Engine Ajh Awc Mechanics Eng PDF

Service
Sharan 1996 ➤
4-cyl. injection engine (5-valve), Mechanics
Engine ID AJH AWC
Edition 02.2005
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Sharan 1996 ➤
4-cyl. injection engine (5-valve), Mechanics
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, Valve gear
17 - Lubrication
19 - Cooling system
20 - Fuel supply system
21 - Charging
26 - Exhaust system
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.
Sharan 1996 ➤
4-cyl. injection engine (5-valve), Mechanics - Edition 02.2005
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.2 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.4 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.5 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.6 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.7 Additional information and removal instructions for vehicles with air conditioner . . . . . . . . . .16
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.2 Removing and installing ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
2 Removing and installing sealing flanges and flywheel/drive plate . . . . . . . . . . . . . . . . . . . .30
2.1 Removing and installing sealing flanges and flywheel/drive plate . . . . . . . . . . . . . . . . . . . .30
2.2 Renewing crankshaft oil seal -belt pulley end- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
2.3 Removing and installing sealing flange -belt pulley end- . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
2.4 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
3.1 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
3.2 Colour markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
4.1 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
4.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
1.1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
1.2 Removing, installing and tensioning toothed belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
1.4 Checking compression pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
2.1 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
2.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
2.3 Renewing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
2.4 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
2.5 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
2.6 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
2.7 Replacing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
1.1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
1.2 Dismantling and assembling oil filter bracket: engine code AJH . . . . . . . . . . . . . . . . . . . . . .113
1.3 Dismantling and assembling oil filter bracket: engine code AWC . . . . . . . . . . . . . . . . . . . .118
Contents i
Sharan 1996 ➤
1.4 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

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

1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
1.1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
1.2 Parts of cooling system body side: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
1.3 Parts of cooling system body side: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
1.4 Parts of cooling system engine side: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
1.5 Parts of cooling system engine side: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
1.6 Coolant hose connection diagram: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
1.7 Coolant hose connection diagram: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
1.8 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
1.9 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
1.10 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
1.11 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
1.12 Checking coolant circulation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166

1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
1.1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
1.2 Removing and installing fuel tank with attachments and fuel filter: engine code AJH . . . . . .167
1.3 Removing and installing fuel tank with attachments and fuel filter: engine code AWC . . . .175
1.4 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . .182
1.5 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
1.6 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
1.7 Removing and installing fuel gauge sender: engine code AWC . . . . . . . . . . . . . . . . . . . . . .185
1.8 Crash fuel shut-off: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
1.9 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187
2 Accelerator mechanism: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
2.1 Accelerator mechanism: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
2.2 Servicing accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
2.3 Adjusting throttle cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
3 Electronic power control (EPC): engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
3.1 Electronic power control (EPC): engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
3.2 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
3.3 Servicing parts of electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
3.4 Checking accelerator pedal position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
4 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
4.1 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
4.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
4.3 Servicing parts of the activated charcoal filter system: engine code AJH . . . . . . . . . . . . . .206
4.4 Servicing parts of the activated charcoal filter system: engine code AWC . . . . . . . . . . . . . .209
4.5 Checking activated charcoal filter solenoid valve 1: engine code AWC . . . . . . . . . . . . . . . .212
4.6 Checking fuel tank breather: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
4.7 Checking fuel tank breather: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
21 - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
1.1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
1.2 Removing and installing turbocharger and attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
1.3 Removing and installing parts of charge air cooling: Engine code AJH . . . . . . . . . . . . . . . .225
1.4 Removing and installing parts of charge air cooling: engine code AWC . . . . . . . . . . . . . . . .228
1.5 Overview of turbocharging: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233
1.6 Overview of turbocharging: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236
1.7 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
ii Contents
Sharan 1996 ➤
1.8 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240

