Service: Sharan 1996

Service
Sharan 1996 ➤
4-cyl. Diesel engine, Mechanics
Engine ID 1Z AFN AHU AVG
Edition 12.2001
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Service Department. Technical Information

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Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Sharan 1996 ➤
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, Valve gear
17 - Lubrication
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19 - Cooling system
20 - Fuel supply system
21 - Charging
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26 - Exhaust bsystem
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Technical information should always be available to the foremen and mechanics, because their careful
and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In
addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course,
be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg 00056606320

Sharan 1996 ➤
4-cyl. Diesel engine, Mechanics - Edition 12.2001
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . l.ks.wa.g.en. A.G.. V. . . . g. e.n A. G. d.oe. s.n . . . . . . . . . . . . . . .1

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1 Technical data . . . . . . . . . . . . . . .se. d.b.y . . .
. . . . . . . . . . . . . . . . . . . . . . . u.a.ra.n . . . . . . . . . . . . .1
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1.1 Technical data . . . . . . . . . . . . .th.or. . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . t.ee. o. . . . . . . . . . .1
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1.2 Engine number . . . . . . . . . .ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a.c . . . . . . . . .1
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1.3 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
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1.1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
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1.2 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
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1.3 Securing engine to support clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
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1.4 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.5 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.6 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
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1.7 Additional information and removal instructions for vehicles with air conditioner . . . . . . . . . .8
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
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1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
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1.1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
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1.2 Removing and installing ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

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1.3 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
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1.4 Checking semi-automatic toothed belt tensioning roller . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

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1.5 Removing injection pump sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
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2 Removing and installing sealing flanges and flywheel/drive plate . . . . . . . . . . . . . . . . . . . .31
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2.1 Removing and installing sealing flanges and flywheel/drive plate . . . . . . . . . . . . . . . . . . . .31
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2.2 Renewing crankshaft oil seal - pulley end - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
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2.3 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
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3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

3.1 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
4.1 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
4.2 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
1.1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
1.3 Checking compressions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
2.1 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
2.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
2.3 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
2.4 Renewing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
2.5 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
2.6 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
2.7 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
1.1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
1.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Contents i
Sharan 1996 ➤
19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
1.1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
1.2 Parts of cooling system body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
1.3 Parts of cooling system - engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
1.4 Dismantling and assembling coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
1.5 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
1.6 Removing and installing radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
20 - Fuel supply system . . . . . .e.n A. G.. V. o.lk.sw. a.ge.n.AG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

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1.1 Removing and ris installing parts of fuel supply system . a.nt.e . . . . . . . . . . . . . . . . . . . . . . . . . . .97
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1.2 Removing au and installing fuel tank with its attachments . . .r a.c . . . . . . . . . . . . . . . . . . . . . . . .98
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1.3 Safety precautions
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1.4 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
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21 - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
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1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
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1.1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
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1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
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1.3 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
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1.4 Removing and installing turbocharger with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
1.5 Removing and installing parts of charge air cooling system . . . . . . . . . . . . . . . . . . . . . . . .114
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1.6 Turbocharger hose/pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
1.7 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
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1.8 Checking turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

1.9 Checking pressure unit for charge pressure regulating valve . . . . . . . . . . . . . . . . . . . . . . . .123
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1.10 Removing and installing pressure unit for charge pressure regulating valve . . . . . . . . . . . .123
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

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1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

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1.1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

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2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128

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2.1 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
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2.2 Removing and installing parts of exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . .128
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2.3 Checking exhaust gas recirculation valve (mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
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ii Contents
Sharan 1996 ➤
4-cyl. Diesel engine,
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1 - Technical data
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1.1 - Technical data
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1.2 - Engine number
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-> The engine number ("Code letters" and "Serial number") can be found between injection pump and vacuum
pump on cylinder block.
Additionally there is a sticker on the toothed belt guard with "Engine code" and "Serial number".
The engine code is also included on the vehicle data plate.
1.3 - Engine data
Code letters 1Z AFN AHU AVG

Manufactured 12.95 ... 07.96 10.96 ▸ 08.96 ▸ 08.99 ▸
Capacity ltr. 1.9 1.9 1.9 1.9
Output kW at rpm 66/4000 81/4150 66/4000 81/4150
Torque Nm at rpm 202/1900 235/1900 202/1900 235/1900
Bore ø mm 79.5 79.5 79.5 79.5
Stroke mm 95.5 95.5 95.5 95.5
Compression ratio 19.5 19.5 19.5 19.5
CN min. 45 45 45 45
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Catalyst x x x x
Exhaust gas recirculation x x x x
Charging x x x x
Charge air cooling x x x x
1.1 - Technical data 1

Sharan 1996 ➤

1.1 - Removing and installing engine
Special tools, testers and auxiliary items
◆ Pliers V.A.G 1921 for spring type clips

◆ Drip tray V.A.G 1306
◆ Engine bracket 3396
◆ Engine/gearbox jack V.A.G 1383 A
◆ Grease G 000 100
(for vehicles with manual gearbox)
◆ V.A.G 1331 Torque wrench (5...50 Nm)
◆ Cable tie
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1.2 - Notes on removing
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- The engine is removed
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- With the ignition
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- Remove battery.
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- All cable ties which are opened or cut open when removing engine, must be replaced in the same position
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- Drain coolant => Page 93 .

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- Remove intake hose and air cleaner housing.

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- Pull fuel supply and return hoses off injection pump.

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- Pull pipe/hose off slave cylinder on gearbox:

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=> 5-Speed manual gearbox 006; Repair group 30; Assembly overview; Hydraulics and clutch release mech‐
anism Assembly overview Hydraulics and clutch release mechanism
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- Remove operating cable from gearbox:

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=> 5-speed manual gearbox 006; Repair group 34; Servicing selector mechanism; Removing and installing
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operating cables Servicing selector mechanism Removing and installing operating cables
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- Remove drive shafts:

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=> Running gear; Repair group 40; Servicing drive shafts; Removing and installing drive shafts. Servicing drive
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- Remove selector lever cable from gearbox:
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2 10 - Removing and installing engine

Sharan 1996 ➤
=> Automatic gearbox 099; Repair group 37; Servicing selector mechanism; Dismantling and assembling se‐
lector mechanism Servicing selector mechanism Dismantling and assembling selector mechanism
- Unbolt drive shafts from gearbox flange shaft and tie up.
Vehicles with air conditioner
- Observe additional information and removal instructions => Page 8 .
Continuation for all vehicles
- Unbolt P.A.S. hydraulic pipe at engine support.
=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes Assembly over‐
view: vane pump, reservoir, hydraulic pipes
- Remove power assisted steering vane pump with bracket and secure to body with wire; hoses remain con‐
nected.
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- Remove front exhaust pipe => Page ris 126 , removing and installing
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Insert engine bracket 3396 in engine/gearbox jack V.A.G 1383 A. eo
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- -> Fit engine bracket 3396 on cylinder block and tighten securing bolts -1- to 40 Nm.
- Remove pendulum support.
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=> Running gear; Repair group 40; Servicing front wheel mounting; I - Assembly overview, assembly carrier,
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anti-roll bar, wishbone Servicing front wheel mounting I - Assembly overview, assembly carrier, anti-roll bar,
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- -> Remove counter weight securing nuts -2-.
1.2 - Notes on removing 3

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- Unbolt right assembly mounting yV
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- -> Unbolt assembly mounting, left securing bolts -A-.
- Lower assembly carefully.
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The assembly must be carefully guided when lowering, to prevent damage to the bodywork.
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1.3 - Securing engine to support clamp
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When working on the engine, it should be secured to engine bracket VW 540 using support clamp VW 313.
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◆ Workshop crane V.A.G 1202 A

◆ Lifting tackle 2024 A
◆ Engine/gearbox bracket VW 540
◆ Supplementary set VW 540/1 A
◆ Support clamp VW 313
Work sequence
- Remove gearbox.
- Bolt engine/gearbox bracket VW 540 with supplementary set VW 540/1 A on cylinder block.
- -> Attach lifting device 2024 A as follows and lift engine out of engine/gearbox jack using workshop crane.
Pulley end:
4th hole in hook at position 1
Flywheel end:
4th hole in hook at position 8

Sharan 1996 ➤
Warning!
The hooks and locating pins must be secured with locking pins.
Notes:
◆ The positions marked 1...4 on the bar must be towards the pulley end.
◆ The holes in the hook rails are counted up from the hook.
- Fit engine in support clamp VW 313 using workshop crane V.A.G 1202 A.
1.4 - Notes on installing
Installation is carried out in the reverse sequence, when doing this note the following:
- Check release bearing in slave cylinder for wear, renew slave cylinder with release bearing if necessary.
- Clean input shaft splines and lightly grease with G 000 100.
satelettronica
- Check whether the dowel sleeves for centring engine/gearbox are in the cylinder block and install if neces‐
sary.
- Screw in all bolts on assembly mountings by hand approx. 5...6 turns.
- Align assembly mountings stress-free by rocking.
Note:
Assembly mounting tightening torques
=> Page 7 .
n AG. Volkswagen AG do
lkswage es n
o ot g
- Install pendulum d byV support: ua
ran
ir se tee
ho
=> Running
s aut
gear; Repair group 40; Servicing front wheel or
acmounting; I - Assembly overview, assembly carrier,
anti-roll bar, wishbone Servicing front wheel mounting I - Assembly overview, assembly carrier, anti-roll bar,
s
ce
e
wishbone
nl
pt
du
an
itte
y li
- Installing air conditioner compressor:

erm
ab
ility
ot p
wit
=> Heating, Air conditioning; Repair group 87; removing and installing compressor bracket removing and in‐
, is n
h re
stalling compressor bracket

hole
spec
es, in part or in w

t to the co
- Connect pipe/hose on slave cylinder and secure with clip:

rrectness of i
=> 5-Speed manual gearbox 006; Repair group 30; Assembly overview; hydraulics and clutch release mech‐
l purpos
anism Assembly overview hydraulics and clutch release mechanism
- Attach operating cable to gearbox, adjust if necessary:

nf
ercia
orm
m
=> 5-Speed manual gearbox 006; Repair group 34; Servicing selector mechanism; Removing and installing
atio
m
operating cables Servicing selector mechanism Removing and installing operating cables
o
n in
or c
thi
te
- Install drive shafts.

sd
iva
o
r
rp
cu
o
m
f
=> Running gear; Repair group 40; Servicing drive shafts; Removing and installing drive shafts Servicing drive
en
ng
t.
yi
shafts Removing and installing drive shafts
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.3 - Securing engine to support clamp 5

Sharan 1996 ➤
Vehicles with automatic gearbox
- Install selector cable on gearbox, adjust if necessary:
=> Automatic gearbox 099; Repair group 37; Servicing selector mechanism Servicing selector mechanism
- Install drive shafts.
- Install P.A.S. vane pump with bracket:
=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes; Installing vane
pump. Assembly overview: vane pump, reservoir, hydraulic pipes Installing vane pump.
- Install front exhaust pipe => Page 126 , removing and installing parts of exhaust system.
- Fill with coolant => Page 93 n AG. Volkswagen AG do
- Electrical connections and routing: wage es n
olks ot
yV gu
db ara
se
=> Current flow diagrams, Electrical fault finding ri and Fitting locations nte
satelettronica
tho eo
s au ra
c
s
- Matching engine electronics control unit to electronic immobilizer
ce
e
nl
pt
du
an
itte
=> Repair group 23; Servicing Diesel direct injection system; Matching engine electronics control unit to elec‐
y li
erm
ab
tronic immobilizer Servicing Diesel direct injection system Matching engine electronics control unit to electronic
ility
ot p
immobilizer
wit
, is n
h re
- Interrogate fault memory:
hole
spec
es, in part or in w
=> Repair group 01; Self-diagnosis; Interrogating fault memory Self-diagnosis Interrogating fault memory
t to the co
rrectness of i
1.5 - Tightening torques
l purpos
Bolted connec‐ Tightening torque

tion nform
ercia
Engine to gear‐ M10 60 Nm

m
at
box
om
ion
c
in t
M12 80 Nm
or
his
ate
Hydraulic pipe to engine support 20 Nm

do
priv
cum
Starter to engine and gearbox 45 Nm

for
en
ng
t.
Hydraulic pipe to engine support 20 Nm
yi Co
Cop py
Drive shafts to flanged shafts (vehi‐ 80 Nm
ht. rig
rig ht
by
cles with automatic gearbox) copy Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
1.6 - Assembly mountings
satelettronica
Tightening torques
(Bolts oiled)
-> Assembly mounting, right:
A = 60 Nm
B = 55 Nm
C = 30 Nm
AG. Volkswagen AG d
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-> Assembly mounting, left on vehicles with manual gearbox:

erm
ab
ility
A = 55 Nm
ot p
wit
B = 110 Nm
is n
h re
C = 100 Nm
ole,
D = 20 Nm + 1/4 turn (90°) further1)

spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
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Cop py
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rig ht
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7
by lksw
cted agen
Prote 1.6 - Assembly mountings
AG.
Sharan 1996 ➤
-> Assembly mounting, left on vehicles with automatic gearbox:
A = 55 Nm
B = 110 Nm
C = 60 Nm
1.7 - Additional information and removal instructions for vehicles with air conditioner
Warning!
The air conditioning system refrigerant circuit must not be opened.
Note:
The opening of the refrigerant circuit can only be carried out in workshops, which have trained personnel and
the necessary range of tools and workshop equipment.
To facilitate removing and installing the engine without opening the refrigerant circuit:
satelettronica
- Remove retaining clamp(s) from refrigerant pipes.
- Remove ribbed belt => Page 23 .
- Remove alternator:
=> Electrical system; Repair group 27; alternator with ribbed belt, 4-Cyl. Diesel engine alternator with ribbed
belt, 4-Cyl. Diesel engine
. Volkswagen AG
gen AG does
- Removing air conditioner compressor:
Vol
ksw
a
not
y gu
db ara
se nte
=> Heating, Air conditioning; Repair
ho
ri group 87; removing and installing compressor eo bracket removing and in‐
ut
stalling compressor bracketss a ra
c
ce
le
un
pt
- Secure air conditioner compressor to body so that the refrigerant hoses/pipes are relieved.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
13 - Crankshaft group
1 - Dismantling and assembling engine

