nte
eo
aut ra
ss c
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
– Press buttons 4 and 5 on display number block -arrow-.
l purpos
Adaption channel 45 adapts the dash panel insert to the quality

of oil.
nform
ercia
– Confirm entry with Q button on display number block.

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

Sharan 1996 ➤
– Move position indicator -arrow- on display to left until adaption
value 1 is displayed above scroll bar -1-.
Note
♦ Pressing the scroll bar briefly to the right -2- of the position
indicator moves the value to the next number.
♦ Pressing the scroll bar briefly on the left -3- of the position in‐
dicator moves the value to the previous number.
♦ The adaption value indicates the current status of the engine
oil quality
Note
If the dash panel insert is to be coded to “flexible” (long-life serv‐

ice), the adaption value 4 must be entered for diesel engines and
adaption value 2 entered for petrol engines.
satelettronica
Entering the adaption value 1 sets the dash panel insert to “non-
flexible”, that is, “time or distance dependent service”.
– Press the “Save” button on display -4-. AG. Volkswagen AG d

agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Press the “Accept” button on display -arrow-.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Press »arrow« button on display.
– Press “10 - Adaption” on display -arrow-.
satelettronica
Indicated on display: agen
AG. Volkswagen AG d
oes
olksw not
– Press buttons 4 and 4 on display number block -arrow-.ed by
V gu
ara
ris nte
o eo
Adaptation channel 44 adapts the time to the next
aut service.
h
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Move position indicator -arrow- on display to left until “adap‐
tation value 365” is displayed above scroll bar -1-.
Note
♦ Pressing the scroll bar briefly to the right -2- of the position AG. Volkswagen AG d
indicator moves the value to the next number. agen oes
olksw not
y V gu
b ara
♦ Pressing the scroll bar briefly on the left -3- of the position risin‐
ed
nte
dicator moves the value to the previous number. autho eo
ra
ss c
♦ The adaption value indicates the maximum time until the next
ce
le
un
service is due (365 = 365 days = 12 months).
pt
an
d
itte
y li
erm
ab
730 - LongLife service (maximum 24 months until the next
ility
ot p
service is due)
wit
is n
h re
365 - Time or distance dependent service (max. 12 months
ole,
spec
until the next service is due)
t to the co
satelettronica
Note
rrectne
If the dash panel insert must be coded to “flexible” (long-life serv‐
ice), the adaption value 730 is to be entered.
ss o
cial p
f in
Entering the adaption value 365 sets the dash panel insert to
form
mer
“non-flexible”, that is, “time or distance dependent service”.
atio
om
n
c
– Press the »Save« button on display -4-.
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.
– Press the »Accept« button on display -arrow-.

Sharan 1996 ➤
– Press -arrow- button on display.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
o
satelettronica
th 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
Adaptation channel 43 adapts the maximum distance which can
t to the co
be travelled until the next service is due.
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 ➤
– Move position indicator -arrow- on display to left until adaption
value 15 is displayed above scroll bar -1-.
Note
♦ Pressing the scroll bar briefly to the right -2- of the position
indicator moves the value to the next number.
♦ Pressing the scroll bar briefly on the left -3- of the position in‐
dicator moves the value to the previous number. AG. Volkswagen AG d
agen oes
lksw not
♦ The adaption value in the upper line shows the maximum bdis‐
y Vo gu
ara
tance to the next service due (15 = 15,000 km, 30 = o30,000ed
ris nte
km, 50 = 50,000 km). auth eo
ra
ss c
ce
e
nl
50 - Long-life service, diesel engines:
pt
du
an
itte
y li
30 - Long-life service - petrol engines:
erm
ab
ility
ot p
15 - Time or distance dependent service
wit
, is n
h re
Entering the adaption value 15 sets the dash panel insert to “non-
hole
satelettronica
spec
flexible”, that is, “time or distance dependent service”.
es, in part or in w
t to the co
Note
rrectness of i
When the dash panel insert is to be coded to “flexible” (long-life
service), enter adaption value 30 for petrol engines and 50 for
l purpos
diesel engines.
nform
ercia

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.

Sharan 1996 ➤
– Press »GoTo« button on display -arrow-.
– Press »End« button on display -arrow-.
– Press »End« button in End menu.
– Switch off ignition and separate diagnosis connections.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut
4.48 Service interval display: resetting a ra
ss c
ce
le
un
pt
The service interval display must be reset (adapted) during
an
d
itte
y li
erm
♦ delivery inspection
ab
ility
ot p
♦ every oil change service
wit
is n
h re
ole,
♦ every inspection service
spec
t to the co
Service interval display: Reset, vehicles ►2000 ⇒ page 111
Service interval display: Reset vehicles 2001► ⇒ page 122 .
rrectness
Note
o
cial p
f inform
It is also possible to reset the service interval display manually. If

mer
the SID is reset manually, it must be taken into account that the
atio
m
vehicle is coded to non-flexible intervals, i.e. every 15,000 km or

o
n
c
i
or
12 months. This also modifies the adaptation channel for oil qual‐
thi
e
ity.
t
sd
iva
o
pr
cum
r
fo
en
ng
4.48.1 Service interval display: Reset, vehicles

t.
yi Co
op
►2000
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
♦ The service interval display is only fitted in dash panel inserts

with multi-function display.
♦ For delivery inspection it is not possible to reset the display
with the adjustment button for the distance on dash panel in‐
sert.

Sharan 1996 ➤
Function
The service interval display electronics is comprised of, amongst
other items:
♦ a time recorder
and
♦ a distance recorder.
The electronics evaluates both recorders so that the customer
♦ after a predetermined time period is exceeded or
or
♦ after a predetermined distance is reached
is informed via the service interval display that a service is re‐
quired (whichever occurs first).
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
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
Service interval display

Between services, only the total distance and distance travelled
(trip recorder) is shown in the distance display -2-.
If a service is due, the following is shown in the distance display
-2- below the mileage:
♦ with ignition switched off “service”
♦ after the ignition is switched on and up to 3 minutes after the
engine is started the type of service (service table
⇒ page 113 ).
♦ up to 3 minutes after the ignition is switched off the type of
service (service table ⇒ page 113 ).
Note
♦ Pressing the button for distance -1- the display can be switch‐
ed back to “service”.
♦ After the engine is started the display switches back to “serv‐
ice” after 3 minutes.
satelettronica
Service table:
Service type: Type of Service:
(indicated on display):
Mileage Oil change service
and every 12 months or
service OIL every 15,000 km
or: agen
AG. Volkswagen AG d
oes
lksw not
Mileage Inspection
d byV
o
service gu
ara
and oevery
rise 12 months nte
eo
service In 01 aut
h
ra
ss c
or:
ce
e
nl
pt
du
Mileage Inspection service every

an
itte
y li
and 30,000 km
erm
ab
service In 02
ility
ot p
wit
, is n
After a service has been carried out, the respective type of service
h re
must be reset:
hole
spec
es, in part or in w
♦ If a “service OIL” (oil change service every 15,000 km) is car‐

t to the co
ried out, only “service OIL” must be reset.

♦ If a “service In 01” (inspection service every 12 months) and
rrectness of i
oil change service has been carried out “service In 01” and
“service OIL” must be reset.
l purpos
♦ If a “service In 01” (inspection service every 12 months) with‐

out oil change service has been carried out, only “service In
nform
ercia
01” must be reset.

m
at
♦ If a “service In 02” (inspection service every 30,000 km) has

om
ion
been carried out “service In 02”, “service OIL” and “service In

c
in t
or
01” must be reset.

his
ate
do
riv
The service interval display can be reset using different methods:

p
cum
for
en
ng
♦ with adjustment button for distance display on dash panel in‐

t.
yi Co
op
sert ⇒ page 114 (1) C py
ht. rig
rig ht
by
or using copy Vo
by lksw
cted agen
Prote
♦ vehicle diagnostic tester ⇒ page 114 (2).
AG.

Sharan 1996 ➤
1) Resetting service interval display with adjustment button for

distance display on dash panel insert
– Press and hold button 1 below speedometer, left.

– Switch on ignition and press button 1 and hold until four dash‐
es are shown on the display -2- (- - - -). Only then the service
is reset.
– Switch off ignition and release button 1 .
The original single journey mileage (trip recorder) or the next
service will be displayed again after the service interval display
has been reset.
Note
♦ Note that only the actual service display shown can be reset.
♦ To reset a further service, repeat these steps.
satelettronica
2) Resetting service interval display using vehicle diagnostic test‐
er
– Connect diagnostic tester ⇒ page 36 .
Selection of adaption channel for service
– Touch the field or button on the screen for »Vehicle self-diag‐
nosis«. olks
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o
yV t 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
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
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
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Press the adaption channel for the service which is to be reset
on the display number block -arrow-:
♦ if “service OIL” is displayed on dash panel insert, channel 05
and channel 06,
♦ if “service In 01” is displayed on dash panel insert, channel 05,
channel 06 and channel 07.
♦ if “service In 02” is displayed on dash panel insert, channel 05,
channel 06, channel 07 and channel 08.
Adaption table:
Type of Service: Service type to be Adaption channel
adapted
Delivery OIL 05
Inspection OIL 06
In 01 07
In 02 08
Oil change OIL 05
service OIL 06
satelettronica
Inspection every OIL 05
12 months OIL 06
In 01 07
Inspection every OIL 05
30,000 km OIL agen AG. Volkswagen06
AG do
InV01
olks
w
07 es not g
d bIn 02 08
y ua
se ran
ri tee
ho
aut or
ac
ss
Note
ce
le
un
pt
an
d
itte
y li
All service types are reset with adaption value 0.

erm
ab
ility
ot p
wit
Resetting: service OIL (oil change service) ⇒ page 116 .

is n
h re
ole,
Resetting: service In 01 (inspection every 12 months)

spec
⇒ page 119 .
t to the co
Resetting: service In 02 (inspection every 30,000 km)

⇒ page 120 .
rrectne
Resetting: service OIL (oil change service)

ss
o
cial p
f in

form
mer
atio

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

Sharan 1996 ➤
– Move position indicator -arrow- on display until “0” is displayed
above scroll bar -1-.
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
satelettronica
rrectness of i
l purpos
nform
ercia
m
a
com
tio
– Press the OK button -arrow- on display.

n 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.
– Press the arrow button on display -arrow-.

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

Sharan 1996 ➤
– End output.
Resetting: service In 01 (inspection every 12 months)
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se
Indicated on display: tho tee
or
au ac
s
s
ce
e

nl
pt
du
an
itte
y li
– Press »Save« button on display -2-.
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.