1.9 Removing and installing charge air cooler: engine code AWC . . . . . . . . . . . . . . . . . . . . . .240
2 Checking charge air system: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
2.1 Checking charge air system: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
2.2 Checking charge pressure regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
2.3 Checking charge pressure control solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
2.4 Checking pressure unit for charge pressure regulating valve . . . . . . . . . . . . . . . . . . . . . . . .244
2.5 Checking overrun shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
3 Checking charge pressure system: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
3.1 Checking charge pressure system: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
3.2 Checking charge pressure regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
3.3 Checking charge pressure control solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
3.4 Checking charge pressure sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
3.5 Checking pressure unit for charge pressure regulating valve . . . . . . . . . . . . . . . . . . . . . . . .253
3.6 Checking overrun shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256
1.1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256
1.2 Front exhaust pipe and catalyst with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
1.3 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262
2 Secondary air system: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
2.1 Secondary air system: engine code AJH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
2.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264
2.3 Removing and installing parts of the secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . .264
2.4 Checking combi-valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268
3 Secondary air system: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
3.1 Secondary air system: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
3.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
3.3 Removing and installing parts of the secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . .270
3.4 Checking secondary air pump motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
3.5 Checking combi-valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
4 Exhaust gas recirculation system: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
4.1 Exhaust gas recirculation system: engine code AWC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
4.2 Servicing parts of exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278
4.3 Checking potentiometer for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .281
Contents iii
Sharan 1996 ➤
iv Contents
Sharan 1996 ➤
00 - Technical data
1 - Technical data
1.1 - Technical data
1.2 - Engine number
-> The engine number ("Code letters" and "Serial number") can be found on the front by the joint between
engine/gearbox.
Additionally there is a sticker on the toothed belt guard with "Engine code" and "Serial number".
The engine code is also included on the vehicle data plate.
The engine number consists of up to nine characters (alphanumeric). The first part (maximal 3 characters)
makes up the "engine code", and the second part (6 characters), the "serial number". If more than 999,999
engines with the same engine code are produced, the first of the six characters is replaced with a letter.
1.3 - Engine data
Engine code AJH AWC

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

Sharan 1996 ➤
Catalyst yes yes

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

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

1.1 - Removing and installing engine
Special tools, workshop equipment, test and measuring appliances and auxiliary items required
◆ 2024 A Lifting tackle

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

Sharan 1996 ➤
◆ V.A.G 1306 Drip tray

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

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

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

- Unbolt battery trim -2- with coolant expansion tank and lay to side without opening cooling system.
- In preparation for further dismantling work, disconnect the connectors -arrows- behind the battery.
- Remove battery tray.
- Pull off or disconnect all other electrical connections as necessary from engine and body and lay to one
side.
- Remove air cleaner:
=> Repair group 24; Servicing injection system; Dismantling and assembling air cleaner. Servicing injection
system Dismantling and assembling air cleaner.
Vehicles with engine code AJH
- Remove intake hose:=> Page 225 , Removing and installing parts of charge air cooling: engine code AJH.
- -> Disconnect throttle cable at throttle valve control part cable disc and support bracket -arrows- (do not
remove locating clip on support bracket).
Vehicles with engine code AWC
- Remove intake hose:=> Page 228 , Removing and installing parts of charge air cooling: engine code AWC.
1.2 - Notes on removing 5

Sharan 1996 ➤
Continuation for all vehicles
- -> Disconnect fuel supply and return pipes and the pipe from the activated charcoal filter solenoid valve 1 -
arrows- at fuel rail.
Warning!
Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connec‐
tion. Then release pressure by carefully pulling hose off connection.
- Unclip fuel hoses from bracket.

- Seal the pipes so that the fuel system is not contaminated by dirt etc.
- Observe rules for cleanliness => Page 183 .
- Pull vacuum and breather hoses off engine as necessary.
- Remove noise insulation tray.
- Remove pressure hose between secondary air pump motor and combi-valve
=> Page 264 , Removing and installing parts of secondary air system.
Note:
Press buttons on hose couplings to do this.
- Remove air pipes between turbocharger/charge air cooler, turbocharger/air cleaner and charge air cooler/
throttle valve control part => Page 225 , Removing and installing parts of charge air cooling system: engine
code AJH
Note:
- Remove air pipes between turbocharger/charge air cooler, turbocharger/air cleaner and charge air cooler/
throttle valve control part=> Page 228 , Removing and installing parts of charge air cooling system: engine
code AWC
Vehicles with 5-speed manual gearbox 006
- Pull pipe/hose off slave cylinder on gearbox:
=> 5-Speed manual gearbox 006; Repair group 30; Assembly overview; Hydraulics and clutch release mech‐
anism Assembly overview Hydraulics and clutch release mechanism
- Remove operating cable from gearbox:

Sharan 1996 ➤
=> 5-speed manual gearbox 006; Repair group 34; Servicing selector mechanism; Removing and installing
operating cables Servicing selector mechanism Removing and installing operating cables
- Remove drive shafts:
=> Running gear, Axles, Steering; Repair group 40; Removing and installing drive shaft Removing and installing
drive shaft
Vehicles with 6-speed manual gearbox 02N
- Pull pipe/hose off slave cylinder on gearbox and lay to one side.
=> 6-speed manual gearbox 02N; Repair group 30; Assembly overview - Hydraulics and clutch release mech‐
anism Assembly overview - Hydraulics and clutch release mechanism
- Remove operating cable from gearbox:
=> 6-speed manual gearbox 02N; Repair group 34; Servicing selector mechanism; Removing and installing
- Remove drive shafts:
drive shaft
Vehicles with automatic gearbox 099 - 4-speed
- Remove selector lever cable from gearbox:
=> Automatic gearbox 099 - 4-speed; Repair group 37; Servicing selector mechanism; Dismantling and as‐
sembling selector mechanism Servicing selector mechanism Dismantling and assembling selector mechanism
- Unbolt drive shafts from gearbox flange shaft and tie up.
drive shaft
Vehicles with automatic gearbox 09B - 5-speed
- Remove selector lever cable from gearbox:
=> Automatic gearbox 09B - 5-speed; Repair group 37; Servicing selector mechanism; Dismantling and as‐
sembling selector mechanism Servicing selector mechanism Dismantling and assembling selector mechanism
- Unbolt drive shafts at gearbox flanged shaft and tie up.
drive shaft
Vehicles with air conditioner
- Observe additional information and removal instructions => Page 16 .
- Remove ribbed belt => Page 28 .

- Remove power assisted steering vane pump on compact bracket and lay to side; hoses remain connected.
=> Running gear, Axles, Steering; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes
Assembly overview: vane pump, reservoir, hydraulic pipes
- Unbolt P.A.S. hydraulic pipe at right engine bracket.

- Remove front exhaust pipe => Page 257 , front exhaust pipe and catalyst with attachments.
- Drain coolant => Page 152 .
- Pull connectors off thermo-switch and radiator fan.

Sharan 1996 ➤
- Pull radiator coolant hoses off engine using spring-type clip pliers V.A.G 1921 or VAS 5024.
- Removing front bumper:
=> General body repairs, exterior, Repair group 63; Front bumper, Removing and installing front bumper
- Bring lock carrier into service position:
=> General body repairs, exterior; Repair group 50; Body, front; Lock carrier service position Body, front Lock
carrier service position
- Insert engine bracket T 10012 in engine/gearbox jack V.A.G 1383 A.
- -> Bolt engine support T10012 to cylinder block using securing bolt M10x25.
Tightening torque 45 Nm
- Lift engine and gearbox lightly using engine/gearbox jack V.A.G 1383 A.
- Remove pendulum support.
=> Running gear, Axles, Steering; Repair group 40; Servicing front wheel suspension; I - Assembly overview,
subframe, anti-roll bar, wishbone Servicing front wheel suspension I - Assembly overview, subframe, anti-roll
bar, wishbone
- -> Unbolt assembly mounting, right securing bolts -1-.

Sharan 1996 ➤
- -> Unbolt assembly mounting, left securing bolts -A-.
Note:
To remove securing bolts use ladder VAS 5085.
- Carefully lower assembly slightly.
- -> Remove the securing bolts -A- and remove the bracket -B-.
- -> Unbolt securing bolts and nuts on left of subframe -arrows-.
Note:
To remove securing bolts use ladder VAS 5085.
- Carefully lower engine with gearbox.
Note:
Engine and gearbox must be guided carefully when lowering to prevent damage to the bodywork, hoses and
wiring.
1.3 - Securing engine to assembly stand
When working on the engine, it should be secured to the assembly stand support clamp VW 313 using the
engine and gearbox bracket VW 540 and supplementary set VW 540/1B.

Sharan 1996 ➤
Work sequence
- Remove gearbox.
Vehicles with automatic gearbox
- Secure torque converter against "falling out" after separating engine from gearbox.