AG. Volkswagen AG d
agen oes
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1.1 - Dismantling and assembling engine
o
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un
pt
an
d
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erm
ab
ility
ot p
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is n
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ole,
spec
t to the co
satelettronica
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Notes:
◆ If during repair work, metal shavings or larger quantities of small metal particles are found in the engine oil
- caused, for example, by partial seizure of the crankshaft and conrod bearings - then, apart from thoroughly
cleaning out the oil passages, it is necessary to renew the oil cooler.
◆ Defective injectors can cause violent knocking noises in the engine which sound like defective bearings.
When this occurs, run engine at idling speed and slacken off injector pipe unions one after the other. If
knocking stops when a union is loosened, this indicates that the injector concerned is defective.
1.1 - Dismantling and assembling engine 9

Sharan 1996 ➤
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
Servicing injectors.
spec
t to the co
=> Repair group 23; Diesel direct injection system; Servicing injectors Diesel direct injection system Servicing
injectors
rrectne
I =>Page 11
II =>Page 16
ss o
cial p
f in
III =>Page 19
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
10 13 - Crankshaft group
Sharan 1996 ➤
AG. Volkswagen AG d
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ise nte
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aut ra
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ce
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nl
pt
du
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itte
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erm
ab
ility
satelettronica
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
Part I
t.
yi Co
Cop py
t. rig
gh
1 55 Nm
ht
pyri by
Vo
o
by c
2 20 Nm
lksw
cted agen
Prote AG.
3 Engine support bracket
4 Toothed belt guard - upper part
5 Toothed belt
◆ Mark D.O.R. before removing
◆ Check for wear
◆ Do not kink
◆ Removing, installing and tensioning
=> Page 25
6 Eccentric
7 Tensioning roller
◆ Checking => Page 30
◆ Tensioning toothed belts
=> Page 25

Sharan 1996 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
8 45 Nm
9 Camshaft sprocket
◆ Drive off camshaft taper using hammer and drift through toothed belt guard openings
10 25 Nm
11 Idler wheel
12 10 Nm
13 Rear toothed belt guard
14 Retaining clip
15 Injection pump sprocket
16 Intermediate shaft sprocket
17 Crankshaft toothed belt sprocket
Sharan 1996 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
r
satelettronica
o
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
18 90 Nm + 1/4 turn (90 °) further

◆ Counter-hold with 3099 to loosen and tighten
◆ Renew
◆ Oil threads and shoulder
◆ The quarter turn further can be done in several stages.
19 Injection pump
◆ Removing and installing:
=> Repair group 23; Diesel direct injection system; Removing and installing injection pump Diesel direct injec‐
tion system Removing and installing injection pump
20 Woodruff key
◆ Check for tight fit
21 Bracket
22 Console
23 Toothed belt guard - lower part

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
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erm
ab
ility
ot p
wit
24 Pulley
, is n
h re
◆ For coolant pump

hole
spec
◆ Version for ribbed belt

es, in part or in w
t to the co
25 Ribbed belt
◆ Mark direction of rotation before removing
◆ Removing and installing
rrectness of i
=> Page 23
26 Belt pulley/vibration damper
l purpos
◆ Can only be installed in one position. Holes are off-set

27 V-belt
nform
ercia
◆ Adjusting V-belt tension:

m
at
om
ion
=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir and hydraulic pipes Assembly
c
in t
or
overview: vane pump, reservoir and hydraulic pipes

his
ate
do
priv
28 Belt pulley
um
for
en
ng
◆ For coolant pump

t.
yi Co
op
◆ V-belt version C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
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V gu
d by ara
ise nte
or eo
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aut ra
ss c
ce
le
un
pt
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d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
29 Belt pulley
rrectness of i
30 Dust cap
l purpos
31 Tensioning lever
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
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ara
ed
ris nte
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aut ra
ss c
ce
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nl
pt
du
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ility
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wit
, is n
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hole
spec
Part II
es, in part or in w
t to the co
1 Cylinder head cover

2 Cap
rrectness of i
◆ Renew seal if damaged

l purpos
3 Upper sealing washer

4 Dished washer
nform
ercia
5 10 Nm
6 Cap
m
at
om
io
7 To intake hose
n
c
in t
or
8 Retaining clip
his
ate
do
riv
9 Pressure regulating valve

p
cum
or
◆ For crankcase breather

f
en
ng
t.
yi
10 Gasket
Co
Cop py
. rig
◆ Renew if damaged
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Sharan 1996 ➤
satelettronica
lkswage es n
o ot g
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d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
11 Crankcase breather
12 Cylinder head cover gasket
rrectness of i
◆ Insert projections into holes on cylinder head
l purpos
13 Cylinder head bolt

◆ Note sequence when loosening and tightening
nform
ercia
=> Page 56 , removing and installing cylinder head

14 Lower sealing cone
m
a
com
tio
15 Injector pipes
n in
r
te o
◆ Tighten to 25 Nm
thi
s
iva
◆ Remove with 3035

do
r
◆ Always remove pipework complete

rp
cum
fo
◆ Do not alter shape

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

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
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erm
ab
ility
ot p
wit
, is n
16 Cylinder head
h re
hole
spec
=> Page 51
es, in part or in w
t to the co
◆ If replaced renew the complete
coolant
17 Cylinder head gasket rrectness of i
◆ Renew
◆ Note marking
l purpos
=>Page 49
nf
ercia
coolant
orm
18 20 Nm
m
atio
m
19 Lifting eye
o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
satelettronica
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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cu
o
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
Part III
agen
Prote AG.
1 Cylinder block
◆ Removing and installing sealing flange and flywheel/drive plate => Page 31
◆ Removing and installing crankshaft => Page 38
◆ Dismantling and assembling pistons and conrods
=> Page 42
2 O-ring
3 Turn 20 Nm + 1/4 turn (90 °)
further
◆ Renew
4 Vacuum pump
5 Clamp
6 20 Nm

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
8 Gasket
◆ Renew
9 Banjo bolt, 25 Nm
10 To turbocharger
11 Seal
◆ Renew
12 25 Nm
13 Oil filter bracket
14 Oil cooler
◆ Coat contact area to flange, outside the seal, with AMV 188 100 02
◆ Ensure clearance to adjacent components
◆ See note
=> Page 9
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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ara
ed
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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
satelettronica
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
15 Oil filter
◆ Loosen with strap wrench
◆ Tighten by hand
◆ Note instructions on filter when installing
16 10 Nm
17 Engine speed sender (G28)
◆ Checking:
18 Clamp
19 Spreader rivet
20 Sump cover
21 Tensioning element
22 Sealing ring

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
satelettronica
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
23 30 Nm
24 Bracket
25 Tensioning lever
26 Hammer head bolt
27 Coolant pump
◆ Dismantling and assembling => Page 92
28 Sump
◆ Clean sealing surface before installing
29 20 Nm
◆ Remove and install both rear bolts gearbox end with jointed spanner 3185
30 Bracket
◆ For vane pump
AG. Volkswagen AG d
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ed
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ra
Sharan 1996 ➤
a
ss 4-cyl. Diesel engine, c Mechanics - Edition 12.2001
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
satelettronica
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
31 Gasket
◆ Renew
◆ Before fitting gasket coat sump flange/cylinder block flange with "D2"
32 Woodruff key
◆ Check for tight fit
1.2 - Removing and installing ribbed belt
Note:
Before removing the ribbed belt mark the direction of rotation. When installing the belt ensure it is correctly
seated in the pulley.
◆ Lever 3299

Sharan 1996 ➤
Removing ribbed belt
AG. Volkswagen AG d
agen oes
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byV gu
ara
ed
ris nte
ho eo
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ss c
ce
e
nl
pt
du
an
itte
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- -> Lift tensioning roller with lever 3299 and remove ribbed belt from the alternator pulley. erm
ab
- Remove power assisted steering vane pump V-belt:
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
- Remove ribbed belt.
satelettronica
Installing ribbed belt
rrectness of i
- Place ribbed belt on crankshaft pulley/vibration damper.
l purpos
- Fit power assisted steering vane pump V-belt:
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.
- Lift tensioning roller with 3299 and fit ribbed belt.
-> Belt drive without air conditioner compressor
Sharan 1996 ➤
-> Belt drive with air conditioner compressor
1.3 - Removing and installing toothed belt
◆ Lever 3299
◆ Setting bar 2065 A
◆ Pin 2064
◆ Pin wrench Matra V159 n AG. Volkswagen AG do
◆ V.A.G 1331 Torque lkswage
wrench (5...50 Nm) es n
o ot g
yV
◆ V.A.G 1332sTorque
ed
b wrench (40...200 Nm) ua
ran
ri tee
utho or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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satelettronica
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
With engine removed:

nf
ercia
◆ TDC setting device 2068 A

rm
m
atio
om
Removing
n in
or c
thi
te
sd
a

iv
o
r
rp
cu
- Remove ribbed belt tensioning roller.

o
m
f
- -> Unscrew counter weight securing nuts -2- and remove counter weight.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> Remove securing bolts -1- and -2- and remove engine mounting -3-.
- Remove upper toothed belt guard and cylinder head cover.
1.2 - Removing and installing ribbed belt 25

Sharan 1996 ➤
- -> Turn crankshaft to TDC No. 1 cylinder -arrow-.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
- -> Turn crankshaft
aut to TDC No. 1 cylinder (vehicles with automatic ra
c
gearbox):
Turn crankshaft
ss
until the TDC marking on the drive plate and the sight hole reference edge align -arrows-.
ce
e
nl
pt
du
an
Engine removed:
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c

in t
or
his
ate
do
riv
- -> Install adjustment device 2068 A as shown.

p
cum
or
- Set adjustment device to 96 mm -arrow A-. The left-hand notch of the vernier scale is reference point.
f
en
ng
- Turn crankshaft until flywheel TDC marking aligns with point of setting device -arrow B-.
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Sharan 1996 ➤
Vehicles with automatic gearbox
lkswage es n
o ot g
- -> Install adjustment device 2068 A as shown. d byV ua
r
- Set adjustment device to 75 mm -arrow A-. o
ir seThe left-hand notch of the vernier scaleanis teereference point.
- Turn crankshaft until the TDC markingaonu drive plate aligns with point of setting deviceo-arrow
th
ra B-.
ss c
ce
le

un
pt
an
d
itte
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rm
ab
pe
satelettronica
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
- -> Lock camshaft with setting bar.

m
a
- Centralize setting bar as follows:
com
tion in
Turn camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge establish the
r
te o
thi
gap at the other end of the setting bar. Place a feeler gauge corresponding to half the gap between setting
s
iva
bar and cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd feeler do
r
rp
gauge, of same thickness, at the other end between setting bar and cylinder head.
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> Lock injection pump sprocket with pin.

- Loosen tensioner.
- Remove vibration damper and belt pulley.
- Remove lower toothed belt guard.
- Mark D.O.R. of toothed belt.
- Remove idler roller.
- Take off toothed belt.
1.3 - Removing and installing toothed belt 27

Sharan 1996 ➤
Installing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
- Check whether TDC mark on flywheel and reference mark are aligned.
itte
y li
erm
ab
ility
Note: ot p
wit
, is n
h re
Never use setting bar as a counter hold when loosening and tightening the camshaft sprocket, use retainer
hole
3036.
spec
es, in part or in w
t to the co
- -> Loosen camshaft sprocket securing bolt 1/2 turn. Release camshaft sprocket from camshaft taper by
satelettronica
tapping with a hammer (using a drift through rear toothed belt guard opening).
- Fit toothed belts (note D.O.R.) on crankshaft toothed belt sprocket, intermediate wheel, injection pump
rrectness of i
sprocket and tensioning roller.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
- Fit camshaft sprocket together with toothed belt and locate with securing bolt (camshaft sprocket can still
turn).
- Install idler roller.
Tightening torque: 25 Nm
- -> Turn tensioning roller with pin wrench (e.g. Matra V159) to right until notch aligns with raised portion
(arrows).
Note:
If the eccentric has been turned too far the tensioning roller must be relieved completely and retensioned. The
eccentric must never be turned back when it has been turned too far.
- Tighten lock nut on tensioning roller.
Tightening torque: 20 Nm
- Check again whether TDC mark on flywheel and reference mark are aligned.
- Tighten camshaft sprocket securing bolt to
45 Nm.
- Remove setting bar.
- Turn crankshaft two rotations in engine D.O.R. until crankshaft is set to TDC No. 1 cylinder again.
- Check if
the TDC marking on the flywheel
the setting bar in the camshaft
the tensioning roller adjustment (notch/raised mark)
aligns.
Sharan 1996 ➤
4-cyl. Diesel
a n AG. VolkswMechanics
geengine,
agen AG
do - Edition 12.2001
ksw esn
Vol ot g
by ua
- If notch and raised mark do not align, tension
ris
ed the tensioning roller. To do this, holdrantensioning
te roller with pin
wrench Matra V159, loosen securing nut, ut
h turn eccentric clockwise further until notcheand
o
or raised mark align
opposite one another and tighten securing
ss
a
nut to 20 Nm. ac
- Install toothed belt guard, vibration damper, belt pulley, and cylinder head cover.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
- -> Attach engine mounting -3- with securing bolts -1- and -2-.
m
- Tighten securing bolts -2- to
at
om
io
20 Nm
n
c
in t
r
and securing bolts -1- to

o
his
te
55 Nm.
a
satelettronica
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.
- -> Tighten counter weight securing nuts -2- to 30 Nm.