Sharan 1996 ➤
If an inspection service has been performed without an oil
change, then end output .
If an inspection service has been performed with an oil change,
then continue as described:
– Press -arrow- button on display.
Reset the service “service OIL”.
Resetting: service In 02 (inspection every 30,000 km)
satelettronica
lkswage es n
o ot g
Indicated on display: byV ua
d ran
ir se tee
o
– Press buttons 0 and 8 on display number block
auth -arrow-. 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
rrectne
s

s o
cial p
f in
– Press »Save« button on display -2-.

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.

Sharan 1996 ➤
satelettronica
wage es n
yV
olks ot g
b ua
ed ran
– Press hor the arrow button on display -arrow-.
is tee
ut or
a ac
Reset
ss the service “service In 01” and then the service “service
ce
e
OIL”.
nl
pt
du
an
itte
– End output.
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
– Press GoTo button on display -arrow-.

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 ➤
– Press the End button on display -arrow-.
swage es n
– Press End button in End menu. byV
olk ot g
ua
d ran
ir se
– Switch off ignition and separate diagnosisth connections.
o tee
or
au ac
– Switch on ignition. ss
ce
e
nl
pt
du
After the ignition is switched on, the type of service is no longer
an
itte
y li
displayed in the distance display in the dash panel insert. erm
ab
ility
ot p
wit
, is n
h re
hole
spec
4.48.2 Service interval display: Reset, vehicles
es, in part or in w
t to the co
2001 ►
Vehicles with long-life service or time or distance dependent serv‐
rrectness of i
ice
l purpos
The service interval display can be reset using different methods:

♦ 1) With the adjustment button for distance on dash panel insert
nform
ercia
satelettronica
(only for non-flexible intervals “time or distance dependent”
⇒ page 122 )
m
at
om
ion
c
♦ 2) With vehicle diagnostic tester ⇒ page 123 .
in t
or
his
ate
1) Adjusting via the distance and clock adjustment buttons on
do
priv
dash panel insert
cum
for
en
ng
t.
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Cop py
Note
t. rig
gh ht
pyri by
Vo
co lksw
by
♦ At delivery inspection for vehicles with “LongLife service” (PR
cted agen
Prote AG.
number QG1), the service interval display must not be reset
using the distance and clock adjustment buttons. Reason:
When the service interval display is reset using the adjustment
buttons for distance and clock on dash panel insert, the dash
panel insert is automatically coded to non-flexible, i.e. to “time
or distance dependent” service.
♦ For vehicles with “long-life service” (PR number QG1), the
service interval display must not be reset using the distance
display and clock adjustment buttons. Reason: When the serv‐
ice interval display is reset using the adjustment buttons for
distance and clock on dash panel insert, the dash panel insert
is automatically coded to non-flexible, i.e. to “time or distance
dependent” service.
♦ Vehicles with “long-life service” (PR number QG1), which have
an oil change service at approx. 15,000 km or 12 months the
service interval display must be recoded to non-flexible. Rea‐
son: This ensures that these vehicles resume the normal long-
life service rhythm.
Reset the display as follows:


Sharan 1996 ➤
– Press and hold button 1 next to speedometer.

AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
On display 1 *) or 2*)
d
of dash panel insert (depending
orise on vehicle nte
eo
equipment) “service” or “SERVICE NOW” appears.
aut
h
ra
ss c
1)*) Display unit in centre of dash panel insert
ce
e
nl
pt
du
an
itte
2)*) Display unit in speedometer
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
– Release button 1 .
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Turn adjusting knob -1- next to rev. counter to right. Prote
cted AG.
agen
The service displayed is being reset and the display in the dis‐
tance display or centre display changes to the normal state.
2) Adjusting using vehicle diagnostic tester

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
Sharan 1996 ➤ horis
eo
ut
Maintenance - Edition 03.2018 ss a ra
c
ce
e
nl
pt
du
an
itte
y li
erm
– Press button for »Vehicle self-diagnosis« on display -arrow-.
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
op
satelettronica
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
The service interval display is reset via the adaption channel 02.
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
mercia
a
com
tion in
r
te o
thi
s
iva
– Press »GoTo« button on display -arrow-.

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

Sharan 1996 ➤
– Press the End button on display -arrow-.
– Press End button in End menu.
After the ignition is switched on, the type of service is no longer
displayed in the distance display in the dash panel insert.
4.49 Power assisted steering: check fluid lev‐

el.
4.49.1 Oil level check, oil in cold condition:

• Engine switched off
satelettronica
• Front wheels in straight-ahead position
– Remove reservoir cap with built-in dipstick -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Wipe off dipstick using a clean cloth.
t to the co
– Screw filler cap on hand tight and unscrew again.
– Check oil level: The oil level must be within the area of “cool”
rrectne
grid -A-.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
Note
♦ If the fluid level is above the specified area -A-, the excessive
fluid must be extracted.
♦ If fluid level is below above-mentioned area, hydraulic system
must be checked for leaks (repair measure). It is not sufficient
just to fill fluid.
♦ If the hydraulic system is not leaking, replenish power steering
oil, oil specification »Running gear; Steering« ⇒ Rep. gr. 48
»Repairing power steering; Assembly overview«.
– Screw cap on hand tight.
4.49.2 Oil level check, oil at operating temper‐

ature (from approx. 50 °C):
• Engine switched off
• Front wheels in straight-ahead position
olks
wage es n
ot g
V
satelettronica
by ua
– Remove reservoir cap with built-in
ris
ed dipstick -arrow-. ran
tee
tho or
– Wipe off dipstick using a sclean
sa
u
cloth. ac
ce
e
– Screw filler cap on hand tight and unscrew again.

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Check oil level: The oil level must be within the area of “hot”
grid -A-.
l purpos
nf
ercia
Note
orm
m
atio
m
♦ If fluid level is above specified range, fluid must be extracted.

o
n in
or c
♦ If fluid level is below above-mentioned area, hydraulic system

thi
te
sd
a
must be checked for leaks (repair measure). It is not sufficient

iv
o
r
rp
cu
just to fill fluid.

o
m
f
en
ng
t.
yi
♦ If the hydraulic system is not leaking, replenish power steering
Co
op py
oil, oil specification »Running gear; Steering« ⇒ Rep. gr. 48 t. C rig
gh ht
»Repairing power steering; Assembly overview«. pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Screw cap on hand tight.
4.50 Checking/adjusting headlight setting

Test conditions ⇒ page 127
Checking headlight adjustment using test screen without 15° set‐
ting line ⇒ page 129
Headlights: Adjusting ⇒ page 130
4.50.1 Conditions for testing


Sharan 1996 ➤
♦ Headlight adjustment unit - VAS 5046- or:
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
♦ Headlight adjustment unitaut-h VAS 5047- ra
c
ss
♦ Headlight adjustment unit - VAS 5208A-
ce
e
nl
pt
du
an
itte
♦ Headlight adjustment unit - VAS 5209A-
y li
erm
ab
♦ Headlight adjustment unit - VAS 5209B-
ility
ot p
wit
, is n
♦ Vehicle diagnostic tester
h re
hole
satelettronica
spec
Conditions for testing and adjustment:
es, in part or in w
t to the co
♦ Tyre pressures OK.
♦ Lenses must not be damaged or dirty
rrectness of i
♦ The vehicle must be rolled forward or backward several me‐
tres or front and rear springs must be bounced fully several
l purpos
times so that springs settle.

♦ Vehicle and headlight adjustment unit must be on a level sur‐
nf
ercia
face ⇒ Operating instructions for headlight adjustment unit. orm

m
atio
m
♦ Vehicle and headlight adjuster must be aligned.

o
n in
or c
thi
♦ Inclination must be set.

te
sd
iva
o
r
♦ Reflectors and bulbs OK.

rp
cu
o
m
f
en
ng
t.
♦ Vehicle must be loaded.
yi Co
Cop py
ht. rig
♦ On vehicles with gas discharge headlights the event memory rig ht
py by
should be cleared before every headlight adjustment using di‐ co Vo
by lksw
agnostic tester and the headlight range control should be set
cted agen
Prote AG.
to basic setting.
Note
If the vehicle is equipped with separate dipped and main beam,

adjust main beam additionally. When adjusting main beam en‐
sure that the adjustment unit is set to 0%.
Loading: with one person or 75 kg on the driver seat and the ve‐
hicle otherwise unloaded (unladen weight).
The unladen weight is the weight of vehicle ready for operation
with a full fuel tank (at least 90 %) including weight of all equip‐
ment usually carried (e.g. spare wheel, tools, jack, fire extinguish‐
er etc.).
If the fuel tank is not at least 90 % full, then load as follows:
– Read level of fuel in fuel tank on fuel gauge. Determine addi‐
tional weight from following table and place weight in luggage
compartment.

Sharan 1996 ➤
Fuel Additional weight

gauge in kg
To 1/4 45
To 1/2 30
To 3/4 15
Full 0
Example:
When the fuel tank is half full an additional weight of 30 kg must
be placed in the luggage compartment.
Note
AG. Volkswagen AG d
agen oes
olksw no
♦ For this purpose, a dcontainer
by
V filled with water or gravelt gcan
ua be
ra
used, for example oris (a 5-litre fuel canister filled with water ntee
e
weighs approx. au 5 kg).
th or
ac
ss
♦ Write the weight in kg on the container and secure it against
ce
e
nl
pt
being opened again in order to prevent misuse.
du
an
itte
y li
satelettronica
erm
♦ In order to avoid soiling vehicle, place a mat or covering of
ab
ility
some kind in the luggage compartment.
ot p
wit
, is n
h re
Inclination:
hole
spec
es, in part or in w
Inclination in “%” is stamped into upper headlight housing. The
t to the co
headlights must be adjusted to this dimension. Percentage infor‐
mation on sticker is based on a projection distance of 10 metres.
Example: Converting a dip setting of e.g. 1.2 % is equivalent to
12 cm. rrectness of i
l purpos
Fog light dip setting: 2.0 %

Vehicles with manually regulated headlight range control:
nform
ercia
♦ Check headlight height adjustment by setting the maximum

m
at
level and monitoring the headlights' light.

om
ion
c
in t
r
♦ If fitted, then set the headlight range control thumb wheel to

o
his
te
position 0 .
a
do
priv
cum
or
4.50.2 Checking headlight adjustment using

f
en
ng
t.
yi Co
test screen without 15° setting line Cop py
t. rig
gh ht
yri by
Headlights:
op Vo
by c lksw
cted agen
Prote AG.
Please check the following:
– Whether, with the dipped beam switched on, the horizontal
light-dark border contacts the dividing line -1- of the test area
and
– Whether the breaking point -2- between the horizontal part of
the bright/dark boundary on the left and the rising part on the
right lies on the vertical line of the central point -3-. The bright
core of the light beam must be to the right of the vertical line.
Note
♦ To simplify finding the breaking point -2-, cover and uncover

left (from driver perspective) half of the headlight a few times.
Then check dipped beam again.
♦ After correct adjustment of dipped beams, the centre point of
the main beam must lie on the centre mark -3-.