- Bolt engine/gearbox bracket VW 540 with supplementary set VW 540/1 B onto 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 rail at position 1
Flywheel end:
3rd hole in hook rail at position 8
Warning!
The hooks and locating pins must be secured with locking pins.
Notes:
◆ The positions marked 1...4 on the bar must be towards the pulley end.
◆ The holes in the hook rails are counted up from the hook.
- Fit engine in support clamp VW 313 using workshop crane V.A.G 1202 A.
1.4 - Notes on installing
Installation is carried out in the reverse order, when doing this note the following:
Warning!
When doing any repair work, especially in the engine compartment, pay attention to the following due to the
cramped conditions:
◆ Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant, refrigerant,
brake fluid and vacuum pipes and hoses) and electrical wiring so that the original positions are restored.
◆ Ensure sufficient clearance to all moving or hot components.

Sharan 1996 ➤
- Check whether the dowel sleeves for centring engine/gearbox are in the cylinder block and install if neces‐
sary.
- -> Fit intermediate plate onto sealing flange and slide onto dowel sleeves -arrows-.
- Clean input shaft splines and lightly grease with G 000 100.
- Check clutch and clutch operating mechanism, then install:
=> 5-Speed manual gearbox 006; Repair group 30; Assembly overview; hydraulics and clutch release mech‐
anism Assembly overview hydraulics and clutch release mechanism
- Clean input shaft splines and lightly grease with G 000 100.
- Check clutch and clutch operating mechanism, then install:
- Screw in all bolts on assembly mountings by hand approx. 5...6 turns.
Note:
-> Before inserting the bolts for the assembly mounting the bracket -B- must be installed and tightened
Tightening torque for bracket => Page 14 .
1.4 - Notes on installing 11

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- Align assembly mountings stress-free by rocking.
Note:
Assembly mounting tightening torques
=> Page 14 .
- Connect pipe/hose on slave cylinder and secure with clip:
=> 5-Speed manual gearbox 006; Repair group 30; Assembly overview; hydraulics and clutch release mech‐
anism Assembly overview hydraulics and clutch release mechanism
- Attach operating cable to gearbox, adjust if necessary:
=> 5-Speed manual gearbox 006; Repair group 34; Servicing selector mechanism; Removing and installing
- Connect pipe/hose on slave cylinder and secure with clip:
- Attach operating cable to gearbox, adjust if necessary:
=> 6-speed manual gearbox 02N; Repair group 34; Servicing selector mechanism; Removing and installing
- Install selector cable on gearbox, adjust if necessary:
=> Automatic gearbox 099 - 4-speed; Repair group 37; Servicing selector mechanism; Servicing selector
mechanism
- Install selector cable on gearbox, adjust if necessary:
=> Automatic gearbox 09B - 5-speed; Repair group 37; Servicing selector mechanism Servicing selector
mechanism
- Remove front exhaust pipe => Page 257 , front exhaust pipe and catalyst with attachments.
- Install drive shafts:
drive shaft
- Install pendulum support:
bar, wishbone
- Installing P.A.S. vane pump:

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

Tightening torque: 20 Nm.
Vehicles with air conditioner
- Installing air conditioner compressor:
=> Heating, Air conditioning; Repair group 87; removing and installing compressor bracket removing and in‐
stalling compressor bracket
- Install ribbed belt => Page 28 .
- Install air pipes between turbocharger/charge air cooler, turbocharger/air cleaner and charge air cooler/
throttle valve control part: => Page 225 , Removing and installing parts of charge air cooling system: engine
code AJH
- Install intake hose: => Page 225 , Removing and installing parts of charge air cooling system: engine code
AJH
- Install pressure hose between secondary air pump motor and combi-valve
- Adjusting accelerator cable =>Page 195 , Servicing accelerator mechanism.
- Install air pipes between turbocharger/charge air cooler, turbocharger/air cleaner and charge air cooler/
throttle valve control part: => Page 228 , Removing and installing parts of charge air cooling: engine code
AWC
- Install intake hose: => Page 228 , Removing and installing parts of charge air cooling: engine code AWC
- Install pressure hose between secondary air pump motor and combi-valve
=> Page 270 , Removing and installing parts of secondary air system
- Install air cleaner:
- Install battery tray and battery.
- Electrical connections and routing:
=> Current flow diagrams, Electrical fault finding and Fitting locations
Filling with new coolant => Page 152 .
- Install noise insulation tray.
- Carry out a test drive and interrogate fault memory:
=> Repair group 01; Fault memory; Interrogating and erasing fault memory Fault memory Interrogating and
erasing fault memory
- Match engine electronics control unit to throttle valve control part:
1.4 - Notes on installing 13