- Install ribbed belt => Page 23 .
- Checking injection pump commencement of delivery:
=> Repair group 23; Servicing Diesel direct injection system; Dynamically checking and adjusting injection
pump commencement of delivery. Servicing Diesel direct injection system Dynamically checking and adjusting
injection pump commencement of delivery.
1.3 - Removing and installing toothed belt 29

Sharan 1996 ➤
1.4 - Checking semi-automatic toothed belt tensioning roller
Test conditions
• Toothed belt installed and tensioned
Test sequence
satelettronica
- -> Tension toothed belt with firm thumb pressure.
Notch and raised portion -arrows- must move apart.
- Release thumb pressure on toothed belt. The tensioning roller must move back to its initial position. (Notch
and raised portion align again).
1.5 - Removing injection pump sprocket olkswage es n
ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
◆ Puller 3032
nform
mercia
Work sequence
a
com
tion in
r
te o
- Remove injection pump sprocket securing nut.

thi
s
iva
- -> Loosen puller arms and offer up.

do
r
- Locate puller arms through holes in injection pump sprocket and tighten.
rp
cum
fo
- Place injection pump sprocket under tension with puller.

en
ng
t.
yi
- Release injection pump sprocket from injection pump taper by tapping on spindle of puller -arrow- (thereby
Co
op py
hold sprocket so that it does not fall off).
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Sharan 1996 ➤
2 - Removing and installing sealing flanges and flywheel/drive plate

2.1 - Removing and installing sealing flanges and flywheel/drive plate
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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
Note: rrectness of i
l purpos
For repairs to the clutch:

nf
ercia
=> 5 Speed manual gearbox 006; Repair group 30; servicing clutch servicing clutch
orm
m
atio
1 Oil seal
om
n in
c
◆ To remove oil seal, remove sealing flange

or
thi
e
◆ Install with 10-203

t
sd
iva
◆ Lightly oil sealing lip

o
r
rp
cu
o
2 Woodruff key
f
en
ng
t.
yi
◆ Ensure tight fit
Co
Cop py
t. rig
3 25 Nm gh ht
pyri by
Vo
4 Sealing flange
o
by c lksw
cted agen
Prote AG.
2.1 - Removing and installing sealing flanges and flywheel/drive plate 31

Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
5 Gasket
rm
ab
pe
ility
◆ Renew
ot
wit
, is n
6 Cylinder block
h re
hole
◆ Removing and installing crankshaft => Page 38

spec
◆ Dismantling and assembling pistons and conrods

es, in part or in w
t to the co
=> Page 42
7 60 Nm + 1/4 turn (90 °) further
◆ Renew
rrectness of i
8 Flywheel/drive plate
l purpos
◆ Engine codes AFN, AVG with twin mass flwheel

◆ Engine codes 1Z, AHU with single mass flywheel
◆ To remove and install flywheel counter-hold with 3067
nform
ercia
◆ Removing and installing drive plate =>Page 35

m
9 Intermediate plate
com
tion in
◆ Must be located on dowel sleeves

r
te o
thi
◆ Do not damage/bend when assembling

s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Sharan 1996 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
satelettronica
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
10 10 Nm
co lksw
by
cted agen
Prote
11 Sealing flange with oil seal
AG.
◆ Only renew complete

◆ Lightly oil sealing lip of oil seal
12 Oil seal
◆ Renewing => Page 33
13 Intermediate shaft
14 O-ring
15 Sealing flange intermediate shaft
2.2 - Renewing crankshaft oil seal - pulley end -
◆ Counter-hold tool 3099

◆ Oil seal extractor 2085
◆ Oil seal fitting tool 3083
2.1 - Removing and installing sealing flanges and flywheel/drive plate 33

Sharan 1996 ➤
Removing

- Remove toothed belt => Page 25 .
- Remove crankshaft sprocket. To do this counter-hold sprocket with 3099.
- -> To guide the oil seal extractor, screw bolt from 3083 into crankshaft as far as it will go.
- Unscrew inner part of the oil seal extractor 2085 two turns (approx. 3 mm) out of the outer part and lock with
knurled screw.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
- -> Lubricate threaded head of oil seal extractor, place it in position and exerting firm pressure screw it as
ility
ot p
far as possible into oil seal.

wit
, is n
- Loosen knurled screw and turn inner part against crankshaft until the oil seal is pulled out.
h re
hole
spec
Installing
es, in part or in w
t to the co
- Lightly oil sealing lip of oil seal.

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
- -> Place guide sleeve from 3083 onto crankshaft journal.
py by
co Vo
by lksw
- Slide oil seal over guide sleeve. Prote
cted AG.
agen
Sharan 1996 ➤
- -> Press oil seal in onto stop with press sleeve from 3083.
- Install and tension toothed belt => Page 25
2.3 - Removing and installing drive plate
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Loosening and tightening drive plate

nform
mercia
- -> Secure counter-hold tool VW 558 to the drive plate with a hexagon bolt M8x45. Place two M10 hexagon
com
tio
nuts between counter-hold tool and drive plate.

n in
r
te o
thi
s
iva
Position of counter-hold tool:

do
r
rp
A - To loosen
um
fo
B - To tighten
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2.2 - Renewing crankshaft oil seal - pulley end - 35

Sharan 1996 ➤
Installing drive plate
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,
satelettronica
spec
t to the co
rrectness
- -> Locate drive plate and packing plate with recesses -1-.
o
cial p
- Fit new bolts -3- and tighten to

inform
30 Nm.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
- -> Check dimension -a- at three points and calculate average.

Specification: 19.5...21.1 mm
If the specification is not attained:
Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u
a drive plate again and fit shim -2-. Again tightenr abolts
- -> Remove
ss c -3- to
30 Nm.
ce
e
nl
pt
- Tighten bolts -3- to 60 Nm and turn

du
an
itte
90° (1/4 turn)

y li
erm
ab
further (the additional 1/4 turn can be done in several stages).

ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.3 - Removing and installing drive plate 37

Sharan 1996 ➤
3 - Removing and installing crankshaft

3.1 - Removing and installing crankshaft
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f i
1 Bearing shells 1, 2, 4 and 5

nform
mer
◆ For bearing caps without oil groove

atio
◆ For cylinder block with oil groove

om
◆ Do not interchange used bearing shells (mark)

c
i
or
n thi
e
2 65 Nm + 1/4turn (90 °) further

t
sd
iva
◆ Renew
pr
cum
r
fo
◆ To measure radial clearance tighten to 65 Nm but not further

en
ng
t.
yi
3 Bearing cap
Co
Cop py
t. rig
◆ Bearing cap 1: Pulley end yri
gh by
ht
◆ Bearing cap 3 with recesses for thrust washers cop Vo
by lksw
◆ Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side
cted agen
Prote AG.
AG. Volkswagen AG d
agen
olksw
oes
not Sharan 1996 ➤
yV gu
e4-cyl.
d b Diesel engine, Mechanics ara- Edition 12.2001
nte
ris
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
satelettronica
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4 Bearing shell 3
◆ For bearing cap without oil groove
◆ For cylinder block with oil groove
5 Thrust washer
◆ For bearing cap 3
◆ Note fixing arrangement
6 Sender wheel
◆ For speed sender
7 10 Nm + 1/4 turn (90 °) further
◆ Renew
8 Fitted pin
◆ Checking projection from crankshaft => Fig. 1
3.1 - Removing and installing crankshaft 39

Sharan 1996 ➤
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
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
9 Crankshaft
m
at
◆ Axial clearance new: 0.07...0.17 mm

om
ion
Wear limit: 0.37 mm

c
in t
or
◆ Check radial clearance with Plastigage

his
ate
New: 0.03...0.08 mm
do
priv
Wear limit: 0.17 mm

um
for
en
◆ Do not rotate the crankshaft when checking the radial clearance

ng
t.
yi Co
◆ Crankshaft dimensions Cop py
=> Page 41
t. rig
gh ht
pyri by
10 Thrust washer
co Vo
by lksw
cted agen
◆ For cylinder block, bearing 3
Prote AG.
Sharan 1996 ➤
-> Fig. 1 Checking fitted pin projection out of crankshaft
Dowel pin projection -3- out of crankshaft

a =2.5...3.0 mm
3.2 - Crankshaft dimensions
satelettronica
(in mm)
Honing Main journal Conrod

dimension -ø journal-ø
Basic -0.022 -0.022
dimension 54.00 47.80
-0.042 -0.042
1st undersize -0.022 -0.022
agen
AG. Volkswagen AG d
oes
53.75 o lksw
47.55 not
V gu
by
-0.042 rised -0.042 ara
nte
o eo
2nd undersize -0.022 aut h -0.022 ra
53.50 ss 47.30 c
ce
le
-0.042 -0.042
un
pt
an
d
3rd undersize -0.022 -0.022

itte
y li
rm
53.25 47.05
ab
pe
ility
-0.042 -0.042
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.
3.1 - Removing and installing crankshaft 41

wage es n
Sharan 1996 ➤ yV
olks ot g
b ua
4-cyl. Diesel engine, ir se Mechanics - Edition 12.2001 ante
d r
tho eo
au ra
4 - Dismantling and assembling pistons and conrods ss c
ce
le
un
pt
an
d
4.1 - Dismantling and assembling pistons and conrods
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
satelettronica
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1 Piston ring
◆ Offset gaps by 120 °
◆ Remove and install with piston ring pliers
◆ "TOP" faces towards piston crown
◆ Checking ring gap=> Fig. 1
◆ Checking ring to groove clearance
=> Fig. 2
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
satelettronica
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
2 Piston
o
m
f
en
ng
◆ Mark installation position and cylinder number

t.
yi Co
op
◆ Installation position and piston/cylinder allocation => Fig. 4 C py
ht. rig
◆ Arrow on piston crown points to pulley end rig ht
py by
◆ Install using piston ring clamp
co Vo
by lksw
cted agen
◆ Cracks on piston skirt, renew piston Prote AG.
◆ Checking piston projection at TDC
=>Page 49
3 Piston pin
◆ If difficult to remove, heat piston to 60 °C
◆ Remove and install with VW 222a
4 Circlip
4.1 - Dismantling and assembling pistons and conrods 43

Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
5 Conrod
rm
ab
pe
ility
◆ Only renew as a set
ot
wit
, is n
◆ Mark cylinder number -A-

◆ Installation position: h re
hole
spec
Marking -B- faces towards pulley end
es, in part or in w
6 Bearing shell
t to the co
◆ Note version:
for engine codes AFN, AVG upper bearing shell (towards piston) of more durable material
rrectness of i
Identification:
Black line on bearing surface in area of separating point
l purpos
◆ Note installation position

◆ Do not interchange used bearing shells
◆ Ensure retaining lugs fit tightly in recesses
nform
ercia
◆ Axial clearance
m
Wear limit: 0.37 mm

a
com
tio
◆ Check radial clearance with Plastigage:

n in
Wear limit: 0.08 mm

r
te o
thi
Do not rotate crankshaft when checking radial clearance

s
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Cop py
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Prote AG.
Sharan 1996 ➤
satelettronica
lkswage es n
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nl
pt
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7 Cylinder block
h re
hole
◆ Checking cylinder bores
spec
=>Fig. 3
es, in part or in w
t to the co
◆ Piston and cylinder dimensions
=>Page 50
8 Conrod bearing cap rrectness of i
l purpos
9 Fitted pin
◆ The fitted pin must seat securely in the conrod, not in the bearing cap
nform
ercia
10 Oil spray jet

◆ For piston cooling
m
at
om
io
11 10 Nm
n
c
in t
or
◆ Install with AMV 188 100 02

his
ate
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cum
for
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Cop py
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pyri by
Vo
co lksw
by
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Prote AG.

Sharan 1996 ➤
AG. Volkswagen AG d
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nl
pt
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es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nf
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Cop py
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Prote AG.
12 Conrod bolt, 30 Nm + 1/4 turn (90 °) further

◆ Renew
◆ Oil threads and contact surface
◆ To measure radial clearance use old bolts
-> Fig. 1 Checking piston ring gap
- Push ring squarely from above down to approx. 15 mm from bottom end of cylinder.
Sharan 1996 ➤
Piston ring Gap

New Wear
limit
Compression rings mm 0.20...0.40 1.0
Oil scraper ring mm 0.25...0.50 1.0
satelettronica
-> Fig. 2 Checking ring to groove clearance
AG. Volkswagen AG d
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Clean groove before check. horis nte
eo
aut ra
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Piston ring New Wear limit
ce
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nl
Dimensions in mm pt
du
an
itte
1st Compression ring 0.06...0.09 0.25 y li

erm
ab
ility
2nd compression ring 0.05...0.08 0.25
ot p
wit
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Oil scraper ring 0.03...0.06 0.15

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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Cop py
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Prote AG.

Sharan 1996 ➤
-> Fig. 3 Checking cylinder bores
satelettronica
◆ Internal dial gauge 50...100 mm
- Take measurements at 3 positions in both lateral -A- and longitudinal -B- directions, as illustrated. Deviation
from nominal dimension
max. 0.10 mm
Note:
Measuring the cylinder bores must not be done when the cylinder block is mounted on a repair stand with
adapter bracket VW 540, as incorrect measurements would then be possible.gen AG
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-> Fig.4 Piston installation position and piston/cylinder allocation

l purpos
Piston in cylinders 1 and 2:

nform
mercia
Larger inlet valve chamber towards flywheel -arrows-

a
com
tion in
r
te o
Piston in cylinders 3 and 4:

thi
s
iva
do
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rp
Larger inlet valve chamber towards belt pulley side -arrows-.