Sharan 1996 ➤
Fog lights
– Check whether the upper bright/dark boundary touches the
setting line and runs horizontally over the entire width of the
test screen.
Other additional lights:
Additionally retrofitted lights of other systems must be checked
and set according to valid guidelines. en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
4.50.3 Headlights: Adjusting
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
When adjusting the headlights, the main beam is adjusted at the
es, in part or in w
same time.
t to the co
satelettronica
Adjusting headlights with gas discharge bulbs ⇒ page 130 .
rrectness of i
Adjusting headlights with halogen bulbs ⇒ page 131 .
l purpos
Adjusting fog lights and other additional lights ⇒ page 131 .

Adjusting headlights with gas discharge bulbs, vehicles 06.00►
nf
ercia
orm
– Apply handbrake.
m
atio
om
n in
c
– Automatic gearbox: Move selector lever to position “P” or “N”.

or
thi
te
sd
a
– Manual gearbox: gear lever in neutral.

iv
o
r
rp
cu
o

f
en
ng
t.
yi Co
op
– Switch on ignition. C py
t. rig
gh ht
yri
– Press “Guided functions”.
p by
co Vo
by lksw
cted agen
– Select “Automatic headlight range control”
Prote AG.
– Select “Carry out basic setting”

– Follow the instructions of tester.
– Check headlight adjustment and adjust if necessary.
Headlight (right):
– Pull cover -1- out upwards.

Sharan 1996 ➤
– Adjust headlight using a suitable cross head screwdriver.

1 - Lateral adjustment
2 - Height adjustment
AG. Volkswagen
agen are a mirrorAG does
Both adjustment screws on the left-hand oheadlight
lksw not
image. db
yV gu
ar
e an
ris tee
– Press the “End” button on display.
ut
ho or
a ac
ss
– Press “End” button in End menu.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Headlights with halogen bulbs, vehicles ►2000
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Both adjustment screws on the left-hand headlight are a mirror
image.
l purpos
satelettronica
Adjusting headlights, vehicles 06.00 ►
nform
ercia
Headlight (right):
m
at
om
ion
c
in t
or
– Pull cover -1- out upwards.
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.

Both adjustment screws on the left-hand headlight are a mirror
image.
Fog lights and other auxiliary lights: adjusting

Sharan 1996 ➤
Fog light (right): Vehicles ►2000

– Pull cover -arrow A- forwards and leave in this position.
. Volkswagen AG
a gen AG does
– To reduce the beam range turn adjustment screw Vol -arrow B- to
ksw not
gu
the left. There is no provision for lateral adjustment.
ed by ara
nte
is
or eo
Location of adjustment screw on left-handau headlight
th is a mirror ra
image. ss c
ce
le
un
pt
Fog light (right): vehicles 06.00►
an
d
itte
y li
erm
Location of adjustment screw on left-hand fog light is a mirror im‐
ab
ility
age.
ot p
wit
is n
– Set corresponding inclination on headlight adjustment unit.
h re
ole,
spec
• The inclination for fog lights is “2.0 %”
t to the co
Note
rrectne
Percentage given is based on a projection distance of 10 metres.
ss o
cial p
f i
– Press the centre rib together -arrows- to unclip the cover in
satelettronica
nform
lower part of bumper on right side.
mer
atio
m
– Pull cover out of bumper.

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
o
by c lksw
cted agen
Prote AG.
– To reduce the beam range turn adjustment screw -1- to the

left. There is no provision for lateral adjustment.
Location of adjustment screw on left-hand headlight is a mirror
image.
Other additional lights
Additionally retrofitted lights of other systems must be checked
and set according to valid guidelines.
4.51 Door arrester: grease.


Sharan 1996 ➤
– Grease door arrester at points shown -arrows-.

– Grease door arrester in side area -arrow A- with solid grease
- G 000 150- .
4.52 Dust and pollen filter: renew filter ele‐

ment
Procedure
Heating, ventilation, air conditioning system ⇒ Rep. gr. 80 →
Repairing heating system → Removing and installing dust and
pollen filter
satelettronica
Note

4.53 Underbody sealant: inspecting for dam‐

age to underbody sealant, underbody
panels, routing of lines and plugs
During inspection, also check floor pan, wheel housings and sills.
olkswagen AG
en AG. V
Always ensure that all lines are secured inoltheir
ksw mountings, all
ag does
not
plugs are available and that there is no bvisible
yV damage on the gu
ara
ed
underbody. horis nte
eo
t
au ra
c
ss
ce
e
Note
nl
pt
du
an
itte
y li
erm
Faults found must always be rectified (repair measure). This in‐

ab
ility
hibits corrosion and rusting through.

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
133
Prote AG.
Sharan 1996 ➤
4.54 Clock: setting to correct time

Vehicles ►2000
To set the time there are two press buttons located in front of
interior light in the roof area.
Setting hours:
♦ The hours -h- are set with the “left” button -1-.
♦ Press the button briefly -1-, to advance the time one hour.
♦ Pressing the button continuously speeds up selection of
hours.
Setting minutes:
♦ The minutes -min- are set with the “right” button -2-.
♦ Press the button briefly -2-, to advance the time one minute.
♦ Pressing the button continuously speeds up selection of mi‐
nutes.
♦ With the minute button the clock can be set exactly to the sec‐
ond:
satelettronica
♦ Press button until time is one minute before time to be set.
Press button at the moment when the seconds indicator of
accurate clock shows a full minute.
Vehicles 2001►
Setting hours:
– Turn setting knob -1- (on lower right next to rev counter) anti-
clockwise.
By turning the setting knob shortly, the clock will be altered by one
hour. By turning and holding the knob the alteration will be con‐
tinuous.
Setting minutes: agen
AG. Volkswagen AG d
oes
olksw not
V
– Turn setting knob e-1- d byclockwise. gu
ara
ris nte
o
By turning the setting
aut
h knob shortly, the clock will be altered by one eo
ra
minute. By turning
ss and holding the setting knob the alteration will c
be continuous.
ce
e
nl
pt
du
an
itte
With the setting knob -1- the clock can be set exactly to the second
y li
erm
ab
as follows:
ility
ot p
wit
– Turn setting knob to right until the time is one minute before
, is n
h re
time to be set.
hole
spec
– Turn adjustment knob to the right at the moment when the

es, in part or in w
t to the co
seconds indicator of accurate clock shows a full minute.
4.55 Camshaft drive belt: Renew (TDI en‐

rrectness of i
gine)
l purpos
nf
ercia
Note
orm
m
atio
m
Generally it is not necessary to renew the toothed belt before the

o
n in
c
actual change interval is reached. Especially cracks on the belt

or
thi
side are not relevant for service life and cannot be covered by
te
sd
a
goodwill or warranty processing.

iv
o
r
rp
cu
o
m
f
en
ng
t.
»Engine, Mechanics« ⇒ Rep. gr. 13 »Dismantling and assem‐
yi Co
op
bling engine; Removing and installing toothed belt«.
C py
ht. rig
rig ht
py by
co Vo
134
by lksw
cted agen
4. Descriptions of work: Prote AG.
Sharan 1996 ➤
4.56 Toothed belt and camshaft drive ten‐

sioning roller: Renew (TDI unit injector
engine)
Note
Generally it is not necessary to renew the toothed belt before the

actual change interval is reached. Especially cracks on the belt
side are not relevant for service life and cannot be covered by
goodwill or warranty processing.
»Power unit« ⇒ Rep. gr. 15 »Cylinder head; Removing and in‐

stalling toothed belt«.
4.57 Camshaft drive toothed belt: Renew (4-

cylinder petrol engine, 5-valve)
»Power unit« ⇒ Rep. gr. 15 »Cylinder head; Removing and in‐
stalling toothed belt«.
4.58 Toothed belt: Check for wear (diesel en‐
satelettronica
gine)
♦ Workshop vernier caliper - VAS 5276-
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
– Remove engine cover panel.

ility
ot p
wit
– Open clips on upper toothed belt guard.

, is n
h re
hole
– Pull upper toothed belt guard to side or remove.

spec
es, in part or in w
– Measure the width of the toothed belt with a vernier caliper.

t to the co
Engine code Wear limit

rrectness of i
AFN, AHU, AVG, 1Z 22 mm

l purpos
ANU 27 mm
nf
ercia
Note
rm
m
atio
om
♦ When a toothed belt has reached a width of 22 mm or 27 mm

n in
or c
respectively, the wear limit has been reached and it must be

thi
te
sd
a
renewed (repair measure). Inform customer!

iv
o
r
rp
cu
o
♦ The engine must never under any circumstances be turned

f
en
ng
t.
over using the camshaft when checking and making adjust‐
yi Co
op
ments. Not observing this can lead to severe engine damage.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
4.59 Camshaft drive toothed belt: Check (4-

cylinder petrol engine)
– Open clips for upper toothed belt guard and remove cover.
– While turning crankshaft at least one full turn, check toothed
belt condition for:
♦ -A- Cracks, cross-sectional breaks, tears o(on
lkswcover side)
age es n
ot g
yV ua
♦ -B- Side contact db ran
ir se tee
ho
ut or
♦ -C- Fraying of cord strands ss
a ac
ce
e
♦ -D- Cracks (in teeth base)

nl
pt
du
an
itte
y li
♦ Layer separation (toothed belt body, tensile cords)
erm
ab
ility
ot p
♦ Surface cracks (synthetic coating)
wit
, is n
h re
♦ Traces of oil and grease
hole
spec
es, in part or in w
t to the co
Note
satelettronica
If faults are found, always renew toothed belt. This can avoid
rrectness of i
breakdowns and malfunctions. The replacement of a toothed belt
is a repair measure.
l purpos
nform
ercia
4.60 Spark plugs: renewing

m
at
om
ion
c
Caution
in t
or
his
ate
do
riv
♦ When connectors are disconnected, faults are stored.

p
cum
for
en
g
♦ Read all event memories: ⇒ page 68 .

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
WARNING Prote AG.
Before doing this, switch off ignition.