Sharan 1996 ➤
=> Repair group 24; Engine control unit; Adapting engine control unit to the throttle valve control part Engine
control unit Adapting engine control unit to the throttle valve control part
- Carry out a test drive and interrogate fault memory:
=> Repair group 01; Fault memory; Interrogating and erasing fault memory of engine control unit Fault memory
Interrogating and erasing fault memory of engine control unit
- Adapt engine control unit to throttle valve control part and to EGR valve.
=> Repair group 24; Engine control unit; Adapting engine control unit to throttle valve control part and EGR
valve Engine control unit Adapting engine control unit to throttle valve control part and EGR valve
- On vehicles with automatic gearbox the gearbox control unit must be matched additionally:
=> Self-diagnosis for automatic gearbox 09B - 5-speed; Repair group 01; Performing self-diagnosis; Initiating
basic setting Performing self-diagnosis Initiating basic setting
1.5 - Tightening torques
Bolted connections Tightening torque

Bolts, nuts M6 10 Nm
M7 15 Nm
M8 20 Nm
M10 40 Nm
M 12 60 Nm
Deviating from above
Hydraulic pipe to engine bracket 20 Nm
Starter to engine and gearbox 45 Nm
Front exhaust pipe to turbocharger 25 Nm
Note:
Assembly mounting tightening torques
=> Page 14 .
1.6 - Assembly mountings
Tightening torques
(Bolts oiled)

Sharan 1996 ➤
-> Assembly mounting, right:
A = 55 Nm
B = 60 Nm
-> Assembly mounting, left on vehicles with manual gearbox:

A = 55 Nm
B = 110 Nm
C = 100 Nm
D = 20 Nm
-> Assembly mounting, left on vehicles with automatic gearbox:

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

Sharan 1996 ➤
-> Assembly mounting, left:
A = 60 Nm + 1/4 turn (90 °) further1)

B = 90 Nm + 1/4 turn (90 °) further1)
C = 50 Nm + 1/4 turn (90 °) further1)
D = 25
1) Replace bolts or nuts
Note:
All threaded holes into which self-locking bolts were screwed must be cleaned of residue from locking fluid
using a thread cutter.
1.7 - Additional information and removal instructions for vehicles with air conditioner
Warning!
The air conditioning system refrigerant circuit must not be opened.
Notes:
◆ The refrigerant circuit can only be opened in workshops having specially trained personnel and the neces‐
sary tools and workshop equipment.
◆ To avoid damage to condenser as well as to refrigerant pipes and hoses, ensure that the pipes and hoses
are not stretched, kinked or bent.
To facilitate removing and installing the engine without opening the refrigerant circuit:
- Remove retaining clamp(s) from refrigerant pipes.

- Remove alternator:
=> Electrical system; Repair group 27; alternator with ribbed belt alternator with ribbed belt
- Removing air conditioner compressor:
=> Heating, Air conditioning; Repair group 87; removing and installing compressor bracket removing and in‐
stalling compressor bracket
- Secure air conditioner compressor to body so that the refrigerant hoses/pipes are relieved.

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

1.1 - Dismantling and assembling engine
Notes:
◆ When stripping and assembling the engine it should be secured to the engine frame with engine and gearbox
bracket VW 540 and supplementary set VW 540/1B.
◆ If large quantities of metal shavings or small metal particles are found in the engine oil during an engine
repair this can be due to partial seizure of crankshaft or conrod bearings. In this case it is not only necessary
to thoroughly clean the oil passages, but also to replace the oil cooler and oil filter to prevent subsequent
damage.
I =>Page 18
1.1 - Dismantling and assembling engine 17

Sharan 1996 ➤
II =>Page 23
Part I Volkswagen Technical Site: http://vwts.ru http://vwts.info