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Prote AG.
Sharan 1996 ➤
Note:
New piston allocation to cylinders is shown by a coloured marking on piston crown.
◆ Piston for cylinder 1 and 2:

marked 1/2
◆ Piston for cylinder 3 and 4:
marked 3/4
4.2 - Checking piston projection at TDC

AG. Volkswagen AG d
agen oes
lksw not
Special tools,d by testers and auxiliary items
V o gu
ara
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◆ VW aut 382/7
h
ra
◆ sVW 385/17
s c
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nl
pt
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ab
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satelettronica
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Test sequence
m
at
om
ion
c
-> Piston projection at TDC must be measured when installing new pistons or a short engine. Depending upon
in t
or
his
piston projection, install the corresponding cylinder head gasket according to following table:
ate
do
priv
cum
or
Piston projection Identification

f
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t.
Holes/notches
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Cop py
0.91 mm ... 1.00 mm 1
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1.01 mm ... 1.10 mm 2
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1.11 mm ... 1.20 mm
Prote
3
AG.
-> Cylinder head gasket identification
◆ Part No. = black arrow

Sharan 1996 ➤
◆ Holes/notches = white arrow
Note:
n AG. Volkswagen A
If differing figures are obtained whenolkmeasuring
swa
ge piston projection,
G do
es n the highest figure should be taken when
ot g
selecting the gasket. d by V ua
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ris tee
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4.3 - Piston and cylinder dimensions
ce
le
un
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Honing Piston-ø Cylinder bore-ø
ab
ility
dimension
ot p
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Basic dimen. mm 79.47 79.51
h re
ole,
1st oversize mm 79.72 79.76
spec
2nd oversize mm 79.97 80.01
t to the co
rrectness o
satelettronica
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
Sharan 1996 ➤
15 - Cylinder head, Valve gear
AG. Volkswagen AG d
agen oes
1 - Removing and installing cylinder head
d by Volksw not
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1.1 - Removingss aand installing cylinder head
ut ra
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nl
pt
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ab
ility
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es, in part or in w
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rrectness of i
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satelettronica
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
Checking compressions
=> Page 58
Notes:
◆ When installing an exchange cylinder head with fitted camshaft, the contact surfaces between bucket tappet
and cam must be oiled after installation.
◆ The plastic protectors fitted to protect the open valves must only be removed immediately before fitting the
cylinder head.
1.1 - Removing and installing cylinder head 51

Sharan 1996 ➤
◆ When replacing the cylinder head the complete coolant must be renewed.
1 55 Nm
2 20 Nm
AG. Volkswagen AG d
agen oes
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satelettronica
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un
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ab
ility
ot p
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spec
t to the co
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cial p
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mer
atio
om
n
c
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3 Engine support bracket

p
cum
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4 45 Nm
t.
yi Co
op
5 Camshaft sprocket C py
t. rig
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◆ Drive off camshaft taper using hammer and drift through toothed belt guard openings
yri
p by
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6 10 Nm Prote
cted AG.
agen
7 Rear toothed belt guard

8 Cylinder head cover
9 Cap
◆ Renew seal if damaged
10 Upper sealing washer
11 Dished washer
12 Cap
52 15 - Cylinder head, Valve gear

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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rise nte
tho eo
au ra
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
satelettronica
n
c
in t
or
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ate
do
priv
cum
for
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Cop py
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pyri by
Vo
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by
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Prote AG.
13 To intake hose
14 Retaining clip
15 Pressure regulating valve
◆ For crankcase breather
16 Gasket
17 Cylinder head cover gasket
◆ Insert projections into holes on cylinder head
19 Cylinder head bolt
◆ Renew
◆ Note sequence when loosening and tightening
=> Page 56 , removing and installing cylinder head

Sharan 1996 ➤
lkswage es n
o ot g
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pt
du
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ab
ility
ot p
wit
satelettronica
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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21 Injector pipes
t.
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op
C py
t. rig
gh
◆ Remove with 3035
ht
pyri by
Vo
o
◆ Always remove pipework complete
c by lksw
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◆ Do not alter shape Prote AG.
22 Cylinder head
◆ Check for distortion => Fig. 1
=> Page 56
coolant
23 Injector
=> Repair group 23; Diesel direct system; Servicing injectors Diesel direct system Servicing injectors
24 Glow plug
◆ Checking
=> Repair group 28; Checking glow plug system; Checking glow plugs Checking glow plug system Checking
glow plugs

Sharan 1996 ➤
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ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
satelettronica
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25 Lifting eye
26 Cylinder head gasket
◆ Renew
◆ Note marking
=>Fig. 2
coolant
27 Idler roller
28 25 Nm
29 Tensioning roller
30 Eccentric
31 Toothed belt
◆ Mark D.O.R. before removing
◆ Check for wear
◆ Do not kink
◆ Removing, installing and tensioning
=> Page 25
32 Toothed belt guard - upper part

Sharan 1996 ➤
-> Fig. 1 Checking cylinder head for distortion
Max. permissible distortion: 0.1 mm
Note:
Reworking diesel cylinder heads is not permissible.
satelettronica
AG. Volkswagen AG d
agen oes
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-> Fig.2 Cylinder head gasket identification

erm
ab
ility
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◆ Part No. = black arrow

wit
is n
◆ Holes/notches = white arrow

h re
ole,
spec
Note:
t to the co
Different thicknesses of cylinder head gasket are fitted depending on the piston projection. When replacing the
cylinder head gasket, install a new gasket with the same identification.
rrectness
1.2 - Removing and installing cylinder head

o
cial p
f inform
mer
atio
m

o
n
c
i
or
n thi
e

t
sd
va
◆ Guide pins 3070

i
o
pr
cum
r
fo
en
ng
Prerequisites
t.
yi Co
Cop py
ht. rig
• Engine cold
rig ht
py by
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• Pistons not positioned at TDC by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
Work sequence
Notes:
◆ Always renew cylinder head bolts.
◆ Only remove the new cylinder head gasket from its packing immediately before installing.
◆ Handle the new gasket with extreme care. Damaging will lead to leaks.
Removing
- -> Maintain sequence when loosening and tightening cylinder head bolts.
satelettronica
Installing
- Carefully remove remains of gasket. When doing this ensure that no long scoring or scratches are formed
(when using abrasive paper it must not have a grade less than 100).
- Carefully remove metal particles and emery remains.
- Turn crankshaft to TDC marking before fitting cylinder head.
- Turn crankshaft against engine direction of rotation until all pistons are approximately equally placed below
TDC.
- Place cylinder head gasket on.
AG. Volkswagen AG d
agen oes
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ility
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- -> To centralize, screw guide pins from 3070 into the outer threaded holes on the intake side.
- Fit cylinder head, screw in 8 remaining cylinder head bolts and tighten by hand.
rrectness of i
- Remove guide pins with removal tool from 3070 and install cylinder head bolts.
l purpos
nf
ercia
orm
m
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Cop py
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rig ht
py by
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by lksw
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Prote AG.

Sharan 1996 ➤
- -> Tighten cylinder head in four stages in sequence shown as follows:
- 1. Tighten initially with torque wrench:
Stage I = 40 Nm
Stage II = 60 Nm
- 2. Turn further with normal spanner:
Stage III = 1/4 turn (90 °)
Stage IV = 1/4 turn (90 °)
- After tightening the cylinder head turn camshaft so that the cams for No. 1 cylinder point evenly upwards.
Turn crankshaft, in engine D.O.R., To TDC before fitting toothed belt.
1.3 - Checking compressions
◆ Compression tester V.A.G 1381 or V.A.G 1763

◆ Adapter V.A.G 1381/12
◆ Jointed spanner 3220
Test conditions
satelettronica
• Engine oil temperature min. 30 °C.
Test sequence
- Pull connector off fuel cut-off valve on injection pump.

- Separate connector to quantity adjuster on injection pump.
- Remove all glow plugs using socket spannersw3220. AG. Volkswagen AG d
agen oes
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, is n
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spec
es, in part or in w
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rrectness of i
- -> Screw in adapter V.A.G 1323/12 in place of the glow plugs.

- Check compressions with compression tester V.A.G 1381 or V.A.G 1763.
l purpos
Note:
nform
ercia
Using the compression tester => Operating instructions.

m
a
com
tion in
- Operate starter until tester shows no further pressure increase.

r
te o
thi
s
iva
do
Compression pressure:
r
rp
cum
fo
en
g
New: 25...31 bar

n
t.
yi Co
op
Wear limit: 19 bar C py
ht. rig
rig ht
py by
Vo
Permissible difference between all cylinders: 5 bar
co lksw
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cted agen
Prote AG.
- Install glow plugs with socket and jointed extension 3220

Tightening torque: 15 Nm.

Sharan 1996 ➤
- Interrogate fault memory:
Note:
Faults will have been stored because the connector to injection pump has been separated. Therefore inter‐
rogate and erase fault memory.
2 - Servicing valve gear

2.1 - Servicing valve gear
satelettronica
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ility
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, is n
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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
Note:
co Vo
by lksw
cted agen
Prote AG.
Cylinder heads with cracks between the valve seats may be used without reducing engine life, provided the
cracks are small and not more than 0.5 mm wide.
1 Bearing cap
◆ Installation position => Fig. 4
◆ Installation sequence
=> Page 69 , removing and installing camshaft
1.3 - Checking compressions 59

Sharan 1996 ➤
2 20 Nm
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ility
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es, in part or in w
t to the co
rrectness of i
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satelettronica
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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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.
3 Camshaft
◆ Checking axial clearance => Fig. 1
=> Page 69
◆ Checking radial clearance with plastigage
Wear limit: 0.11 mm
◆ Run-out: max. 0.01 mm
◆ Identification and valve timing
=> Fig. 3
4 Bucket tappet
◆ Do not interchange
◆ With hydraulic valve clearance compensation
◆ Store with cam lobe contact surface downwards
◆ Before installing check camshaft axial clearance => Fig. 1
◆ Oil contact surface

Sharan 1996 ➤
satelettronica
lkswage es n
o ot g
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d ran
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pt
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ab
ility
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spec
es, in part or in w
t to the co
5 Cotters
6 Valve spring plate vehicles approx. 04.96 ▸
rrectness of i
◆ Additionally with lower valve spring plate. Remove and install lower valve spring plate with 3047A
l purpos
7 Valve springs vehicles approx.

04.96 ▸
nf
◆ With outer and inner valve springs

ercia

rm
m
atio
Cylinder head
om
removed: with 2037

n in
or c
installed: => Page 67 , renewing valve stem seals

thi
te
sd
a
8 Valve stem seal

iv
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◆ Renewing=> Page 67
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t.
9 Valve guide
yi Co
Cop py
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yri
◆ Renewing => Page 67
p by
co Vo
by lksw
◆ Service version with collar Prote
cted AG.
agen
2.1 - Servicing valve gear 61

Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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tho eo
au ra
ss c
ce
le
un
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an
d
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ab
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
10 Cylinder head
◆ See note
l purpos
=> Page 59
◆ Reworking valve seats
nform
ercia
=> Page 64
11 Oil seal
m
a
com
ti
◆ To remove and install, remove bearing cap

on in
◆ Removing and installing toothed belt =>Page 25

r
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thi
12 Valves
s
iva
do
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rp
◆ Valve dimensions => Fig. 2

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Prote AG.

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
ho eo
-> Fig. 1 Checking camshafts aaxial clearance
ut ra
c
s
ce
e
nl
Wear limit: max. 0.15 mm
pt
du
an
itte
y li
Check with bucket tappets removed and with first and last bearing caps fitted.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
satelettronica
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
-> Fig. 2 Valve dimensions
n in
or c
thi
te
sd
a
Note:
iv
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cu
Valves must not be reworked. Only lapping-in is permitted.

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t.
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Dimension Inlet valve Exhaust valve
C py
t. rig
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øa mm 35.95 yri
31.45
p by
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øb mm 7.971) 7.951) cted agen
Prote AG.
6.9632) 6.9432)
c mm 96.85 96.85
α <° 45 45
1) Valve stem ø 8 mm
2) Valve stem ø 7 mm
2.1 - Servicing valve gear 63

Sharan 1996 ➤
-> Fig.3 Camshaft identification, valve timing
Identification
◆ Cam base diameter: a = 38 mm ø

◆ Identification by stamped numbers and letters between inlet and exhaust cams:
Cylinder 1 -arrow A- W
Cylinder 2 -arrow B- 028
F
Valve timing at 1 mm valve lift
satelettronica
AG. Volkswagen AG d
agen oes
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Inlet opens after TDC 16 °

Inlet closes after BDC 25 °
Exhaust opens before BDC 28 °
rrectne
Exhaust closes before TDC 19 °

ss o
-> Fig. 4 Fitting position of camshaft bearing caps

cial p
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atio
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Note offset. Before installing camshaft fit bearing caps and determine fitting position.
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2.2 - Reworking valve seats

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◆ Depth gauge
AG.

Sharan 1996 ➤
◆ Valve seat refacing tool
Notes:
◆ When repairing engines with leaking valves, it is not always sufficient to reface or renew valve seats and
valves. It is also necessary to check the valve guides for wear. This is particularly important on high mileage
engines.
◆ The valve seats should only be reworked just enough to produce a perfect seating pattern. The maximum
permissible reworking dimension must be calculated before work is carried out. If the reworking dimension
is exceeded, the function of the hydraulic tappets can no longer be guaranteed and therefore the cylinder
head should be renewed.
Calculating max. permissible reworking dimension
- Insert valve and press firmly against seat.
Note:
If the valve is to be renewed as part of a repair, use a new valve for the calculation.
satelettronica
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- -> Measure distance -a- between end of valve stem and upper edge of cylinder head.
es, in part or in w
- Calculate max. permissible reworking dimension from measured distance -a- and minimum dimension.
t to the co
Minimum dimension:
Inlet valve 35.8 mm
rrectness of i
Exhaust valve 36.1 mm
l purpos
Measured distance minus minimum dimension

= max. permissible reworking dimension.
nform
ercia
Example:
m
a
com
tion in
- Measured distance 36.5 mm

r
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Minimum dimension 35.8 mm

s
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rp
= max. perm. rework dimension 0.7 mm

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Prote AG.
2.2 - Reworking valve seats 65

Sharan 1996 ➤
-> Reworking inlet valve seat
a = 35.7 mm ø
b = 1.6 mm
45 ° = Valve seat angle
Note:
The 30 ° lower valve seat chamfer is necessary to ensure that the inlet channel flow characteristics are main‐
tained.
satelettronica
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-> Reworking exhaust valve seat d byV ua
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a = 31.4 mm ø ss
au ac
b = 2.7 mm
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45 ° = Valve seat angle
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2.3 - Checking valve guides
, is n
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◆ VW 387 Universal dial gauge bracket
rrectness of i
◆ Dial gauge
l purpos
Test sequence
nform
mercia
at
om
ion
c
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ate
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priv
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for
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t. rig
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pyri by
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by
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Prote AG.
- -> Insert new valve into guide until end of valve stem is flush with end of guide. Due to the slight difference
in stem dimensions, ensure that only an inlet valve is used in the inlet guide and an exhaust valve in the
exhaust guide.
- Rock: Max. 1.3mm

Sharan 1996 ➤
2.4 - Renewing valve guides

Valve stem ø 8 mm:
◆ Drift 3121
◆ Hand reamer 3120 and cutting fluid
Valve stem ø 7 mm:

◆ Drift 3121
◆ Hand reamer 3120 and cutting fluid
Removing
- Clean and check cylinder head. Cylinder heads in which the valve seats can no longer be reworked, or
cylinder heads which have already been machined to the minimum dimension, should not have the valve
guides replaced.
- Press worn valve guides out with
Valve stem ø 8 mm: 10-206
Valve stem ø 7 mm: 3121
from the camshaft side (valve guides with collar -service version- from the combustion chamber side).
Installing
- Coat new guides with oil and press in with 10-206/3121 from the camshaft side with head cold until shoulder
makes contact.
satelettronica
Note:
When the shoulder on guide makes contact, the pressure must not exceed 1.0 t otherwise shoulder may break
off.
- Ream guides out with hand reamer
Valve stem ø 8 mm: 10-215
using plenty of cutting fluid.
- Rework valve seats => Page 64 .
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2.5 - Renewing valve stem seals oris d ara
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(with cylinder head fitted) s
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nl

pt
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◆ Puller 3047A
itte
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◆ Assembly tool 2036

ab
ility
◆ Lever VW 541/1A with press piece VW 541/5

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Valve stem ø 8 mm:

hole
spec
◆ Fitting tool 3129

es, in part or in w
t to the co
Valve stem ø 7 mm:

◆ Fitting tool 3129
rrectness of i
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Prote AG.
2.4 - Renewing valve guides 67

Sharan 1996 ➤
Removing
- Remove camshaft => Page 69 .