• Safety measures of ignition system, ⇒ Rep. gr. 28 ;
Checking ignition system, safety measures.
Renewing spark plugs, VR6 2-valve engines ⇒ page 138

Renewing spark plugs, 2.0 l 2-valve engines (Simos)
⇒ page 139 .
Renewing spark plugs, 1.8 l 5-valve engines ⇒ page 139 .
Renewing spark plugs, 2.0l 2-valve engines (without intermediate
shaft) ⇒ page 140 .
Renewing spark plugs, VR6 4-valve engines ⇒ page 141 .

Sharan 1996 ➤
♦ Spark plug socket - 3122 B-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b
satelettronica
d ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
♦ Assembly tool - T10029- for VR6-cylinder, 2-valve engines
wit
is n
and 2.0 l 2-valve engines (without intermediate shaft)
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
♦ Puller - T10095 A- for VR6-cylinder, 4-valve

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 ➤
♦ Assembly tool - T10118- for VR6-cylinder, 4-valve
4.60.1 Renewing spark plugs, VR6 2-valve en‐ lksw

agen
AG. Volkswagen AG d
oes
not
gines
o
byV gu
ara
ed
s n ri tee
ho
Removing: aut or
ac
ss
– Pull off spark plug connector using assembly tool - T10029- .
ce
le
un
pt
an
d
itte
y li
erm
ab
satelettronica
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
– Unscrew spark plugs using spark plug socket - VAS 3122 B- .
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e

t
sd
iva
o
pr
cum
r
fo
Installing:
en
ng
t.
yi Co
op
– Screw in new spark plugs using spark plug socket and exten‐
C py
ht. rig
sion - VAS 3122 B- .
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Spark plug designation and torque setting ⇒ Rep. gr. 28 ; Serv‐

icing ignition system, test data, spark plugs.
– Fit spark plug connectors using assembly tool - T10029- .

– Check that ignition cables and spark plug connectors are fitted
securely.
– Clip ignition cable into engine cover.

Sharan 1996 ➤
4.60.2 Spark plugs: renewing, 2.0 l 2-valve en‐

gines (Simos) olks
wage es n
ot
yV gu
db ara
Removing: rise nte
tho eo
– Pull off spark plug connector and unscrew spark plugs with au ra
c
ss
spark plug socket and extension - VAS 3122 B- .
ce
e
nl
pt
du
an
Installing:
itte
y li
erm
ab
ility
ot p
sion - VAS 3122 B- .
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ Spark plug designation and torque setting ⇒ Rep. gr. 28 ;
Servicing ignition system, test data, spark plugs.
rrectness of i
l purpos
– Fit spark plug connectors.
nf
ercia
o
– Check ignition cables are seated securely.
satelettronica
m
m
atio
m

o
n in
or c
gines
thi
te
sd
iva
o
r
rp
cu
Removing:
o
m
f
en
ng
t.
Removing and installing engine cover panel -top- ⇒ page 87 .
yi Co
Cop py
t. rig
– Pull connector -2- off ignition coil with output stage -1-.
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Unscrew bolts -1- from ignition coil with output stage.

– Carefully pull ignition coil with output stage off spark plug by
hand.
– Unscrew spark plugs using spark plug socket - 3122 B- .
Note

AG. Volkswagen AG d
Installing: lksw
agen oes
not
Vo gu
by
– Screw in new spark plugs withrised spark plug wrench - 3122 B- B. ara
nte
ho eo
aut ra
ss c
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Insert ignition coils with output stages in cylinder head and
hole
satelettronica
spec
align ignition coils in respective recesses of cylinder head cov‐
es, in part or in w
er.
t to the co
– Push ignition coils with output stages onto spark plugs until
stop, they must be felt to engage.
rrectness of i
– Tighten ignition coils -2- to 10 Nm.
l purpos
– Check ignition cables are seated securely.
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.
gines (without intermediate shaft)

Removing:
Removing and installing engine cover panel -top- ⇒ page 87 .
– Unscrew the two hexagon socket head bolts -arrows- from
cable guide.

Sharan 1996 ➤
– Pull off spark plug connector using assembly tool - T10029- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
– Unscrew spark
aut plugs using spark plug socket - 3122 B- .
h
ra
ss c
Installing:
ce
le
un
pt
an
d
itte
y li
rm
sion - 3122 B- .
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
satelettronica
es, in part or in w
♦ Spark plug designation and torque setting ⇒ Rep. gr. 28 ;
t to the co
Servicing ignition system, test data, spark plugs.
rrectness of i
l purpos
– Fit spark plug connectors using assembly tool - T10029- .

– Check that ignition cables and spark plug connectors are fitted nform
ercia
securely.
m
a
com
ti
– Tighten cable guide with hexagon socket head bolts

on in
-arrows-.
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4.60.5 Spark plugs: renewing, VR6 4-valve en‐

gines
Removing:
– Remove engine cover panel.
Release connector lock:

Sharan 1996 ➤
– Apply assembly tool - T10118- to connector lock -arrow- and

carefully pull upwards until connector lock releases.
– Pull off connectors for ignition coils with output stages upwards
-arrow-.
– Before pulling off, note positions of ignition coils with output
stages relative to connectors.
The flat side of the connector must align with the flat side of igni‐
tion coil with final output stage. AG. Volkswagen AG d
agen oes
olksw not
V
satelettronica
by gu
d ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Slide puller - T10095 A- from the flat side of the connector in
ility
ot p
direction of arrow onto ignition coil with final output stage.
wit
, is n
h re
– Pull out ignition coil with output stage upwards vertically.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
– Unscrew spark plugs using spark plug socket - 3122 B- .
om
n in
or c
thi
te
sd
a
Note
iv
o
r
rp
cu
o
m
f
en
ng

t.
yi Co
Cop py
t. rig
gh ht
Installing: yri
p by
co Vo
by lksw
cted
agen
Prote AG.
sion - 3122 B- .
Note

– Carefully fit ignition coils with spark plug connector.

– Connect connectors at ignition coils with spark plug connector.
– Install engine cover panel.

Sharan 1996 ➤
5 Exhaust emissions test

Exhaust emissions test for petrol engines without OBD
⇒ page 143
Exhaust emissions test for petrol engines with OBD
⇒ page 152
Exhaust emissions test for diesel engines without OBD
⇒ page 154
Exhaust emissions test for diesel engines with OBD
⇒ page 167
Note
♦ Please observe the country specific legal regulations.

♦ The exhaust emissions test described below has been created
according to the legal regulations valid in Germany.
satelettronica
♦ If the vehicle is equipped with or without OBD, see ⇒ page 1 .
5.1 Exhaust emissions test for petrol en‐

gines without OBD
Vehicles which are fitted with or without onboard diagnosis can
be found in the engine list ⇒ page 1 .
Caution
• Observe “SAFETY AND DAMAGE AVOIDANCE PRE‐

CAUTIONS” in the operating instructions for VAS 6300. n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
Note ss
a ac
ce
le
un
pt
♦ All test conditions and data required for exhaust emissions

an
d
itte
y li
test: ⇒ Data sheets for exhaust emissions test

rm
ab
pe
ility
♦ The ignition timing is determined by the control unit and cannot

ot
wit
, is n
be displayed. Adjustment is not possible.

h re
hole
♦ Idling speed and CO content are not adjustable (check only).

spec
For deviations from test value: carry out repair measures.

es, in part or in w
t to the co
♦ The CO content is regulated by the lambda regulation. Faults

in the lambda regulation are detected in self-diagnosis and
stored in event memory.
rrectness of i
♦ Faults (engine electronics) identified when event memory is

l purpos
read must be rectified and the event memory then cleared.

♦ To prevent injuries to personnel and/or damage to ignition and
nform
ercia
injection system, the ignition system wiring (including high

m
voltage wiring) should be connected and disconnected only

a
com
tio
with ignition switched off.

n in
r
te o
thi
♦ The following description refers to vehicles without OBD with

s
iva
do
regulated catalytic converter.

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. Exhaust emissions test 143

Sharan 1996 ➤
♦ Exhaust emissions station - VAS 6300-
♦ Diagnostic cable - VAS 5051/6A-

♦ Adapter for older vehicles - VAS 5051/2-
or
♦ Engine speed adapter - VAS 5087 A-
♦ ⇒ Data sheets for exhaust emissions test
satelettronica
Note
♦ It is only possible to carry out an exhaust emissions test when

all units of the exhaust emissions station - VAS 6300- are con‐
nected properly and combined with each other according to
the operating instructions.
♦ All work to be performed is displayed by the exhaust emissions
station - VAS 6300- .
Test requirements: AG. Volkswagen AG d

agen oes
o lksw not
yV gu
• All test conditions and data required for exhaust
ised b emissions ara
nte
test: ⇒ Data sheets for exhaust emissions hor
test for respective eo
ut
engine. ss a ra
c
ce
le
• For bar code reading the EET data sheet must be printed out.
un
pt
an
d
itte
y li
• Apply handbrake.
rm
ab
pe
ility
• Automatic gearbox: Move selector lever to position “P” or “N”.

ot
wit
, is n
h re
• Manual gearbox: gear lever in neutral.

hole
spec
• Install engine speed adjuster - V.A.G 1788/10- .

es, in part or in w
t to the co
– Perform exhaust emissions test according to instructions on

display.
rrectness of i
Initial screen:
l purpos
– Select button -arrow- “exhaust emissions test”.

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.
144 5. Exhaust emissions test

Sharan 1996 ➤
An overview is displayed to select the respective EET type.

– Select “EET petrol” -arrow-.
The display for warm-up phase appears.
satelettronica
Continue exhaust emissions test according to instructions on dis‐
play.
– If the EET specification selection is displayed, select respec‐
tive “EET specification selection” -arrow-.
♦ When exhaust emissions test is performed for the first
ntime,
AG. Volkswagen AG d
either select “Standard values”, wage oes
olks not
V gu
by ara
♦ Or “Last vehicle” when an exhaust emissions
oris
ed test is to be car‐ nte
ried out again. au
th eo
ra
ss c
– Select “Continue” on display, see -item 1-.
ce
le
un
pt
an
d
Vehicle data input:

itte
y li
rm
ab
The vehicle data input menu is displayed.

pe
ility
ot
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
♦ For new models the document previously known as the vehicle

registration document is now called the vehicle registration
certificate part 1.
rrectness of i

l purpos
log book is now called the vehicle registration certificate part

2.
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 ➤
♦ -1- Vehicle manufacturer: “e.g. VOLKSWAGEN - VW”

♦ -2- Vehicle type: “e.g. Golf”
♦ -3- Key number for 1: “e.g. 11”
♦ -4- Key number for 2: “e.g. 0603” (vehicle registration docu‐
ment)
♦ -4- Key number for 2.1 (code for 2): “e.g. 0603” (vehicle reg‐
istration certificate part 1)
ment)
♦ -5- Key number for 2.2 (code for D2): “e.g. 358” (vehicle reg‐
♦ -6- Engine code “e.g. AQY”
♦ -7- Registration number: “e.g. WOB-HH 1234”
♦ -8- Vehicle identification number: “e.g.
WVWZZZ1JZYW123456”
– Enter odometer reading at -item 9- “e.g. 32000”.
satelettronica
Note
♦ Further functions can be called up using GoTo button.