1 Toothed belt guard - upper part
2 Toothed belt
◆ Mark D.O.R. before removing
◆ Check for wear
◆ Do not kink
◆ Removing, installing and tensioning
=> Page 60
3 Idler wheel
4 27 Nm
5 65 Nm
◆ Use counter-hold 3036 to loosen and tighten
6 Camshaft sprocket
◆ Note installation position:
The small web of the camshaft sprocket points outwards and the No. 1 Cyl. TDC marking is visible
◆ Note position when installing toothed belt
18 13 - Crankshaft group
Sharan 1996 ➤
=> Page 60 , Removing, installing and tensioning toothed belt
7 Tensioning roller
◆ Removing, installing and tensioningtoothed belt => Page 60
8 Washer
9 Tensioning device for toothed belt
◆ Removing, installing and tensioningtoothed belt => Page 60
10 O-ring
◆ Renew
11 Coolant pump
◆ Check for ease of movement
◆ If damaged or leaking renew complete
◆ Removing and installing
=> Page 159
12 15 Nm
13 Crankshaft toothed belt sprocket

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

◆ Renew
◆ Counter-hold with 3415 to loosen and tighten
◆ Threads and shoulder must be free of oil and grease
◆ The quarter turn further can be done in several stages.
15 20 Nm
16 Toothed belt guard - centre section
17 Toothed belt guard - lower part
18 10 Nm
◆ Insert with locking fluid "D 000 600 A2"
19 Ribbed belt
◆ Mark direction of rotation before removing
◆ Check for wear
◆ Do not kink
=> Page 28
Sharan 1996 ➤
20 Pulley
◆ For power assisted steering pump
21 25 Nm
22 Belt pulley/vibration damper
◆ Can only be installed in one position.
23 Tensioning device for ribbed belt
◆ To slacken ribbed belt, turn with open-end spanner => Page 28 , Removing and installing ribbed belts

Sharan 1996 ➤
24 45 Nm
25 Right engine bracket
Sharan 1996 ➤
Part II
1 Knock sensor 1 (G61)

◆ Checking (engine code AJH):
=> Repair Group 01; Fault memory; Interrogating and erasing fault memory Fault memory Interrogating and
◆ Checking (engine code AWC):
=> Repair Group 01; Fault memory; Interrogating and erasing engine control unit fault memory Fault memory
Interrogating and erasing engine control unit fault memory
2 20 Nm
◆ Tightening torque influences the function of the knock sensor
3 Knock sensor 2 (G66)

Sharan 1996 ➤
4 Dipstick
◆ The oil level must not be above the max. mark!
◆ Markings => Page 112 , Fig. 1
5 Guide
◆ For dipstick
◆ Secured to intake manifold with bracket
6 O-ring
◆ Renew
7 Coolant pipe
◆ Coolant hose connection diagram: engine code AJH =>Page 148
◆ Coolant hose connection diagram: engine code AWC =>Page 150
8 20 Nm
9 Gasket
◆ Renew
Sharan 1996 ➤
10 Oil filter bracket

◆ Ensure clearance to adjacent components
◆ Dismantling and assembling: engine code AJH => Page 113
◆ Dismantling and assembling: engine code AWC => Page 118
11 15 Nm + 1/4 turn (90 °) further
◆ Renew
12 10 Nm
13 Engine speed sender (G28)

Sharan 1996 ➤
14 Connection
15 15 Nm
16 Coolant thermostat
=> Page 161
◆ Observe installation position,
=> Page 161 Removing and installing thermostat
◆ Checking: heat-up thermostat in water
◆ Opening commences approx. 87 °C
◆ Ends approx. 102 °C
◆ Opening lift min. 7 mm
17 25 Nm
18 Support
◆ Between intake manifold and cylinder block
19 45 Nm
20 Compact bracket
◆ For alternator, air conditioner compressor and vane pump for power assisted steering
Sharan 1996 ➤
21 Bracket
◆ Only vehicles with engine code AJH
◆ For air pipe exhaust turbocharger/charge air cooler
22 40 Nm
23 Cylinder block
◆ Removing and installing crankshaft => Page 43
◆ Dismantling and assembling pistons and conrods
=> Page 48
24 Spacer sleeve
◆ Only vehicles with manual gearbox
25 25 Nm
26 Support
◆ Between turbocharger and cylinder block

Sharan 1996 ➤
1.2 - Removing and installing ribbed belt
Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
◆ T10060 Mandrel
Removing 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.
- Mark direction of rotation of ribbed belt.