- Remove bucket tappets (do not interchange) and store with the contact surface downwards.
- Set piston of respective cylinder to top dead centre (TDC).
- -> Fit assembly tool 2036 and adjust mountings to height of studs.
- Remove valve springs with lever VW 541/1A and press piece VW 541/5.
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agen does
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satelettronica
ss o
cial p
f inform
mer
atio
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n
c
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Note: p by
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by c lksw
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Prote AG.
The valves are supported by the piston crown.
- -> Pull off valve stem seals with 3047A.
Installing
- -> To prevent damage to the new valve stem seals, place plastic sleeve -A- on valve shaft.
- Oil valve stem seal -B-, place it in tool
Valve shaft ø 8 mm: 10-204
and push carefully onto the valve guide.

Sharan 1996 ➤
2.6 - Removing and installing camshaft n AG. Volkswagen AG do

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Special tools, testers and auxiliarythoitems tee
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mer
Removing
atio
satelettronica
om
n
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- -> Unscrew counter weight securing nuts -2- and remove counter weight.
thi
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Prote AG.
- -> Remove securing bolts -1- and -2- and remove engine mounting -3-.
- Remove upper toothed belt guard and cylinder head cover.
- -> Turn crankshaft to TDC No. 1 cylinder -arrow-.

- Loosen tensioner.
- Remove idler roller.
- Take off toothed belt.
- Loosen camshaft sprocket securing bolt 1/2 turn. Release camshaft sprocket from camshaft taper by tapping
with a hammer (using a drift through rear toothed belt guard opening).
- Take off camshaft sprocket.
2.6 - Removing and installing camshaft 69

Sharan 1996 ➤
- First remove bearing caps 5, 1 and 3. Then loosen bearing ncaps 2lkand
AG. Vo swag4
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A
and diagonally.
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Installing ed
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Notes: au ac
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◆ When installing the camshaft No. 1 cylinder cams must point upwards.
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satelettronica
ion in
r
te o
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s
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◆ -> When installing the bearing cap note offset, before installing camshaft fit bearing caps and determine
fitting position.
- Oil camshaft running surfaces.

- Tighten bearing caps 2 and 4 alternately and
diagonally to
20 Nm.
- Install bearing caps 5, 1 and 3 and also tighten to
20 Nm.
- Locate bearing cap 5 by tapping lightly on the end of the camshaft.
- Install camshaft sprocket.
- Install and tension toothed belt => Page 25 .
Note:
When new tappets have been installed the engine must not be started for about 30 minutes. Hydraulic com‐
pensation elements must settle (otherwise valves will strike pistons).
2.7 - Checking hydraulic bucket tappets
◆ Feeler gauge
◆ Wood or plastic wedge

Sharan 1996 ➤
wagen AMechanics
G. Volkswagen A-G dEdition 12.2001
oe
ks s no
Vol t gu
Notes: ed by ara
nte
ris
tho eo
◆ Renew defective tappet complete (cannot be au ra
ss adjusted or repaired). c
◆ Irregular valve noises when starting engine are normal.
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le
un
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d
itte
Test sequence
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- Start engine and run until the radiator fan has switched on once.
wit
is n
- Increase engine speed to about 2500 rpm for 2 minutes.
h re
ole,
spec
If the hydraulic tappets are still noisy, locate defective tappets as follows:
t to the co
- Remove cylinder head cover.
- Rotate crankshaft clockwise, until cam of the tappet to be checked is pointing upwards.
rrectne
- Determine play between cam and bucket tappet.
- If the play is in excess of 0.1 mm, renew bucket tappet. If the play is less than 0.1 mm or no play, proceed
with check as follows:
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
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satelettronica
t
sd
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t.
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t. rig
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pyri by
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- -> Press tappet down with a wooden or plastic wedge. If free travel in excess of 1 mm is felt before tappet
contacts valve, renew
tappet.
Note:
After installing new tappets the engine must not be started for approx. 30 minutes. Hydraulic compensation
elements must settle (otherwise valves will strike pistons).
2.7 - Checking hydraulic bucket tappets 71

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

1.1 - Removing and installing parts of the lubrication system
Notes:
◆ If large quantities of metal particles or other deposits (caused, for example, by partial seizure of the crank‐
shaft or conrod bearings) are found in the engine oil when performing repairs, clean the oil passages
thoroughly and renew the oil cooler in order to prevent further damage from occurring later.
◆ The oil level must not be above the max. mark - danger of damage to catalyst!
Checking oil pressure => Page 83
Oil system capacity1):
satelettronica
without oil filter 3.8 ltrs.
with oil filter 4.3 ltrs.
1) Up-to-date figures:
=> Exhaust emissions test binder
Engine oil specifications:
Only use engine oil conforming to VW standard 50500.
AG. Volkswagen AG d
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es, in part or in w
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at
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c
in t
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ate
do
priv
cum
for
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t.
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t. rig
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72 17 - Lubrication
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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tho eo
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un
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t to the co
rrectness o
cial p
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satelettronica
mer
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om
n
c
i
or
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t. rig
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by
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Prote AG.
Part I
Part II removing and installing oil supply pipe => page 80
1 Cap
2 Gasket
3 Guide
◆ Pull off to extract oil
4 Dipstick
◆ The oil level must not be above the max. mark!
◆ Area above shaded zone up to max. mark: Do not top up with engine oil!
◆ Oil level in shaded zone: Engine oil can be topped up
◆ Area min. mark up to shaded zone: Top-up engine oil
1.1 - Removing and installing parts of the lubrication system 73

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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satelettronica
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ility
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t to the co
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mer
atio
om
5 Oil supply pipe

n
c
i
or
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◆ To turbocharger
te
sd
a
◆ With oil filter bracket item 17

iv
o
pr
◆ Removing and installing =>page 80

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6 Seal
t.
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◆ Renew t. C rig
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7 Banjo bolt p by
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◆ Tightening torque => page 80 , item 4
cted agen
Prote AG.
8 0.25 bar oil pressure switch (F22), 25 Nm
◆ Identification: blue
◆ Wiring: blue/black
◆ Fitting location for engine codes AFN, AVG:
gearbox side in cylinder head
◆ If sealing ring is leaking nip open and replace.
9 Oil supply pipe
◆ To turbocharger
◆ With oil filter bracket item 11
74 17 - Lubrication
Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
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10 0.9 bar oil pressure switch (F1), 25ss Nm
a c
ce
e
◆ Grey
nl
pt
du
◆ Wiring: yellow
an
itte
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◆ If sealing ring is leaking nip open and replace.

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12 25 Nm
hole
spec
13 Restrictor
es, in part or in w
t to the co
14 O-ring
◆ Renew
15 Oil cooler
rrectness of i
◆ Coat contact area to flange, outside the seal, with AMV 188 100 02
l purpos
◆ Ensure clearance to adjacent components

◆ See note
=> Page 72
nf
ercia
orm
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Prote AG.

Sharan 1996 ➤
satelettronica
lkswage es n
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a ac
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es, in part or in w
t to the co
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16 Oil filter
l purpos
◆ Loosen with strap wrench

◆ Tighten by hand
◆ Observe installation instructions on oil filter
nform
ercia

m
at
om
io
18 Gasket
n
c
in t
or
◆ Renew
his
ate
do
19 Clamp
priv
cum
or
20 Gears
f
en
ng
t.
yi
◆ Checking backlash
Co
op py
=> Fig. 1 t. C rig
gh ht
◆ Checking axial clearance pyri by
Vo
co
=> Fig. 2
by lksw
cted agen
Prote AG.
21 Oil pump cover with pressure relief valve
◆ Opening pressure: 5.7...6.7 bar
22 10 Nm
23 20 Nm
24 Spreader rivet
76 17 - Lubrication
Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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spec
es, in part or in w
t to the co
rrectness of i
25 Sump cover
l purpos
26 Oil drain plug, 30 Nm

◆ Renew plug with attached seal
nform
ercia
27 20 Nm
m
◆ Remove and install both rear bolts gearbox end with jointed spanner 3185
a
com
tion in
28 Sump
r
te o
thi
◆ Clean sealing surface before installing

s
iva
do
29 Gasket
r
rp
cum
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◆ Renew
en
ng
t.
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◆ Before fitting gasket coat sump flange/cylinder block flange with "D2"
Co
Cop py
. rig
30 Baffle plate
ht ht
rig by
py
31 Suction pipe
co Vo
by lksw
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◆ Clean strainer if soiled
Prote AG.

Sharan 1996 ➤
lkswage es n
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satelettronica
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nl
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es, in part or in w
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32 10 Nm
nform
ercia
◆ Insert with AMV 188 100 02

m
at
33 Oil spray jet

om
ion
c
◆ For piston cooling

in t
or
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ate
do
priv
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for
en
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.
78 17 - Lubrication
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
satelettronica
es, in part or in w
t to the co
rrectness of i
l purpos
-> Fig. 1 Checking oil pump backlash
nform
ercia
New: 0.05 mm
m
at
om
ion
Wear limit: 0.20 mm
c
in t
or
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ate
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t.
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Cop py
t. rig
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by
cted agen
Prote AG.

Sharan 1996 ➤
-> Fig. 2 Checking oil pump axial clearance
Wear limit: 0.15 mm
satelettronica
AG. Volkswagen AG d
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ility
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es, in part or in w
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Part II
rrectness of i
Assembly overview
l purpos
1 Oil supply pipe

nform
◆ To turbocharger
ercia
2 Union nut, 22 Nm
m
at
om
◆ When loosening and tightening counter-hold connection

on
c
in t
r
3 Seal
o
his
ate
◆ Renew
do
priv
cum
4 Banjo bolt, 25 Nm
for
en
ng
t.
yi
5 Clip
Co
Cop py
.
6 10 Nm
ht rig
rig ht
py by
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7 Bracket by c lksw
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Prote AG.
8 25 Nm
80 17 - Lubrication
Sharan 1996 ➤
◆ Renew AG. Volkswagen AG d
agen oes
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9 10 Nm d byV gu
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10 10 Nm ut
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nl
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du
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itte
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
satelettronica
n in
or c
thi
te
sd
iva
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cu
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f
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Assembly sequence
Removing
- Remove noise insulation.

- Place drain tank V.A.G 1306 underneath.
- Remove air cleaner housing.
- Remove union nut -2- or banjo bolt -4- from oil filter bracket.
- Remove bolt -6-.
- Remove union nut -2- from exhaust turbocharger.
- Remove bolt -9- from bracket -7-.
- Remove nut -8- and take off bracket -7-.
- Remove oil supply line -1-.

Sharan 1996 ➤
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
Installing au ac
ss
ce
e
nl
pt
du
an
itte
Install in reverse order. When doing this note the following:

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erm
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ility
ot p
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Warning!
, is n
h re
The installation of oil supply line must be carried out as described below.
hole
spec
es, in part or in w
t to the co
- Screw bracket -7- with nut -8- loosely to exhaust manifold.

- Tighten union nut -2- or banjo bolt -4- on oil filter bracket by hand.
- Tighten union nut -2- on turbocharger by hand.
rrectness of i
- Tighten union nut -2- or banjo bolt -4- on oil filter bracket to tightening torque.
l purpos
nf
ercia
orm
m
atio
om
n in
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thi
te
sd
iva
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cu
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co
82 17 - Lubrication
by lksw
cted agen
Prote AG.
Sharan 1996 ➤
4-cyl. Dieselwaengine,
gen AG
. VolkMechanics
swagen AG
does- Edition 12.2001
lkso n ot g
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tho or
au ac
ss
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e
satelettronica
t
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.
- Tighten union nut -2- on exhaust turbocharger to tightening torque.

- Position clamps -5- on oil supply line.
- Tighten bolts -6- and -9- to tightening torque.
- Tighten nut -8- to tightening torque.
1.2 - Checking oil pressure and oil pressure switch
Note:
Functional check and servicing the optical and acoustic oil pressure warning:
=> Current flow diagrams, Electrical fault finding and Fitting locations
◆ Oil pressure tester V.A.G 1342

◆ Diode test lamp V.A.G 1527
◆ Adapter set V.A.G 1594

lkswage es n
Vo ot g
Sharan 1996 ➤ ed by ua
ran
ir s
tho Mechanics - Edition 12.2001 tee o
au ra
c
ss
Test sequence
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
or
- -> Remove 0.25 bar oil pressure switch (blue insulation) and screw into tester.
m
m
atio
- Screw tester into the oil filter bracket in place of the oil pressure switch.
om
- Connect brown wire -3- of tester to earth (-).
n in
or c
- Connect diode test lamp V.A.G 1527 using adapter cables from V.A.G 1594 to battery positive (+) and to
thi
te
sd
a
0.25 bar oil pressure switch (F22, blue insulation) -A-. LED must light up.
iv
o
r
rp
cu
o
m
f
en
- Start engine and slowly raise rpm. At
ng
t.
satelettronica
yi Co
0.25 bar switch: 0.15...0.35 bar Cop py
the LED must go out, otherwise renew oil pressure switch.
t. rig
gh ht
yri by
- Connect diode test lamp to 0.9 bar oil pressure switch (F1) -B-. cop Vo
by lksw
At cted agen
Prote AG.
0.75...1.05 bar
The LED must light up, otherwise renew oil pressure switch.
- Increase engine speed further.
At 2000 rpm and an oil temperature of 80 °C the oil pressure should be at least 2.0 bar.
At higher engine speed the oil pressure must not exceed 7.0 bar. If necessary renew oil pump cover with
pressure relief valve.
84 17 - Lubrication
Sharan 1996 ➤
19 - Cooling system
1 - Removing and installing parts of cooling system

1.1 - Removing and installing parts of cooling system
Notes:
◆ When the engine is warm the cooling system is under pressure. If necessary release pressure before com‐
mencing repair work.
◆ Hoses are secured with spring-type clips. In cases of repair only use spring-type clips.
◆ V.A.G 1921 pliers are recommended when installing spring-type clips.
◆ When installing coolant hoses route stress-free, so that they do not come into contact with other components
(observe markings on coolant connection and hose).
Draining and filling with coolant=> Page 93
satelettronica
Coolant mixture ratios => Page 93 , draining and filling with coolant
Carry out cooling system leakage check with V.A.G 1274 and adapter 1274/7.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.1 - Removing and installing parts of cooling system 85