♦ The test can be terminated using GoTo button.
– Select “without OBD”, -arrow-.

Specified data input for EET:
There are different ways to enter the specified data:
♦ 1) By manual input agen
AG. Volkswagen AG d
oes
olksw not
yV gu
♦ 2) By bar code input from EET data sheet ed b ara
nte
ris
o eo
♦ 3) Through ELSA web service aut
h
ra
s s c
ce
e
nl
pt
du
an
Note
itte
y li
erm
ab
ility
♦ To use the ELSA web service, the vehicle diagnostic tester

ot p
wit
which is used for the exhaust emissions test, must be integra‐

, is n
h re
ted in the workshop network.

hole
spec
♦ For the ELSA web service the vehicle specified data are au‐
es, in part or in w
t to the co
tomatically transmitted via the network to the respective mask.
Manual specified data input for EET:

rrectness of i
l purpos
Note
nf
ercia
All test conditions and data required for exhaust emissions test
orm
⇒ Data sheets for exhaust emissions test for respective engine.

m
atio
om
n in
or c
– Perform manual data input according to instructions on dis‐

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

Sharan 1996 ➤
– Enter displayed values on EET data sheet in column “Test

values for exhaust emissions test” on display as follows:
1- Test speed (idling speed)
2- Warm-up phase for catalytic converter
3- Engine temperature wage
es n
lks ot g
Vo
4- Increased idling speed d by ua
ran
ir se tee
o
5- CO content at increasedau idling speed
th or
ac
ss
6- Lambda at increased idling speed
ce
e
nl
pt
du
an
7- Idling speed
itte
y li
erm
ab
8- Select regulating probe type, either “step-type probe”, or
ility
ot p
“broad-band probe” -item 1-.
wit
, is n
h re
9- Lambda probe value
hole
spec
es, in part or in w
– When all data has been entered properly, press → button
t to the co
-arrow-.
Specified data input for EET as bar code:
rrectness of i
satelettronica
– If specified data for EET are available as bar code, read bar
l purpos
code of EET data sheet with bar code reader.

All data required is shown on display.
nf
ercia
orm
m
– Press → button -arrow- to proceed.
atio
om
n in
c
Visual inspection:
or
thi
te
sd
a
Follow instructions on display:

iv
o
r
rp
cu
o
m
– Perform visual check.
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
– If visual check is OK press “OK” button -arrow-.
co Vo
by lksw
cted agen
Prote AG.
Note
When "not OK" button is pressed a check will be carried out
The visual check is displayed with the request to connect the ca‐
bles to the vehicle.
– Connect adapter for older vehicles - VAS 5051/2- or engine
speed adapter - VAS 5087/- or diagnostic cable - VAS
5051/6A- to the vehicle.
Note
♦ On some engines the inductive sender for cylinder 1 cannot

be connected.
♦ The engine speed adapter - VAS 5087/- can be used for these
engines.
♦ On some vehicles the engine speed adapter - VAS 5087/-
must be used.
– Connect diagnosis cable connector to diagnostic connection.

wage es n
Sharan 1996 ➤ yV
olks ot g
b ua
Maintenance - Edition ir se03.2018
d ran
tee
tho
u or
a ac
Vehicles up to ►2000 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
Vehicles as of 2001►
nform
ercia
– Switch ignition on.

m
– Start engine.
a
com
tion in
– Insert emission probe in exhaust tail pipe.
r
te o
thi
s
iva
do
r
rp
cum
Note
fo
satelettronica
en
ng
t.
yi Co
op py
The exhaust emissions test is only continued when the test probe t. C rig
gh ht
is in the exhaust tail pipe. yri
p by
co Vo
by lksw
cted agen
Prote AG.
It is automatically switched to test for readiness of operation.
Catalytic converter conditioning:
It is automatically switched to warm-up phase of catalytic con‐
verter.
– Follow instructions on display.

Measurement starts when the engine speed has reached the re‐
quired level.
– Maintain engine speed in required engine speed range.
The remaining time to perform the warm-up phase is displayed
-arrow A-.
Warm-up phase:
It is automatically switched to display for measuring engine tem‐
perature.
Note
This is only indicated on display if engine temperature has not

reached 80°C.
– Bring engine to required temperature.

Sharan 1996 ➤
Measurement at increased idling speed:

It is automatically switched to display for measuring increased
idling speed.
quired level.
Note
♦ Measurement can be skipped using → button, i.e. the exhaust

emissions test has failed.
♦ Measured values are reset using ← button, and the test can
be repeated.

The remaining time to perform measurement is displayed
-arrow A-.
satelettronica
Measuring idling speed and CO content:
It is automatically switched to display for measuring the idling
speed and CO content.
quired level.
-arrow A-.
AG. Volkswagen AG d
Regulating probe test: lksw
agen oes
not
Vo gu
by
It is automatically switched
rise
d to display for regulating probe test. ara
nte
tho eo
au ra
ss c
Note
ce
e
nl
pt
du
an
itte
y li
If “Control circuit test - alternative proc.” is indicated on display,

erm
ab
the disturbance variable relevant for the engine code must be ac‐
ility
ot p
tivated ⇒ page 150 .

wit
, is n
h re
hole
spec
es, in part or in w
quired level.
t to the co

rrectness of i
-arrow A-.
l purpos
Evaluation:
nform
ercia
When the exhaust emissions test is performed, the log is shown

on display.
m
at
om
ion
The test result is displayed.

c
in t
or
his
te
Now remarks concerning the exhaust emissions test can be en‐

a
do
riv
tered -arrow A-. They will then be included in the test log.
p
cum
for
en
ng
– When the exhaust emissions test is classed as passed, select

t.
yi Co
op
-arrow B- “EET sticker issued” in drop-down menu and date. C py
t. rig
gh ht
yri by
– Then confirm with “Yes”, see -arrow C-. cop Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Sharanut 1996 ➤
ho eo
ra
a
Maintenance
ss - Edition 03.2018 c
ce
le
un
pt
an
After confirming, the two “TEST CERTIFICATES” are printed out
d
itte
y li
automatically.
rm
ab
pe
ility
– If a further test certificate is required, press -arrow A- “Print”
ot
wit
, is n
button.
h re
hole
spec
es, in part or in w
t to the co
– Take emission probe out of exhaust tail pipe.
– Then press → button -arrow B-.
rrectness of i
The exhaust emissions test is completed, a new exhaust emis‐
sions test can be performed.
l purpos
nform
ercia
5.1.1 Exhaust emissions test for petrol en‐

m
a
gines, methods to activate disturbance
com
tion in
variable for control circuit test according
r
te o
thi
s
iva
to basic procedure
do
r
rp
cum
fo
en
g
Activate disturbance variable.

n
t.
yi Co
Cop py
satelettronica
t.
Engine Disturbance variable
rig
gh ht
yri by
code: op Vo
by c lksw
cted agen
Prote
AAA ⇒ page 150
AG.
ADY ⇒ page 150

AMY ⇒ page 150
AJH ⇒ page 151
5.1.2 Disturbance variable for engine codes:

AAA, AMY
Activate disturbance variable within 60 seconds as follows:
– Disconnect vacuum hose from intake manifold upper part at
fuel pressure regulator -arrow-.
The control unit must recognise the disturbance variable and
eliminate through regulation within 60 seconds.
Deactivate the disturbance variable as follows:
– Reconnect vacuum hose.
5.1.3 Disturbance variable for engine code:

ADY

Sharan 1996 ➤
– Pull vacuum hose -1- off fuel pressure regulator -2- and seal
hose. Wait 20 seconds.
– Open vacuum hose -1-.
eliminate through regulation within 60 seconds.
Deactivate the disturbance variable as follows:
– Reconnect vacuum hose to fuel pressure regulator.
5.1.4 Disturbance variable for engine kswcode:

AG. V olkswagen AG
agen does
ol not
AJH ise
db
yV gu
ara
nte
r
ho eo
Fit the following parts: aut ra
c
ss
1 - Sealing cap - 034 133 335- (Qty. 3)
ce
le
un
pt
an
d
itte
2 - Angled piece - 034 129 737 3-
y li
erm
ab
satelettronica
ility
3 - Hose, 50 mm in length - 050 133 784 G-
ot p
wit
is n
– Fit angled piece -2- with hose and sealing caps as shown in
h re
ole,
the illustration.
spec
t to the co
Note
rrectne
♦ Check that cross section of angled piece is not blocked using
wire.
ss
♦ Reduce width of angled piece connection if necessary, to sim‐
o
cial p
f
plify inserting into hose.
inform
mer
atio
m
– Pull angled hose -1- off intake manifold connection -2-.