Sharan 1996 ➤
1.2 - Parts of cooling system body side
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
satelettronica
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1 Rubber mounting
2 Radiator
=>Page 95
◆ After replacing renew entire coolant
3 Reinforcing strip
4 Upper coolant hose
◆ To connection
=>Page 89 , Item 1
5 10 Nm
6 Speed nut
7 Lower coolant hose
◆ To coolant pump
=>Page 90 , Item 15
86 19 - Cooling system
Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
yV gu
8 Air intake ductingrised b ara
nte
o
9 Actuator unit auth eo
ra
s c
◆ Opens ats 28±2 °C
ce
le
◆ Checking: if engine is cold (coolant temperature below 25 °C) shut-off ring item 12 closed
un
pt
an
d
10 4 pin connector
itte
y li
rm
ab
◆ Black
pe
ility
ot
11 Retaining clip
wit
, is n
h re
12 Shut-off ring
hole
spec
13 Radiator fan
es, in part or in w
t to the co
◆ Engine codes AFN, AVG with additional fan as optional extra

=>Page 95
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
87
py by
co Vo
1.2 - Parts of cooling system body side
by lksw
cted agen
Prote AG.
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
14 Connector
pr
cum
r
fo
◆ Black, 3 pin
en
ng
t.
yi
◆ For radiator fan thermo switch
Co
Cop py
t. rig
15 Radiator fan thermo switch (F18), yri
gh by
ht
35 Nm cop Vo
by lksw
cted agen
◆ Switching temperatures: Prote AG.
Stage 1
on: 92...97 °C
off: 84...91 °C
Stage 2
on: 99...105 °C
off: 91...98 °C
16 Retainer
Sharan 1996 ➤
1.3 - Parts of cooling system - engine side
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
1 To top of radiator
itte
y li
erm
ab
◆ =>Page 86 , Item 4
ility
ot p
2 O-ring
wit
is n
h re
◆ Renew
ole,
spec
3 10 Nm
4 Connection
t to the co
5 Retaining clip
6 Coolant temperature sender (G62)
rrectne
◆ With coolant temperature gauge sender (G2)

7 To heat exchanger
ss
8 From heat exchanger

o
cial p
f in
9 Bracket
form
mer
10 Coolant pipe
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.3 - Parts of cooling system - engine side 89

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
satelettronica
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
11 Cap
o
n
c
i
or
◆ Check with coolant system tester V.A.G 1274 and adapter 1274/1A
thi
e
◆ Test pressure 1.4...1.6 bar

t
sd
iva
o
r
12 Expansion tank
p
cum
r
fo
en
ng
13 Connector
t.
yi Co
op
◆ Black, 2 pin C py
t. rig
gh ht
14 Oil cooler yri
p by
o Vo
by c lksw
◆ Removing and installing Prote
cted AG.
agen
=>Page 75 , Item 15
15 From bottom of radiator
◆ =>Page 86 , Item 7
16 20 Nm + 1/4 turn (90 °) further
◆ Renew
17 Bracket
◆ For alternator
Sharan 1996 ➤
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
18 30 Nm utho
or
a ac
19 V-belt/ribbed belt ss
ce
e
◆ Removing and installing ribbed belt => Page 23

nl
pt
du
an
◆ Adjusting V-belt tension:

itte
y li
erm
ab
ility
=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir Assembly overview: vane pump,
ot p
wit
reservoir
, is n
h re
hole
spec
20 Coolant pump
es, in part or in w
◆ Dismantling and assembling => Page 92

t to the co
21 Connector
◆ Brown, 4 pin
rrectness of i
22 Air conditioner cut-off thermo switch (F163) and radiator fan 3rd speed thermo switch (F165)
l purpos
◆ On vehicles with air conditioning
=> Heating, air conditioning; Repair group 87

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
91
cted agen
Prote AG.
1.3 - Parts of cooling system - engine side
Sharan 1996 ➤
1.4 - Dismantling and assembling coolant pump
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
1 25 Nm
2 Belt pulley
rrectne
◆ Version for ribbed belt

3 Coolant pump
s
◆ Check for ease of movement

s o
cial p
4 Gasket
inform
◆ Renew
mer
atio
5 Coolant thermostat
om
n
c
◆ Checking: heat-up thermostat in water

i
or
n thi
◆ Opening commences approx. 85 °C

te
sd
a
◆ Ends approx. 105 °C

iv
o
pr
◆ Opening lift min. 7 mm

um
r
fo
en
ng
6 Connection
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
satelettronica
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
7 O-ring
com
tion in
◆ Renew
r
te o
thi
8 Retaining clip
s
iva
do
r
9 10 Nm
rp
cum
fo
10 Flange
en
ng
t.
yi Co
op
11 Pulley C py
t. rig
gh
◆ Version for V-belt
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.5 - Draining and filling cooling system

◆ Cooling system charging unit VAS 6096
Draining
- Remove cap from coolant expansion tank.
1.4 - Dismantling and assembling coolant pump 93

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
- -> Pull out retaining clip -3-, pull connection -2- off thermostat flange -4- and pull off coolant hose -1- or
nl
pt
du
remove thermostat flange -4-.
an
itte
y li
erm
ab
Note:
ility
ot p
wit
, is n
h re
Observe disposal regulations!
hole
spec
es, in part or in w
Filling
t to the co
satelettronica
Notes:
rrectness of i
◆ Only use coolant additive G 12 in accordance with TL VW 774 F.
l purpos
Distinguishing feature: coloured violet
◆ G 12 and coolant additives marked "In accordance with TL VW 774 F" prevent frost and corrosion damage,
nform
ercia
scaling and also raise boiling point of coolant. For this reason the system must be filled all year round with
frost and corrosion protection additives.
m
at
om
i
◆ G 12 violet (in accordance with TL VW 774 F) can be mixed with the previous coolant additives G 11 and
on
c
G 12 red!
in t
or
his
e
◆ Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in
at
do
riv
countries with tropical climates.

p
cum
or
◆ Protection against frost must be assured to about -25 °C (in arctic climatic countries to about -35 °C).
f
en
g
◆ The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer
n
t.
yi Co
op
countries. The anti-freeze ratio must be at least 40 %. C py
t. rig
◆ If for climatic reasons a greater frost protection is required, the amount of G 12 can be increased, but only
gh ht
pyri by
up to 60 % (frost protection to about -40 °C), as otherwise frost protection is reduced again and cooling
co Vo
by lksw
cted
effectiveness is also reduced.
agen
Prote AG.
◆ If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.
Recommended mixture ratios:
Vehicle Anti-freeze Anti-freeze G 12 Water

equipment to amount1)
one -25 °C 40 % 2.7 l 4.1 l
heat ex‐ -35 °C 50 % 3.4 l 3.4 l
changer
two -25 °C 40 % 3.4 l 5.2 l
heat ex‐ -35 °C 50 % 4.3 l 4.3 l
changers
two -25 °C 40 % 3.7 l 5.5 l
heat ex‐ -35 °C 50 % 4.6 l 4.6 l
changers
and addi‐
tional water
heater
1) The amount of anti-freeze must not exceed 60 %; frost protection and cooling effect will decrease if
amount of anti-freeze is too high.
Sharan 1996 ➤
With cooling system charging unit VAS 6096:
- Screw adapter from V.A.G 1274 suitable for this vehicle onto expansion tank.
- Fill coolant circuit using cooling system charging unit VAS 6096.
=> Operating instructions for cooling system charging unit VAS 6096
Without cooling system charging unit VAS 6096:
- Press top radiator hose down.
satelettronica
- -> Fill with coolant up to MAX. mark on expansion tank.
- Start engine and run at approx. 2500 rpm and at the same time fill with coolant up to overflow hole on
expansion tank.
- Fit expansion tank cap.
- Run engine until radiator fan cuts-in.
- Then run for about a further 10 minutes at approx. 2500 rpm.
- Check coolant level and top-up if necessary.
agen
AG. VoWhen the
lkswagen AG engine
do is at normal operating temperature, the
coolant level must be on the MAX.olkswmark, when the engineesisnocold,
t between the MIN. and MAX. marks.
y V g ua
b
ed ran
oris tee
th or
au ac
ss
1.6 - Removing and installing radiator and radiator fan
ce
e
nl
pt
du
an
itte
y li
erm
ab

ility
ot p
wit
, is n

h re
hole
spec
Removing
es, in part or in w
t to the co
Vehicles without air conditioner

rrectness of i
- Drain coolant => Page 93

- Pull coolant hoses off radiator.
l purpos
- Pull connectors off thermo-switch and radiator fan.

- Remove reinforcement strut.
nform
ercia
- Remove radiator securing bolts.

- Remove radiator downwards.
m
at
om
ion

c
in t
or
his
ate

do
priv
- Removing air conditioner compressor:

um
for
en
ng
t.
yi Co
op
=> Heating, Air conditioning; Repair group 87; removing and installing compressor bracket removing and in‐ C py
ht. rig
stalling compressor bracket rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.5 - Draining and filling cooling system 95

Sharan 1996 ➤
Warning!
The air conditioning system refrigerant circuit must not be opened.
Note:
To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are
not stretched, kinked or bent.
- Remove retaining clamp(s) from refrigerant pipes.

- Remove radiator grille with frame:
=> General body repairs; Repair group 66; Trims; Removing and installing radiator grille with frame Trims
Removing and installing radiator grille with frame
- Remove radiator securing bolts.

- Remove condenser from radiator.
- Remove radiator downwards.
- Secure condenser to body so that refrigerant pipes/hoses are not stressed.
Installing
satelettronica
Installation is carried out in the reverse order, when doing this note the following:
- Filling with coolant => Page 93

- Electrical connections and routing:
=> Electrical system; Repair group 97
- Installing air conditioner compressor:

wage es n
=> Heating, Air conditioning; Repair group y87; Vo removing and installing compressor
lks ot g
ua
bracket removing and in‐
stalling compressor bracket ir se
d b ran
tee
ho
ut or
- Installing radiator grille with frame:
ss
a ac
ce
le
un
pt
=> General body repairs; Repair group 66; Trims; Removing and installing radiator grille with frame Trims
an
d
itte
y li
Removing and installing radiator grille with frame

erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Sharan 1996 ➤
20 - Fuel supply system
wage
1 - Removing and installing parts of fuel supply system byV
olks es n
ot g
ua
d ran
ir se tee
1.1 - Removing and installing parts of afuel supply system
tho
u or
ac
ss
ce
le
un
pt
an
d
Removing and installing fuel filter:
itte
y li
rm
ab
pe
ility
=> Repair group 23; Servicing diesel direct injection system; Servicing fuel filter Servicing diesel direct injection
ot
wit
system Servicing fuel filter
, is n
h re
hole
spec
Servicing accelerator mechanism:
es, in part or in w
t to the co
=> Repair group 23; Servicing diesel direct injection system; Servicing accelerator mechanism Servicing diesel
direct injection system Servicing accelerator mechanism
rrectness of i
Observe safety precautions=> Page 102 .
satelettronica
l purpos
Observe rules for cleanliness => Page 102 .
nform
ercia
Notes:
m
a
com
tio
◆ Hose connections are secured with either screw, spring or clamp-type clips.
n in
r
te o
◆ Always replace clamp-type clips with screw or spring-type clips.
thi
s
◆ V.A.G 1921 pliers are recommended when installing spring-type clips.
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.1 - Removing and installing parts of fuel supply system 97

Sharan 1996 ➤
1.2 - Removing and installing fuel tank with its attachments
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
satelettronica
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
1 Cap Prote AG.
2 Seal
◆ If damaged only replace together with cap
3 Retaining ring
4 Rubber cup
5 Gravity valve
◆ To remove valve unclip upwards out of filler neck
◆ Check valve for through-flow
valve vertical: open,
valve tilted 45 °: closed
98 20 - Fuel supply system

Sharan 1996 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
satelettronica
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
6 O-ring t. Cop py
rig
gh ht
pyri by
Vo
o
7 Vent valve
c by lksw
cted agen
Prote AG.
◆ Cannot be removed, replace together with filler neck => item 12
◆ Checking =>Page 102 , Fig. 2
8 Connector
◆ 2 pin
9 Non-return valve
◆ Check for freedom of movement
10 Rubber grommet
11 10 Nm
12 Filler neck
◆ With expansion tank and vent valve
1.2 - Removing and installing fuel tank with its attachments 99

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
satelettronica
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
13 Vent pipe
thi
te
sd
va
14 Sealing ring
i
o
pr
cum
r
fo
en
ng
t.
yi
15 Retaining ring
Co
Cop py
ht. rig
16 Vent pipe py
rig by
Vo
ht
17 25 Nm
co lksw
by
cted agen
Prote
18 Fuel tank
AG.
◆ Support with engine and gearbox jack V.A.G 1383 A when removing
19 Securing strap
◆ Note differing length
20 Sealing ring
◆ Coat with fuel when installing

AG. Volkswagen AG d Sharan 1996 ➤
agen oes
ksw not
4-cyl. Diesel by V engine, Mechanics - Edition
ol
gu 12.2001
ara
d
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
satelettronica
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.
21 Fuel gauge sender

◆ Note fitting position on fuel tank => Page 102 , Fig. 1
◆ Sender with strainer telescopic to upper part
22 Supply line
◆ Secure with spring-type clips
◆ Check securely seated
◆ Black
23 Return line
◆ Secure with spring-type clips
◆ Check securely seated
◆ Blue
24 Union nut
◆ Remove and install with 3217
1.2 - Removing and installing fuel tank with its attachments 101
agen AG olksw
Sharan 1996 ➤ wage
n AG. V does
olks not
d by V - Edition 12.2001 gu
a
e ran
ris tee
utho or
a ac
ss
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le
un
pt
an
d
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ility
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ole,
spec
t to the co
rrectne
-> Fig. 1 Installation position of fuel gauge sender
ss o
cial p
f inform
mer
Marking on the flange must align with marking on the fuel tank.
atio
om
n
c
i
or
n thi
te
sd
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o
pr
satelettronica
um
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
-> Fig. 2 Checking vent valve
Valve in rest position: Closed
Valve pushed in direction of arrow: Open
1.3 - Safety precautions when working on the fuel supply system
When removing and installing the fuel gauge sender from a full or partly full fuel tank the following must be
observed:
◆ Before commencing work, switch on exhaust extraction system and place an extraction hose close to the
sender opening in the fuel tank to extract escaping fuel fumes.
If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displace‐
ment greater than 15 m3/h can be used.
◆ Prevent skin contact with fuel! Wear fuel-resistant gloves!
1.4 - Rules for cleanliness
When working on the fuel supply/injection system, pay careful attention to the following "6 rules" regarding
cleanliness:

Sharan 1996 ➤
◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
◆ Carefully cover opened components or seal, if the repair cannot be carried out immediately.
◆ Only install clean components: AG. Volkswagen AG d
agen
Only unpack replacement parts immediately prior to installation. olksw
oes
not
Do not use parts that have been stored loose (e.g. in etool yV
d b boxes etc.).
gu
ara
◆ When the system is open: horis nte
eo
aut
Do not work with compressed air if this can be avoided. ra
s c
Do not move vehicle unless absolutely necessary.s
ce
le
◆ Also ensure that no diesel fuel runs onto the coolant hoses. Hoses coming in contact with fuel must be
un
pt
an
d
cleaned immediately. Damaged hoses must be replaced.
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.4 - Rules for cleanliness 103

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

1.1 - Charge air system with turbocharger
1.2 - Safety precautions
Warning! AG. Volkswagen AG d

agen
When doing any repair work, especially in the engine compartment, Volksw pay attention to the following
oes
not due to the
cramped conditions: ed by gu
ara
◆ Route all the various lines (e.g. for fuel, hydraulics, activated
tho
ris charcoal filter system, coolant, refrigerant,
nte
eo
brake fluid and vacuum pipes and hoses) and electrical
s au wiring so that the original positions are restored. ra
c
s
◆ Ensure sufficient clearance to all moving or hot components.
satelettronica
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Observe following if test and measuring instruments are required during a test drive:
wit
, is n
h re
hole
◆ Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this
spec
location.
es, in part or in w
t to the co
If test and measuring instruments are operated from front passenger's seat and the vehicle is involved in
an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the
airbag is triggered.
rrectness of i
l purpos
1.3 - Rules for cleanliness
nf
ercia
orm
m
atio
om
When working on the exhaust gas turbocharger, pay careful attention to the following rules of cleanliness:
n in
or c
thi
te
sd
a
◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
iv
o
r
rp
cu
◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
o
m
f
◆ Carefully cover opened components or seal, if the repair cannot be carried out immediately.
en
ng
t.
yi
◆ Only install clean components:
Co
Cop py
Only unpack replacement parts immediately prior to installation.
t. rig
gh ht
yri
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
p by
co Vo
by lksw
◆ Existing transport and protective packaging and sealing caps must only be removed immediately prior to Prote
cted AG.
agen
installation.
◆ When repairing remove oil from connection and hose ends.
◆ When the system is open:
Do not work with compressed air if this can be avoided.
Do not move vehicle unless absolutely necessary.
1.4 - Removing and installing turbocharger with attachments
Observe safety precautions=> Page 104 .
Observe rules for cleanliness => Page 104 .
104 21 - Charging
Sharan 1996 ➤
Notes:
◆ All hose connections are secured with clamps and/or securing clips.
◆ VAS 5024 A pliers are recommended when installing spring-type clips.
◆ Do not install hose connections with lubricant containing oil.
◆ Charge air system must be free of leaks.
◆ Before screwing on oil supply pipe fill turbocharger at connection with engine oil.
◆ After installing turbocharger run engine for approx. 1 minute at idling speed, do not rev engine. This ensures
that the turbocharger is adequately lubricated.
◆ Renew self-locking nuts.
satelettronica
. Volkswagen AG
gen AG d wa oes
olks not
yV gu
Hose connections with connector couplings ed
b ara
nte
ris
tho eo
au ra
c
ss
Note:
ce
le
un
pt
an
d
itte
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All hose connections of charge air system are secured by spring-type clips or by connector couplings. Always
rm
ab
check the following points with connector couplings:
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
- -> Release connector coupling by pulling the securing clamp -arrow-.

thi
s
iva
do
r
rp
Separate hose/pipe without auxiliary tools.

um
fo
en
ng
t.
yi Co
- When assembling ensure that the retaining lugs -A- are engaged securely. ht. Cop py
rig
rig ht
py by
Engine codes 1Z, AHU =>Page 106 co Vo
by lksw
cted agen
Prote AG.
Engine codes AFN, AVG =>Page 110
Turbocharger hose connections, engine codes 1Z, AHU => Page 116
Turbocharger hose connections, engine codes AFN, AVG => Page 117
1.4 - Removing and installing turbocharger with attachments 105

Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Engine codes 1Z, AHU

rrectness of i
1 Exhaust manifold
l purpos
2 35 Nm
◆ Renew
nform
ercia
◆ Coat threads and bolt head seating surface with G000500

m
at
3 From exhaust gas recirculation valve

om
ion
c
in t
4 From charge air cooler

or
his
te
5 Intake manifold
a
do
priv
6 Gasket
um
for
en
g
◆ Renew
n
t.
yi Co
op
◆ Coating (beading) towards intake manifold C py
ht. rig
ht
7 25 Nm
rig by
copy Vo
by lksw
8 Gasket Prote
cted AG.
agen
◆ Renew
9 20 Nm
106 21 - Charging
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
10 10 Nm
an
itte
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◆ Install with D6
erm
ab
ility
11 Circlip
ot p
wit
, is n
12 Pressure unit
h re
hole
◆ For charge pressure regulating valve spec

◆ Checking =>Page 123
es, in part or in w
t to the co
=> Page 123
13 Hose
rrectness of i
◆ Blue
◆ To charge pressure control solenoid valve (N75) => Page 116 , turbocharger hose connections
l purpos
14 Seal
◆ Renew
nform
ercia
15 Banjo bolt, 15 Nm
m
at
om
16 From air cleaner

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 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
satelettronica
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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.
17 O-ring
18 10 Nm
20 Oil return pipe
◆ To cylinder block
21 30 Nm
22 Gasket
◆ Renew
23 Retainer
24 Hose
◆ rot
108 21 - Charging
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
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
25 Turbocharger
es, in part or in w
t to the co

=> Page 118
◆ Checking boost pressure
rrectness of i
=> Page 121

26 To charge air cooler
l purpos
27 Front exhaust pipe

28 Oil supply pipe
nf
ercia
or
◆ From oil filter bracket

m
m
atio
=> Page 74 , item 5

om
n in
◆ Fill connection with engine oil before screwing on oil supply pipe.
or c
◆ Counterhold connecting pipe item 2 when tightening

thi
te
sd
a

iv
o
r
rp
cu
29 Heat shield
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 ➤
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
Engine codes AFN, AVG

es, in part or in w
t to the co
1 From exhaust gas recirculation valve

2 From charge air cooler
rrectness of i
3 Intake manifold
4 Gasket
l purpos
◆ Renew
◆ Coating (beading) towards intake manifold
nform
ercia
5 25 Nm
m
6 Gasket
com
tion in

r
te o
thi
7 Exhaust manifold
s
iva
do
r
8 Bracket
rp
cum
fo
◆ For heat shield item 9

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
110 21 - Charging
Sharan 1996 ➤
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
9 Heat shield
spec
◆ Engage in bracket item 8

t to the co
10 From air cleaner

11 10 Nm
12 O-ring
rrectne
13 Seal
ss o
cial p
◆ Renew
f inform
mer
15 Oil return pipe

atio
om
◆ To cylinder block
c
i
or
n thi
e
16 30 Nm
t
sd
iva
17 Gasket
pr
cum
r
fo
◆ Renew
en
ng
t.
yi Co
18 Retainer Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤ gen AG
. Volkswagen AG
does
swa
yV
olk not
gu
d b a ran
e
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
satelettronica
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.
19 Hose
20 Pressure unit
◆ For charge pressure control
◆ Integral part of turbocharger cannot be replaced
21 To charge air cooler
22 Turbocharger
=> Page 118
◆ Checking charge pressure
=> Repair group 23; Servicing diesel direct injection system; Checking charge pressure system Servicing diesel
direct injection system Checking charge pressure system
23 Gasket
◆ Renew
112 21 - Charging
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
satelettronica
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

25 Oil supply pipe, 25 Nm
◆ From oil filter bracket
=> Page 74 , item 9
◆ Counterhold connectingpipe item 2 when tightening
26 25 Nm
◆ Renew
◆ Coat threads and bolt head seating surface with G 000 500
27 Connection, 30 Nm
◆ Renew
◆ Coat threads and bolt head seating surface with "G 052 112 A3"

Sharan 1996 ➤ agen
AG. Volkswagen AG d
oes
ksw
4-cyl. Diesel engine, Mechanics - Edition
by
V 12.2001
ol not
gu
ara
ed nte
ris
1.5 - Removing and installing parts of charge
au
tho
air cooling system e or
ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
satelettronica
p
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Notes:
◆ All hose connections secured by clips.

◆ Charge air system must be free of leaks.
1 Intake manifold
2 Connecting pipe
3 From exhaust gas turbocharger
4 20 Nm
5 Retainer
◆ On gearbox
6 10 Nm
7 Air ducting
◆ Only engine codes 1Z, AHU
114 21 - Charging
Sharan 1996 ➤
. Volkswagen AG
- Edition 12.2001
gen AGa d oes
ksw not
y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
satelettronica
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
8 Retainer
9 Charge air cooler
◆ To remove, first remove radiator securing bolts and pull radiator away from body slightly
10 Rubber grommet
11 Retaining clip
12 Intake manifold temperature sender (G72)
13 O-ring
14 Hose
◆ Black
◆ To diesel direct injection system control unit (J248)
1.5 - Removing and installing parts of charge air cooling system 115
Sharan 1996 ➤
1.6 - Turbocharger hose/pipe connections
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
satelettronica
rrectness of i
l purpos
1- -> Intake hose

2- Hose, black
3- Charge pressure control solenoid valve (N75)
nform
ercia
4- Charge air control pressure unit

5- Hose, blue
m
a
com
t
6- Turbocharger
ion in
7- Hose, red
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.
116 21 - Charging
AG. Volkswagen AG d
agen oes
olksw not
V
d by gu
ara Sharan 1996 ➤
ise nte
thor 4-cyl. Diesel engine, Mechanics e or - Edition 12.2001
s au ac
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
satelettronica
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1 Air cleaner
2 Hose
◆ Black
3 Vacuum reservoir
◆ Fitting location: Behind coolant expansion tank
4 Hose
◆ Black, yellow
5 Retainer
6 Rubber bush
7 Solenoid valve for charge pressure control (N75)
◆ Fitting location: On bulkhead
8 10 Nm
9 Hose
◆ Black
10 Non-return valve
1.6 - Turbocharger hose/pipe connections 117

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
satelettronica
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
11 To exhaust gas recirculation valve (N18)
t. rig
gh ht
yri by
12 Pressure unit
op Vo
by c lksw
cted agen
◆ For charge pressure control Prote AG.
13 Hose
◆ Black, yellow
14 Turbocharger
1.7 - Removing and installing turbocharger

◆ Grease G 000 500
Removing
Engine codes AFN, AVG => Page 119
118 21 - Charging
Sharan 1996 ➤
Note:
Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap
must be disconnected. Obtain radio code first if necessary.
- With ignition switched off disconnect battery earth strap.

- Remove pressure pipe intake manifold/turbocharger and intake pipe turbocharger/air cleaner.
- Pull off red hose (or remove banjo bolt) for charge pressure control solenoid valve (N75) on turbocharger.
- Disconnect exhaust pipe from turbocharger. agen
AG. Volkswagen AG d
oes
- Disconnect oil supply pipe from turbocharger. y Volksw not
gu
- Remove turbocharger/cylinder block support. ise
d b ara
nte
- Disconnect oil return pipe on turbocharger. thor eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
satelettronica
rrectness
- -> Remove securing nut -1- from below and securing bolts -2- from above.
o
cial p
f
- Remove turbocharger, downwards.
inform
- Pull blue hose for charge pressure valve off pressure unit.
mer
atio
m
Installing
o
n
c
i
or
n thi
te
- Install blue hose for charge pressure valve on pressure unit and secure with a clamp.
sd
iva
o
r
- Grease securing bolts -2- threads and head contact surfaces with G 000 500 grease.
p
cum
r
fo
- Fit turbocharger on exhaust manifold and tighten securing bolts -2- handtight.
en
ng
t.
- Install securing nut -1- and tighten to
yi Co
op py
20 Nm. t. C rig
gh ht
- Tighten securing bolts -2- to yri
p by
o Vo
35 Nm.
c by lksw
cted agen
- Install turbocharger/cylinder head support and tighten to
Prote AG.
25 Nm.
- Install oil return pipe with new seal and tighten to
30 Nm.
- Install front exhaust pipe with new gasket onto flange and tighten to
25 Nm.
- Fill the turbocharger with engine oil via the oil supply connection.
- Install oil supply pipe and tighten to
25 Nm.
- Install red hose for charge pressure control solenoid valve (N75) on turbocharger and secure with clamp (or
banjo bolt with new seal and tighten to
15 Nm.
- Insert O-ring into intake pipe, then install intake pipe on turbocharger and tighten to
10 Nm.
- Install pressure pipe.
- After installing the turbocharger, run engine for approx. 1 minute at idling speed, do not rev. up immediately.
This ensures the turbocharger is properly lubricated.
Removing
- With ignition switched off disconnect battery earth strap.
1.7 - Removing and installing turbocharger 119

Sharan 1996 ➤
Note:
If necessary the anti-theft coding for the radio must be obtained first.
- Remove noise insulation tray.
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
- -> Remove pressure pipe turbocharger/charge air cooling -1- and intake pipe turbocharger/air cleaner -2-.
ility
ot p
- Pull charge pressure control vacuum pipe off pressure unit.
wit
- Disconnect oil supply pipe from turbocharger and securing clip/exhaust manifold.
is n
h re
- Disconnect exhaust pipe from turbocharger.
ole,
spec
- Remove turbocharger/cylinder block support.
satelettronica
- Disconnect oil return pipe on turbocharger.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
- -> Remove securing nuts -1-. C py
ht. rig
- Remove turbocharger, downwards. rig ht
py by
co Vo
by lksw
cted agen
Installing Prote AG.
- -> Fit turbocharger to exhaust manifold, screw on securing nuts -arrow 1- and tighten to
25 Nm.
- Install oil return pipe with new seal and tighten to
30 Nm.
- Install turbocharger/cylinder head support and tighten to
25 Nm.
- Install front exhaust pipe with new gasket onto flange and tighten to
120 21 - Charging
Sharan 1996 ➤
25 Nm.
- Fill the turbocharger with engine oil via the oil supply connection.
- Install oil supply pipe and tighten to agen
AG. Volkswagen AG d
oes
25 Nm. olksw not
y V gu
- Tighten oil supply pipe support to ise
d b ara
nte
10 Nm. uthor eo
- Insert O-ring into intake pipe and tighten
ss a intake pipe to ra
c
10 Nm
ce
e
nl
pt
on turbocharger and intake manifold.
du
an
itte
- Connect vacuum hose to charge pressure control pressure unit.
y li
erm
ab
- Install turbocharger/charge air cooling pressure pipe.
ility
ot p
- After installing the turbocharger, run engine for approx. 1 minute at idling speed, do not rev. up immediately.
wit
This ensures the turbocharger is properly lubricated.
, is n
h re
hole
spec
es, in part or in w
t to the co
1.8 - Checking turbocharger
rrectness of i
l purpos
nform
ercia
=> Repair group 23; Servicing diesel direct injection system; Checking charge air system Servicing diesel direct
satelettronica
injection system Checking charge air system
m
at
om
ion
c
in t
or
his
ate
do
riv
◆ Turbocharger tester V.A.G 1397 A

p
cum
for
en
ng
t.
Check conditions
yi Co
Cop py
t. rig
gh ht
• No fault stored in fault memory yri
p by
co Vo
by lksw
cted agen
Prote
AG.
• Carry out final control diagnosis
=> Repair group 01; Self-diagnosis; final control diagnosis Self-diagnosis final control diagnosis
• No leaks on intake and exhaust systems.