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.
– Connect prepared angled piece -arrow- to rigid line on intake

manifold.
– Activate disturbance variable within 60 seconds as follows:

Sharan 1996 ➤
– Pull sealing caps -arrows- off angled piece simultaneously (the

other sealing cap always remains connected).
eliminate through regulation within 60 seconds. n AG. Volkswagen AG do
lkswage es n
– Connect sealing caps -arrows- to angled piece simultaneous‐ d byV
o ot g
ua
ly. o
ir se
ran
tee
th or
u
The control unit must recognise deactivation of the disturbance
ss
a ac
variable and eliminate through regulation within 60 seconds.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
5.2 Exhaust emissions test for petrol en‐ hole
spec
gines with OBD
es, in part or in w
t to the co
Vehicles which are fitted with or without “Onboard diagnosis” can
be found in the engine list ⇒ page 1 .
rrectness of i
l purpos
♦ Exhaust emissions station L - VAS 7320 A-
satelettronica
nform
ercia
Note
m
a
com
tion in
♦ The following description refers to vehicles fitted with “On‐
r
te o
thi
board diagnosis” OBD.
s
iva
do
r
rp
c
♦ The OBD monitors all components and part systems influenc‐
um
fo
ing the exhaust emissions quality.
en
ng
t.
yi Co
op py
♦ It is possible to carry out an exhaust emissions test only when t. C rig
gh ht
all units of the exhaust emissions station are connected prop‐ yri
p by
o Vo
erly and joined to each other according to the operating in‐
c by lksw
cted agen
structions.
Prote AG.

station .
Conditions for testing

• All test conditions and data required for exhaust emissions test
are found on EET data sheet for the respective engine.
• For bar code reading the EET data sheet must be printed out.
• Automatic gearbox: selector lever in position “P” or “N”.
• Manual gearbox: gear lever in neutral
• Parking brake applied
• 12V battery fully charged (if battery charge is too low, raise
idling speed if necessary).
display.
Vehicle data input
– Enter the following data:
♦ Registration number
♦ Key numbers
♦ Vehicle identification number
♦ Fuel type
♦ Mileage

Sharan 1996 ➤
The following vehicle data can be found in the vehicle registration

certificate part 1:
♦ Registration number: “e.g. WOB-HH 1234”
♦ Emission key number “Field 14.1 (code for field 14)”
♦ Vehicle manufacturer: “Field 2”, “Field 2.1 (code for field 2)”
♦ Vehicle identification number “field E”
♦ Type and version “Field D2 (type only)”, “Field n AG. Volkswagen AG do
lkswage2.2 (code for es n
field D.2)” by
Vo ot g
ua
ed ran
ris
Specified data input for EET utho
tee
or
sa ac
There are different ways to enters the specified data:
ce
e
nl
pt
du
♦ 1) By manual input
an
itte
y li
erm
ab
♦ 2) By bar code input from EET data sheet
ility
ot p
wit
♦ 3) Through ELSA web service
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
satelettronica
♦ To use the ELSA web service, the exhaust emissions station
which is used for the exhaust emissions test must be integra‐
rrectness of i
l purpos
♦ The ELSA web service automatically transmits the data for the
specific vehicle via the network to the respective mask.
nf
ercia
orm
m
atio
om
n in
or c
thi
e
Note
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
can be found in the ⇒ Data sheets for exhaust emissions test for
yi Co
op
respective engine.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Perform manual data input according to instructions on dis‐ Prote
cted AG.
agen
play.
1- Test speed (idling speed)
2- Warm-up phase for catalytic converter
3- Engine temperature
4- Increased idling speed
5- CO content at increased idling speed
6- Lambda at increased idling speed
7- Idling speed
8- Select regulating probe type; either “Step-type probe” or
“Broad-band probe”.
9- Lambda probe value
All data required is shown on display.

Sharan 1996 ➤
Inspection
– Inspect all exhaust emissions
wage relevant components.
es ks not
Vol g
– Check if exhaust system
ed
by is fitted and complete and check
ua for
ran
leaks and damage.
thoris tee
o
au ra
Procedure ss c
ce
e
nl
pt
– Follow instructions from exhaust emissions station .
du
an
itte
y li
erm
5.3 Exhaust emissions test for diesel en‐
ab
ility
ot p
gines without OBD
wit
, is n
h re
hole
Exhaust emissions test for diesel engines without OBD with emis‐
spec
sions testing station VAS 6300 ⇒ page 158
es, in part or in w
t to the co
5.3.1 Exhaust emissions test for diesel en‐
gines without OBD with diesel tester
rrectness of i
V.A.G 1743
l purpos
nform
ercia
♦ Diesel tester - V.A.G 1743-
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.
♦ Engine speed adapter - VAS 5087-
♦ Adapter cable - VAS 5087/3-
Note
♦ All test conditions and data required for emissions test ⇒ Data
sheets for exhaust emissions test
♦ If possible, the test should be completed outdoors following a
road test. If this is not possible for various reasons (weather,
excessive noise in residential areas), then the test can be car‐
ried out in a workshop.
♦ To reduce noise levels, the bonnet should be closed on first
catch during tests.

Sharan 1996 ➤
Carrying out visual check of components influencing emissions:

⇒ Data sheets for exhaust emissions test
– Performing visual check for:
♦ Installation
♦ Completeness
♦ Leakage
♦ Damage
Note
Faults found are to be rectified.
With ignition switched off, connect testers as follows:

– Apply handbrake.
– Manual gearbox: gear lever in neutral.
– Automatic gearbox: selector lever in position “P” or “N”.wage
satelettronica
es n
olks V ot g
by ua
– Connect diesel tester - V.A.G 1743- according ris
eto
d operating ran
tee
instructions with ignition switched off. utho
or
a ac
ss
Connect engine speed adapter - VAS 5087- as follows:
ce
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
♦ Observe ⇒ operating instructions for engine speed adapter -
h re
ole,
VAS 5087- !
spec
♦ Strictly follow the safety precautions in the operating instruc‐
t to the co
tions!
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Using adapter cable - VAS 5087/3- , connect “Output” of en‐

gine speed adapter - VAS 5087- to pick-up clamp input of
diesel tester - V.A.G 1743- .
– Turn switch for number of cylinders to respective number of
cylinders.
– Connect a wire from adapter - VAS 5087/1- to -VAS 5087-
(socket -VAS 5087/1- ).
– Using the other wires from adapter - VAS 5087/1- make a
connection to the vehicle battery, by connecting:
♦ Red clamp on positive
olkswagen AG
en AG. V
♦ Black clamp on negative olkswag does
not
V y gu
b ara
– Start engine and run riseit at idling speed.
d
nte
tho eo
u
– Press the Start
ss a button on engine speed adapter - VAS ra
c
5087- . The red signal lamp must flash for about 10 seconds.
ce
le
un
pt
Then the green signal lamp must light up.
an
d
itte
y li
The engine speed must now be displayed on diesel tester -
erm
ab
ility
V.A.G 1743- .
ot p
wit
is n
If the engine speed is displayed incorrectly or not at all: ⇒ Oper‐
satelettronica
h re
ole,
ating instructions for VAS 5087 .
spec
Perform exhaust emissions test according to instructions on die‐
t to the co
sel tester - V.A.G 1743- display.
If this message appears on the display:
n 1/min Mode k 1/m T °C rrectne
XXX XXXX B X.XX XX
ss o
cial p
Unit ready to carry out measurements.

inform
mer
Checking idling speed:

atio
om
Idling speed not within specified range:

n
c
i
or
n thi
te
sd
iva
o
pr
Note
cum
r
fo
en
ng
t.
yi Co
The idling speed and maximum speed can be checked but not Cop py
t.
adjusted.
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
– If the values are not within specified range, a repair measure Prote AG.
must be made.
Perform acceleration test:
– Press button for acceleration test.
First, a fresh air comparison is performed.
n 1/min tB s k 1/m Gas T °C M
XXX XXXX -.- X.XX 0 XX -
Current values for temperature and speed are displayed.

The arrow pointing upwards indicates that the unit is waiting for
the throttle burst.
– Depress accelerator pedal fully and hold for specified time.
– Check maximum engine speed (not adjustable).

Sharan 1996 ➤
WARNING
If the governed speed (maximum speed) is exceeded, lift off

accelerator pedal immediately and perform repair measures.
– If the values are not within specified range, a repair measure

must be made.
If the unit detects a valid throttle burst (the speed increases con‐
tinually during measuring period tx), the following is indicated on
display:
XXX XXXX -.- -.- 1 XX -
The display remains “frozen” during the evaluation phase (ap‐

prox. 15 seconds).
After the evaluation phase, the display changes to:
satelettronica
XXX XXXX X.XX X.XX 1 XX -
The arrow pointing upwards indicates that the unit is waiting for
the next throttle burst.
Repeat test 4 times.
The following is indicated on display after each throttle burst:
XXX XXXX X.XX X.XX X XX -
In this way, the unit measures and registers at least four throttle
bursts. After the fourth and for each further throttle burst an aver‐
age of the last three measurements is performed.
AG. Volkswagen AG d
agen oes
The following is indicated on display after each
Vol throttle burst:
ksw not
gu
by ara
ed nte
n 1/min tB s k 1/m Gas T °C M oris eo
XXX XXXX X.XX X.XX X XX - th
au ra
c
ss
After 10 seconds, this display changes to:
ce
e
nl
pt
du
an
itte
y li
tB s k 1/m band width M

erm
ab
Average X.XX X.XX X.XX -

ility
ot p
wit
After 5 seconds, this display changes to:

, is n
h re
hole
spec
tB s k 1/m band width M

es, in part or in w
Average X.XX X.XX XX -

t to the co
The display remains until a further throttle burst is performed or

another measurement is called up.
rrectness of i
If the opacity figures are equal to or less than the prescribed fig‐
ures, cease measurements.
l purpos
But if the determined opacity figures are over the prescribed fig‐
ures, locate fault during a repair measure
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
5.3.2 Exhaust emissions test for diesel en‐

gines without OBD with exhaust emis‐
sions station VAS 6300
Caution
• Observe “SAFETY AND DAMAGE AVOIDANCE PRE‐

CAUTIONS” in the operating instructions for VAS 6300.
Note
The following description refers to vehicles not fitted with “On‐

board diagnosis”, OBD.

♦ Exhaust emissions station - VAS 6300-
satelettronica
AG. Volkswagen AG d
agen oes
ksw
♦ OBD adapter cable - VAS 5052/16- by V ol not
gu
d ara
ise nte
or eo
h
aut ra
Note ss c
ce
e
nl
pt
du
♦ It is only possible to carry out an exhaust emissions test when

an
itte
y li
all units of the exhaust emissions station - VAS 6300- are con‐
erm
ab
nected properly and combined with each other according to

ility
ot p
the operating instructions.

wit
, is n
h re

hole
spec
station - VAS 6300- .

es, in part or in w
t to the co
Test requirements:
rrectness of i

l purpos
• For bar code reading of specified data for EET, the EET data
sheet must be printed out.
nf
ercia

rm
m
atio
m

o
n in
or c
thi

te
sd
iva
o
r

rp
cu
o
display.
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
Initial screen:
– Select button “Exhaust emissions test” -arrow-.
An overview is displayed to selectn Athe
G. Vrespective
olkswagen A EET type. G do
wage es n
Volks ot 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
– Select “EET diesel” -arrow-.
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
The display for warm-up phase appears.