• Control pipe to charge pressure regulating valve is not blocked, loose or leaking.
• No faults in engine and fuel injection system, e.g. commencement of injection, injectors and compression
pressure.
• Engine oil temperature min. 80 °C
Test sequence
- The charge pressure is measured under full load, whilst driving or on a rolling road. Test duration per meas‐
urement max. 10 seconds.
1.7 - Removing and installing turbocharger 121

Sharan 1996 ➤
- -> Pull connector -2- off charge pressure control solenoid valve (N75) -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
- -> Pull off connecting hose running between intake manifold and diesel direct injection system control unit
t to the co
(J248) and using T-piece connect in turbocharger tester V.A.G 1397 A.
- Select measuring range ll.
rrectness of i
Notes:
l purpos
◆ To operate turbocharger tester see operating instructions.
satelettronica
◆ The hoses must be connected so that there is no possibility of leaks.
nform
ercia
◆ If boost pressure is measured whilst driving, it is necessary for safety reasons, for a second person to operate
the turbocharger tester.
m
a
com
ti
◆ Ensure that the pressure hose is not trapped between the bonnet and the body.
on in
r
te o
thi
- Measure charge pressure at full throttle:
s
iva
do
On a rolling road:
r
rp
cum
fo
In 3rd gear or selector lever position 2 at
en
ng
t.
3500...4000 rpm. op
yi Co
Whilst driving:
C py
ht. rig
In 2nd gear or selector lever position 1
rig ht
py by
Vo
at full throttle acceleration whilst observing
co lksw
by
cted agen
rev counter. Prote AG.
Note:
The brake pedal must not be operated whilst taking measurements. The control unit thus reduces the fuel
quantity which leads to incorrect measurements.
- Press the memory button "M" on turbocharger tester at 3500...4000 rpm and read off values.
Specification: (Relative pressure)
0.50...0.65 bar
If the charge pressure is not attained:
- Check charge pressure control valve pressure unit and renew if necessary.
- Repeat charge pressure check.
If the charge pressure has still not been attained:
- Replace turbocharger.
If the charge pressure is exceeded:
- Test charge pressure control solenoid valve (N75). (Through-flow in hose from turbocharger via valve to
pressure unit when connector is pulled off).
- Check pressure unit for charge pressure regulating valve is securely mounted on turbocharger.
- Check charge pressure control valve pressure unit as well as the operating rod and renew if necessary.
- Check shaft mounting for charge pressure regulating valve in turbocharger for ease of movement.
When corroded together, renew turbocharger.
122 21 - Charging
Sharan 1996 ➤
1.9 - Checking pressure unit for charge pressure regulating valve
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
(Only engine codes 1Z, AHU)
ole,
spec
Check conditions
t to the co
• Engine oil temperature min. 80 °C
rrectne
satelettronica
Test sequence
ss
- -> Pull connector -2- off charge pressure control solenoid valve (N75) -1-.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> Start engine and raise to maximum speed briefly by operating throttle. The operating rod -2- for charge
pressure regulating valve must
move.
If the operating rod does not move:
- Check charge pressure regulating valve lever -1- for ease of movement. When corroded together, renew
turbocharger.
If the operating rod does not move, even though the lever is free to move:
- Renew pressure unit for charge pressure regulating valve -3-.
1.10 - Removing and installing pressure unit for charge pressure regulating valve
(Only engine codes 1Z, AHU)
1.9 - Checking pressure unit for charge pressure regulating valve 123
Sharan 1996 ➤
Removing
- Remove turbocharger => Page 118 .
- -> Unclip securing clip -4-.

- Remove securing bolts -2-.
- Take pressure unit -6- off.
Installing
satelettronica
- Install pressure unit -6- on turbocharger and tighten to
10 Nm.
Install securing bolts -2- with D 6.
- Loosen operating rod -3- lock nut -1-.
- Swing charge pressure regulating valve lever -5- in towards pressure unit onto stop and hold.
- Adjust rod length -3- so that the rod eye will fit easily on lever pin -5-. (Lever lies against stop with no play).
- From this position, turn operating rod in
8 full turns
(Rod shortens).
- Tighten lock nut -1-.
- Fit operating rod on to lever and install securing clip -4-. AG. Volkswagen AG d
agen oes
ksw
- Install turbocharger => Page 118 . by Vol not
gu
a
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
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.
124 21 - Charging
Sharan 1996 ➤
26 - Exhaust system
1 - Removing and installing parts of exhaust system

1.1 - Removing and installing parts of exhaust system
olkswa n AG. V gen AG
wage does
Volks not
gu
by ara
d
Notes: oris
e nte
eo
th
u ra
sa c
◆ Removing and installing exhaust manifold =>Page 104 , Removing and installing turbocharger
s with attach‐
ce
e
ments.
nl
pt
du
an
◆ After working on the exhaust system ensure that the system is not under stress, and that it has sufficient
itte
y li
clearance from the bodywork. If necessary, loosen clamps and align silencer so that sufficient clearance is
erm
ab
maintained to the bodywork and the support rings are evenly loaded.
ility
ot p
◆ Renew self-locking nuts.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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.
Front exhaust pipe and catalyst with attachments
1.1 - Removing and installing parts of exhaust system 125

Sharan 1996 ➤
1 Heat shield
2 Sheet metal nut
◆ Must be screwed-on/off
4 Gasket
◆ Renew
5 Retaining ring
6 Heat shield
7 Catalyst
8 To front silencer
◆ => Page 127 , item 7
9 25 Nm
10 From turbocharger
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
satelettronica
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Silencer with mountings
Note:
126 26 - Exhaust system

Sharan 1996 ➤
Align the exhaust system longitudinally so that the dimensions -a- and -b- are maintained.
1 From catalyst
◆ => Page 126 , item 7
2 Clamp
3 40 Nm
◆ Renew
4 Retaining ring
◆ Note fitting position
5 Sheet metal nut
◆ Must be screwed-on/off
6 Heat shield
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
7 Front silencer
Co
Cop py
ht. rig
8 Rear silencer rig ht
py by
o Vo
◆ Engine codes AFN, AVG with twin end pipes by c lksw
cted agen
Prote
9 Dimension -b- = approx. 50 mm
AG.
10 Dimension-a- = ca. 5 mm
1.1 - Removing and installing parts of exhaust system 127

Sharan 1996 ➤
4-cyl. Diesel engine, Mechanics - Edition 12.2001 agen
AG. Volkswagen AG d
oes
olksw not
yV
2 - Exhaust gas recirculation system b gu
d ara
ise nte
or eo
h
aut ra
2.1 - Exhaust gas recirculation system ss c
ce
e
nl
pt
du
an
itte
Notes:
y li
erm
ab
◆ The control of the exhaust gas recirculation system is undertaken by diesel direct injection system control
ility
ot p
unit (J248) via EGR valve (N18) (electric) to exhaust gas recirculation valve (mechanical).
wit
, is n
◆ Checking exhaust gas recirculation valve (N18).
h re
hole
spec
=> Repair group 01; Self-diagnosis; Final control diagnosis Self-diagnosis Final control diagnosis
es, in part or in w
t to the co
◆ The cone-shaped plunger in the mechanical exhaust gas recirculation valve ensures that various cross
sectional openings are possible at different plunger lifts.
◆ Pulsed control makes every conceivable valve position possible.
rrectness of i
◆ Renew self-locking nuts. l purpos
Removing and installing parts of exhaust gas recirculation system, engine codes 1Z, AHU => Page 129
Removing and installing parts of exhaust gas recirculation system, engine codes AFN, AVG => Page 130
nf
ercia
orm
m
atio
om
2.2 - Removing and installing parts of exhaust gas recirculation system
n in
or c
thi
e
satelettronica
t
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 ➤
Engine codes 1Z, AHU AG. Volkswagen AG d
agen oes
olksw not
1 25 Nm d byV gu
ara
ise nte
2 Connecting pipe hor eo
ut ra
◆ When installing, just nip all bolts (partsss must be just free to move), then tighten stress free
a c
ce
3 Gasket
le
un
pt
an
d
◆ Renew
itte
y li
erm
ab
4 Exhaust gas recirculation valve (mechanical)
ility
ot p
wit
is n
◆ Checking activation
h re
ole,
spec
=> Repair Group 01; Self-diagnosis; Final control diagnosis Self-diagnosis Final control diagnosis
t to the co
5 Intake manifold
rrectness o
cial p
f inform
mer
atio
satelettronica
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
6 Retainer
7 Vacuum hose
◆ To vacuum pipe collective connection brake servo
8 10 Nm
9 Exhaust gas recirculation valve (N18)
2.2 - Removing and installing parts of exhaust gas recirculation system 129
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Sharan 1996 ➤ aut ra
c
s
4-cyl. Diesel engine, Mechanics - Edition 12.2001 s
ce
e
nl
pt
du
an
◆ Checking:
itte
y li
erm
ab
ility
=> Repair Group 01; Self diagnosis; Final control diagnosis Self diagnosis Final control diagnosis
ot p
wit
, is n
h re
10 Vacuum hose
hole
spec
◆ To air cleaner
es, in part or in w
t to the co
11 Rubber bush
12 Connector
◆ 2-pin
rrectness of i
13 Exhaust manifold
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
satelettronica
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1 Connector
◆ 2-pin
2 Rubber bush
3 Retainer
4 Exhaust gas recirculation valve (N18)
◆ Fitting location: On bulkhead

Sharan 1996 ➤
◆ Checking:
=> Repair Group 01; Self diagnosis; Final control diagnosis Self diagnosis Final control diagnosis
5 10 Nm
6 Vacuum hose
◆ To vacuum pipe collective connection brake servo
7 Gasket
◆ Renew
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
8 Intake manifold
ng
t.
yi Co
op
9 Exhaust manifold C py
t. rig
gh ht
10 25 Nm yri
p by
o Vo
by c lksw
11 Connecting pipe Prote
cted AG.
agen
12 Exhaust gas recirculation valve (mechanical)

◆ Checking activation
=> Repair Group 01; Self-diagnosis; Final control diagnosis Self-diagnosis Final control diagnosis
13 Vacuum hose
2.2 - Removing and installing parts of exhaust gas recirculation system 131
Sharan 1996 ➤
◆ To air cleaner
2.3 - Checking exhaust gas recirculation valve (mechanical)
◆ Hand vacuum pump V.A.G 1390
Test sequence
- Pull vacuum hose off (mechanical) exhaust gas recirculation valve.

- Connect hand vacuum pump V.A.G 1390 to valve.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
- -> Operate pump. e d byV gu
ara
The membrane rod horis must move towards nte
eo
vacuum connection
aut (observe membrane rod ra
c
s
via opening -arrow-).
s
ce
e
- Pull hand vacuum pump hose of exhaust gas recirculation valve.

nl
pt
du
an
The valve must clearly heard to close (membrane rod moves

itte
y li
towards intake manifold).

erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Service: Sharan 1996

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2010 Volkswagen AG, Wolfsburg 00056606320

00 - Technical data . . . . . . . . . . . . . . . . . . . l.ks.wa.g.en. A.G.. V. . . . g. e.n A. G. d.oe. s.n . . . . . . . . . . . . . . .1

1.2 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1.2 Removing and installing ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

1.3 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

1.4 Checking semi-automatic toothed belt tensioning roller . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

20 - Fuel supply system . . . . . .e.n A. G.. V. o.lk.sw. a.ge.n.AG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

1.4 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

1.3 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

1.8 Checking turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

1.1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128

The engine code is also included on the vehicle data plate.

1.3 - Engine data

Code letters 1Z AFN AHU AVG

1.1 - Technical data 1

10 - Removing and installing engine

1 - Removing and installing engine

Special tools, testers and auxiliary items

◆ Pliers V.A.G 1921 for spring type clips

when installing engine.

- Drain coolant => Page 93 .

- Remove intake hose and air cleaner housing.

- Pull fuel supply and return hoses off injection pump.

Vehicles with manual gearbox

- Pull pipe/hose off slave cylinder on gearbox:

- Remove operating cable from gearbox:

- Remove drive shafts:

2 10 - Removing and installing engine

Vehicles with air conditioner

- Observe additional information and removal instructions => Page 8 .

Continuation for all vehicles

- Unbolt P.A.S. hydraulic pipe at engine support.

- -> Remove counter weight securing nuts -2-.

1.2 - Notes on removing 3

◆ Workshop crane V.A.G 1202 A

4 10 - Removing and installing engine

1.4 - Notes on installing

Vehicles with manual gearbox

Assembly mounting tightening torques

- Installing air conditioner compressor:

stalling compressor bracket

Vehicles with manual gearbox

- Connect pipe/hose on slave cylinder and secure with clip:

anism Assembly overview hydraulics and clutch release mechanism

- Attach operating cable to gearbox, adjust if necessary:

- Install drive shafts.

1.3 - Securing engine to support clamp 5

- Install selector cable on gearbox, adjust if necessary:

- Install drive shafts.

Continuation for all vehicles

- Install P.A.S. vane pump with bracket:

Bolted connec‐ Tightening torque