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

Sharan 1996 ➤
– Continue exhaust emissions test according to instructions on

display.
– If the EET specification selection is displayed, select respec‐
tive “EET specification selection” -arrow-.
♦ When exhaust emissions test is performed for the first time,
either select “Standard values”,
♦ Or “Last vehicle” when an exhaust emissions test is to be car‐
ried out again.
– Select “Continue” -item 1- on display.
Vehicle data input:
The vehicle data input menu is displayed.
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Note ised b ara
nte
o r eo
h
ut ra
♦ For new models
ss a
the document previously known as the vehicle c
registration document is now called the vehicle registration
ce
le
un
pt
certificate part 1.
an
d
itte
y li
rm
ab
satelettronica
pe
ility
log book is now called the vehicle registration certificate part
ot
wit
2.
, is n
h re
hole
spec
es, in part or in w
♦ -1- Vehicle manufacturer: “e.g. VOLKSWAGEN - VW” t to the co
♦ -2- Vehicle type: “e.g. Golf”

rrectness of i
♦ -3- Key number for 1: “e.g. 11”

l purpos

ment)
nform
ercia
♦ -4- Key number for 2.1 (code for 2): “e.g. 0603” (vehicle reg‐
m
a
com
tion in

r
te o
thi
ment)
s
iva
do
r
♦ -5- Key number for 2.2 (code for D2): “e.g. 358” (vehicle reg‐
rp
cum
fo

en
ng
t.
yi Co
op
♦ -6- Engine code “e.g. AQY”
C py
t. rig
gh ht
yri by
♦ -7- Registration number: “e.g. WOB-HH 1234”
op Vo
by c lksw
cted agen
Prote
♦ -8- Vehicle identification number: “e.g.
AG.
WVWZZZ1JZYW123456”
– Enter odometer reading at -item 9- “e.g. 32000”.
Note
♦ Further functions can be called up using GoTo button.

♦ The test can be interrupted using GoTo button.

Sharan 1996 ➤
– Select “diesel below 3.5t” or “diesel above 3.5t” -arrow-.

Specified data input for EET:
There are different ways to enter the specified data:
♦ 1) By manual input
Note n AG. Volkswagen AG do

lkswage es n
o ot g
yV
♦ To use the ELSA web service, the VAS 5052 which ir se
dis used for
b ua
ran
the exhaust emissions test, must be integratedth in the work‐
o tee
or
shop network. ss
au ac
ce
e
♦ For the ELSA web service the vehicle specified data are au‐ nl
pt
du
tomatically transmitted via the network to the respective mask.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
satelettronica
spec
Note
es, in part or in w
t to the co
⇒ Data sheets for exhaust emissions test for respective engine.
rrectness of i
l purpos

play.
nf
ercia
or
m
m
atio
om
1- Speed for conditioning
n in
or c
thi
e
2- Number of throttle bursts for conditioning

t
sd
iva
o
r
rp
cu
3- Engine oil temperature (min. value)
o
m
f
en
ng
t.
yi
4- Select engine oil temperature measurement procedure
Co
Cop py
t. rig
gh
5- Idling speed
ht
pyri by
Vo
co lksw
by
cted
6- Governed speed
agen
Prote AG.
7- Rev limit measuring period (1 second)

8- Opacity figure (average)
9- Select probe type (No. of probe)
10 - Select measuring mode
11 - Measured period portion
– When all data have been entered properly, press → button
-arrow-.

Sharan 1996 ➤
All required data is shown on display -1-.

– Press → button -arrow- to continue procedure.
Visual inspection:
– Perform visual check.
– If visual check is OK, press “OK” button -arrow-.
Note
satelettronica
When "not OK" button is pressed, a check will be carried out.
Connecting diagnostic connector:

• Ignition is switched off.
The visual check is displayed with the request to connect the di‐
agnostic connector -arrow A-
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– Follow instructions on display -arrow A- and -arrow B-.

es, in part or in w
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Sharan 1996 ➤
– Connect diagnosis cable connector to EOBD connection.

Conditioning:
– Start engine.
In the conditioning phase the engine and, if necessary, the emis‐
sion control systems are brought to operating temperature by
throttle bursts and are prepared for the exhaust emissions test.
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– Maintain engine speed in required hor engine speed range. eo
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If no conditioning is necessary, press
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→ button -arrow- for the next
ce
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measurement.
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Measuring engine temperature:
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spec
es, in part or in w
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Sharan 1996 ➤
It is automatically switched to display for measuring engine tem‐

perature.
Note
♦ This is only indicated on display if engine temperature has not

reached 80℃.
♦ Do not insert emission probe into exhaust tail pipe.
♦ Using button “Alternative input” -arrow- other measured value
inputs can be selected to measure the engine temperature.
The measured value must then be entered by hand. At end of
exhaust emissions test the measured value is marked by # in
the evaluating mask and in the log print-out.
♦ The button “Alternative input” isnonly
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a dif‐
ferent method has been Voselected
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EET for “Engine oilisemeasurement”.
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Caution
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Measuring the engine temperature is normally carried out via
erm
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the oil temperature probe. The engine temperature must not
ility
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be determined with engine running, otherwise the engine and wit

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probe could be damaged! h re

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spec
es, in part or in w
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– Bring engine to required temperature.

Measuring idling speed:
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It is automatically switched to display for measuring the idling

speed.
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quired level.
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Note
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♦ The measurement can be skipped by pressing the → button,
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i.e. the exhaust emissions test has failed.
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♦ Measured values are reset using ← button, and the test can
be repeated.

-arrow-.
Measuring rev limit:

Sharan 1996 ➤
It is automatically switched to display for measuring rev limit.

quired level.
– Operate throttle until the measurement is carried out. To do
this, immediately depress accelerator pedal.
-arrow-.
Note

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Air quality check: d byV ua
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An air quality check is carried out before
ss
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the free accel‐ ac
eration. When doing this, no emission probe must be in the
ce
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un
exhaust tail pipe. Otherwise measuring errors or faulty signals
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could occur during further measurements.

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– When the air quality check is carried out, insert emission probe
ility
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into exhaust tail pipe
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Free acceleration:
spec
It is automatically switched to display for “Free acceleration”.
t to the co
During “Free acceleration” the engine is revved up to rev limit
without load as quickly as possible.
rrectne
The “Free acceleration” test consists of at least four throttle
bursts.
ss o
Free acceleration - phase 1:
cial p
f inform
mer
– Follow instructions on display -arrow A- and -arrow C-.
atio
om
n
c
– Maintain idling speed in engine speed range indicated i

or
n thi
-arrow D-.
te
sd
iva
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fo
-arrow B-.
en
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Note
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♦ The emissions probe must be in the exhaust tail pipe.
♦ If the speed deviates from engine speed range indicated, the
measurement starts again.
Free acceleration - phase 2:

Sharan 1996 ➤
– Follow instructions on display -arrow B-.

– Depress accelerator pedal fully when prompted and hold until
the prompt for idling is shown on display.
Free acceleration - phase 3: agen
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– Remove foot from accelerator pedal as soon as the prompt ed for
by ara
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idling is shown on display -arrow B- and run enginethat
o idling
ris
eo
speed. s au ra
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s
ce
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The test results and information on the latest “Free acceleration”
un
pt
are shown on display -arrow A-. If the measured values are not
an
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OK, here you can obtain information why the “Free acceleration”
rm
ab
has failed.
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Note
spec
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♦ If the field is coloured white the measured value is within tol‐
erance.
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♦ If the field is coloured red the measured value is outside tol‐
erance.
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♦ If the field is coloured yellow the measured value is outside
tolerance, but can be assessed by the operator.
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Further throttle bursts:
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tion in
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– Follow instructions on display -arrow B-.
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Now the next throttle burst follows, starting with phase 1 of “free
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acceleration”.
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“Free accelerations” can be carried out until: C py
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♦ three “free accelerations” have been completed in succession copy Vo
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♦ all values are OK, with the exception of range of acceleration,

and the test is continued by pressing the → button -arrow C-.
(In this case, the operator assesses if the value is OK).
♦ the values are not OK and the measurement is terminated/
skipped by pressing the → button -arrow C-.
If the measured values are OK after three throttle bursts in suc‐
cession, i.e. all fields are coloured white, the exhaust emissions
test is completed.
Evaluation:
When the exhaust emissions test has been performed, the log is
shown on display.
The test result is displayed.
Now remarks concerning the exhaust emissions test can be en‐
tered -arrow A-. They will then be included in the test log.
– When the exhaust emissions test is classed as passed, select
“EET sticker issued” and the date from drop-down menu
-arrow B-.
– Then confirm with “Yes” -arrow C-.
The exhaust emissions test log is shown on display and can be
printed out as often as required in the menu “Print preview” using
“Print” button -arrow A-.

Sharan 1996 ➤
– Press button “Close” -arrow B- to close the menu “Print pre‐

view ”.
– Take emission probe out of exhaust tail pipe.
– Then press → button -arrow B-.

The exhaust emissions test is completed, a new exhaust emis‐
sions test can be performed. wage
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5.4 Exhaust emissions test for diesel en‐
es, in part or in w
t to the co
gines with OBD
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♦ Exhaust emissions station L - VAS 7320 A-
l purpos
Note
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♦ The following description refers to vehicles fitted with “On‐

com
tio
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♦ The OBD monitors all components and part systems influenc‐

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ing the exhaust emissions quality.

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♦ It is possible to carry out an exhaust emissions test only when

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all units of the exhaust emissions station are connected prop‐ Cop py
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erly and joined to each other according to the operating in‐ gh ht
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structions.
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station .
Conditions for testing

• For bar code reading of specified data for EET, the EET data
sheet must be printed out.
• 12V battery fully charged (if battery charge is too low, raise
idling speed if necessary).

Sharan 1996 ➤

display.
Vehicle data input
– Enter the following data:
♦ Registration number
♦ Key numbers
♦ Vehicle identification number
♦ Fuel type
♦ Mileage
The following vehicle data can be found in the vehicle registration
certificate part 1:
♦ Registration number: “e.g. WOB-HH 1234”
♦ Emission key No. “field 14.1 (code for field 14)”
♦ Vehicle manufacturer: “Field 2”, “Field 2.1 (code for field 2)”
♦ Vehicle identification number “field E”
satelettronica
♦ Type and version “Field D2 (type only)”, “Field 2.2 (code for
field D.2)”
♦ Nominal speed “field P4”
Specified data input for EET AG. Volkswagen AG d
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There are different ways to enter
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♦ 1) By manual input uth o eo
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Note
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♦ If there is no ESP to deactivate the engine speed limiter, the

es, in part or in w
rev limit can be measured using the engine speed limited by

t to the co
the control unit. To do this, all the EET specifications must be

entered manually.
rrectness of i
♦ To use the ELSA web service, the exhaust emissions station

which is used for the exhaust emissions test must be integra‐
l purpos

♦ The ELSA web service automatically transmits the data for the
nform
ercia
specific vehicle via the network to the respective mask (ex‐

ception: nominal speed can only be entered manually).
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tion in
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Sharan 1996 ➤
Note
♦ See ⇒ Data sheets for exhaust emissions test of the respective

engine for the requisite test conditions and data for the emis‐
sions test.
♦ The nominal speed is located in field P4 of the registration
certificate part 1 or field 7 of the vehicle document and must
always be entered manually.
♦ If the engine speed limiter cannot be deactivated, enter the
value 2500 ± 200 rpm in the box for rev limit and 2500 in the
box for engine speed for conditioning.

play.
G. Volkswagen AG d
– Enter displayed values on EET data sheet in column
lksw
agen “Test
A
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not
values for exhaust emissions test” on display
by
Voas follows: gu
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1- Speed for conditioning tho eo
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2- Number of throttle bursts for conditioning
s
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3- Engine oil temperature (min. value)
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4- Select engine oil temperature measurement procedure
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5- Idling speed
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6- Governed speed
spec
es, in part or in w
7- Nominal speed (registration certification part 1, vehicle
t to the co
document)
8- Governed speed measuring period (1 second)
rrectness of i
9- Type plate value ⇒ page 169
l purpos
10 - Select probe type (No. of probe)
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11 - Select measuring mode

m
12 - Measured period portion a

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Note
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♦ When performing the exhaust emissions test, the respective

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engineer must always use the vehicle-specific exhaust emis‐ Cop py
sions limit value indicated on the type plate. ht. rig
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♦ If no value is indicated on the type plate, the opacity figure
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specified by the manufacturer and indicated in ELSA must be
Prote AG.
used.
♦ If no value is indicated on the type plate and no opacity figure
has been specified by the manufacturer, the statutory opacity
figures (2.5 m -1 or 1.5 m -1, depending on date of initial reg‐
istration) must be used.
♦ For all Euro-6-vehicles an opacity figure of max. 0.5 m -1 ap‐
plies.

The nominal speed can only be entered manually.

AG. Volkswagen AG d
agen oes
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Sharan 1996 ➤auth ra
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Maintenance s- Edition 03.2018
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nl
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If the opacity figure on the EET data sheet is different from the
itte
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value indicated on the type plate, enter the type plate value man‐
ab
ility
ually. ot p
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Inspection
h re
hole
spec
– Inspect all exhaust emissions relevant components.
es, in part or in w
t to the co
– Check if exhaust system is fitted and complete and check for
leaks and damage.
rrectness of i
Procedure
l purpos
– Follow instructions from exhaust emissions station .

Evaluation
nform
mercia
at
om
Note
ion
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in t
or
his
e
If the exhaust emissions test was performed at governed speed,

at
do
riv
the log note “governed speed <90 % of the nominal speed (idle
p
cum
or
speed control)” is entered in the log.

f
en
ng
t.
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Cop py
ht. rig
satelettronica
rig ht
py by
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Sharan 1996 ➤
6 Glossary
These explanations only apply to “Maintenance Manual”. They
are not necessarily generally valid!
Term Explanation
ABS (Anti-lock brake system); the ABS is a regulating system in the brake system, that pre‐
vents locking when braking. This helps to maintain directional stability and steerability.
ATF (Automatic transmission fluid); gear oil for automatic gearboxes
ATF level Filling level of ATF in gearbox
CO (Carbon monoxide); is produced when fuels containing carbon are not combusted com‐
pletely
AG. Volkswagen AG d
CN (Cetane number); measurement agen unit for ignition
oequality of diesel fuel
olksw s no
tg
yV
DIN Deutsches Institut d für Normung e.V (German Instituteuafor
b
ris
e ra nteStandardization)
ho eo
Part no. Abbreviations au for part number
t ra
c
s
EN European standard
ce
le
un
pt
EOBD European On-Board Diagnosis
an
d
itte
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rm
ab
satelettronica
FAME Fatty acid methyl ester
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FSI Fuel stratified injection
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TFSI Turbo fuel stratified injection
hole
spec
TSI From model year 2008 the designation TFSI is replaced by TSI. Therefore the desig‐
es, in part or in w
t to the co
nation TSI is given to TSI turbocharger and TSI twincharger.
TSI turbocharger: charging only with turbocharger
TSI twincharger: charging with turbocharger and compressor
rrectness of i
MIL (Malfunction indicator light); corresponds to exhaust emissions warning lamp K83
l purpos
OBD Onboard diagnosis, the OBD monitors all components influencing the exhaust emis‐
sions quality.
nform
ercia
OBD-II American onboard diagnosis

m
a
com
t
Unit injector Unit injector for diesel engines
ion in
r
PR No. Abbreviation for production control number. Identifies among other things optional
te o
thi
equipment and country-specific deviations

s
iva
do
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rp
PM (Particulate matter); soot particulate value for diesel engine emissions

um
fo
en
ng
t.
QG0 Vehicles are “not” factory-fitted with components for LongLife service. For maintenance,
yi Co
op py
the intervals based on time and distance (non-flexible intervals) apply.
. C rig
ht ht
rig by
QG1 Vehicles are factory-fitted with active LongLife service. This means, vehicles have a
copy Vo
by lksw
flexible service interval display and are fitted with the following components:
cted agen
Prote AG.
♦ Flexible service interval display in combi-instrument
♦ Brake lining wear indicator
QG2 The LongLife service is not factory-activated. This means, vehicles have a non-flexible
service interval display (time and distance dependent service intervals) and are fitted
with the following components:
QG3 The LongLife service is not factory-activated. This means, vehicles have a non-flexible
service interval display (time and distance dependent service intervals) and are fitted
with the following components:
6. Glossary 171
Sharan 1996 ➤
Term Explanation
Readiness code 8-digit binary code which indicates if all exhaust relevant diagnoses have been per‐
formed by the engine management.
Volkswagen AG
AG. measurement
RON (Research octane number); agen dounit
es n of the knock resistance of petrol
olksw ot g
V
SAE (Society of Automotive
edb
y Engineers); society which uacreates proposals/guidelines for im‐
ran
plementing ho ri legal requirements (e.g. standards).
s tee
ut or
SD Naturally
ss
a
aspirated diesel engine ac
ce
le
SDI Naturally aspirated diesel engine - direct injection

un
pt
an
d
itte
TDI Turbo diesel direct injection
y li
rm
ab
pe
DP Distributor injection pump
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ULEV Ultra low emission vehicle
h re
hole
SIE Service interval extension
spec
es, in part or in w
Common rail Refers to a common high-pressure injection line (rail), which supplies all cylinders of the
t to the co
relevant cylinder bank with fuel.
DPF Diesel particulate filter, the particulate filter is installed behind the catalytic converter and
filters soot particles of emissions.
rrectness of i
LongLife service The LongLife service enables extremely long inspection or oil change intervals, de‐
l purpos
pending on individual driving style and conditions under which the vehicle is used. For
satelettronica
the LongLife service a special engine oil is required.
nform
ercia
Step-type probe Also called finger probe (LPH lambda probe heating), (FLP flat lambda probe) or planar
lambda probe. The voltage of the output signal of the lambda probe jumps rapidly. The
m
a
com
ti
lambda probe value is determined by a change in voltage. The probe is used as after
on in
catalytic converter probe.
r
te o
thi
s
iva
Broad-band probe Also called (ULP probe) universal lambda probe. The voltage of the output of the lambda
do
r
probe nearly increases linear. The lambda probe value is determined by a change in
rp
cum
fo
voltage. This enables to measure the lambda probe value via a larger measuring range
en
ng
t.
yi
(broad band). The probe is used as before catalytic converter probe.
Co
Cop py
t. rig
TPMS, TPLI Tyre pressure monitoring, tyre monitor display
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
172 6. Glossary

Service: Sharan 1996

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Service

Service Department. Technical Information

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4.4 Swivel joints and suspension link mountings: inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.6 Diesel particulate filter: Reading ash loading level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.7 Automatic gearbox: changing ATF (099 gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.8 Automatic gearbox: Change ATF strainer (099 gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.10 Automatic gearbox: check ATF level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.14 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4.18 Renewing diesel particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4.19 Electric windows: checking positioning (open and close functions) . . . . . . . . . . . . . . . . . . 68

4.20 Carry out vehicle system test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4.21 Boots: inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

4.41 Checking wiper blade setting angle: if wiper blades judder . . . . . . . . . . . . . . . . . . . . . . . . 99

4.42 Wiper blades: Check park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

4.43 Wiper blade protection: removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

4.44 Manual gearbox/final drive: Check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft drive Chain Toothed belt Toothed belt Toothed belt

Engines ⇒ Petrol engine Petrol engine Petrol engine Petrol engine

Displace‐ l 2.8 2.0 1.8 2.8

No. of cylinders/valves per 6/2 4/2 4/5 6/4

Power kW at rpm 128/5800 85/5200 110/5500 150/6200

Torque Nm at rpm 2351/4200 170/2600 to 4200 210/1850 to 4500 265/3400

Bore ∅ mm 81.0 82.5 81.0 81.0

Stroke mm 90.3 92.8 86.4 90.8

Compression ratio 10.0 10.0 9.5 10.5

Injection/ignition Motronic M 3.8.1 Motronic ME 7.5 Motronic ME 7.5 Motronic ME 7.1

Power kW at rpm 66/4000 66/4000 81/4150 66/4000

Torque Nm at rpm 202/1900 210/1900 235/1900 240/1900

Bore ∅ mm 79.5 79.5 79.5 79.5

Engines ⇒ Diesel engine Diesel engine Diesel engine

Engines ⇒ Diesel engine Diesel engine Diesel engine

2.1 Information on long-life service eand time

Service interval display ⇒ page 6

2.1.1 Service identification

– Check vehicle data sticker ⇒ page 39 to determine whether spec

the vehicle is equipped with PR number “QG0”, “QG1” or

“QG2”. The PR number is decisive for the service intervals

“QG1” indicates LongLife service

“QG0” or “QG2” indicates time or distance dependent service

2.1.2 LongLife service

Vehicles with PR number “QG1”

The LongLife service enables long service intervals, depending

♦ Engine oil level sensor

Volkswagen according to predetermined mileage or time values.

service are non-flexible.

♦ or for which the extended servicing interval (ESI) was stopped

the time or distance dependent service applies.

including an engine oil change.

Vehicles are “not” factory-fitted with components for LongLife

2.1.4 Service interval wadisplay

Service interval display: resetting ⇒ page 111

service, input values such as distance driven, fuel consump‐

tion, oil temperature and load of diesel particulate filter are

Non-flexible service interval display (only vehicles with time or

2.2 Service tables

♦ It is also possible, to perform additional work outside the serv‐

inders and it considerably reduces the cleanliness of pis‐

filter should be changed every 7,500 km.

♦ Countries where diesel has a high sulphur content.

♦ If an extremely uneconomical driving style is adopted or the

007 QG1 vehicles flexible from 15,000 km to max.