- -> Using a 16 mm open jaw spanner swing tensioning element in direction of arrow until tensioning element
can be locked.
Sharan 1996 ➤
- -> Lock tensioning element using mandrel T10060 -arrow-.
- Remove ribbed belt.
Installing ribbed belt
- Install in reverse order.
Notes:
◆ Ensure, before installing ribbed belt, that all ancillaries (alternator, air conditioner compressor, power as‐
sisted steering vane pump) are secured tightly.
◆ When fitting the ribbed belt observe belt direction of rotation and that the belt is seated correctly in the belt
pulleys.
◆ For vehicles with air conditioning, put ribbed belt over air conditioning compressor last.
- Fit ribbed belt.
After completing repairs always:
- Start engine and check belt running.
Ribbed belt routing
-> Belt drive without air conditioner compressor
-> Belt drive with air conditioner compressor
Note:
Engines with an air conditioner compressor are fitted with a double ribbed belt.
1.2 - Removing and installing ribbed belt 29

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

2.1 - Removing and installing sealing flanges and flywheel/drive plate
Notes:
◆ Servicing clutch (engine code AJH):
=> 5 Speed manual gearbox 006; Repair group 30; servicing clutch servicing clutch
◆ Servicing clutch (engine code AWC):
=> 6-speed manual gearbox 02N; Repair group 30; Servicing clutch Servicing clutch
Sharan 1996 ➤
1 90 Nm + 1/4 turn (90 °) further

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

Sharan 1996 ➤
6 Cylinder block
=> Page 48
7 60 Nm + 1/4 turn (90 °) further
◆ Renew
8 Flywheel/drive plate
◆ To remove or install flywheel, hold with counter-hold tool 3067
◆ Removing and installing drive plate =>Page 41
9 Intermediate plate
◆ Do not damage/bend when assembling
Sharan 1996 ➤
10 Sealing flange with oil seal

◆ Only renew complete
◆ To remove and install, remove sump
=> Page 123
◆ Before installing, remove oil residue from crankshaft journal using a clean cloth
◆ Do not additionally oil or grease the oil seal sealing lip
◆ Use protective sleeve supplied when installing
◆ Remove protective sleeve first after sealing flange has been slid onto crankshaft journal
2.1 - Removing and installing sealing flanges and flywheel/drive plate 33

Sharan 1996 ➤
2.2 - Renewing crankshaft oil seal -belt pulley end-
◆ 2080 A Fitting sleeve

◆ 3203 Oil seal extractor
◆ 3265 Fitting sleeve
◆ 3415 Counter-hold tool
Not illustrated, for vehicles with PTFE oil seals:
◆ T10053 Assembly device
Removing
- Removing ribbed belt and tensioning element => Page 28 .

- Remove toothed belt => Page 60 .
Sharan 1996 ➤
- -> Remove crankshaft toothed belt sprocket. To do this counter-hold sprocket with 3415.
- -> To guide seal extractor, screw centre bolt into crankshaft onto stop by hand.
- Unscrew inner part of the oil seal extractor 3203 two turns (approx. 3 mm) out of the outer part and lock with
knurled screw.
- -> Lubricate threaded head of oil seal extractor 3203, place it in position and exerting firm pressure screw
it as far as possible into oil seal.
- Loosen knurled screw and turn inner part against crankshaft until the oil seal is pulled out.
Installing
Note:
Gradual introduction of PTFE oil seals (Poly-Tetra-Fluor-Ethylen). Identifying characteristics: no annular spring,
sealing lip wider. The sealing lip of this oil ring must not be oiled or lubricated. A plain encased seal of older
construction (with annular spring) may be replaced with a PTFE oil seal, but not vice versa.
2.2 - Renewing crankshaft oil seal -belt pulley end- 35

Sharan 1996 ➤
- Before installing, remove oil remains from crankshaft journal with a clean cloth.
Installing seal with annular spring
- Lightly oil sealing lip of oil seal.

- -> Fit guide sleeve from 2080 A onto crankshaft journal.
- Slide oil seal over guide sleeve onto crankshaft stub.
- -> Press in seal with press sleeve from 3265. To do this use old central bolt -1- for crankshaft toothed belt
sprocket:
- Press in oil seal 2...3 mm.
Installing PTFE seal
- -> Fit guide sleeve T10053/1 onto crankshaft journal.

- Slide oil seal over guide sleeve onto crankshaft stub.
Sharan 1996 ➤
- -> Press in oil seal onto stop using press sleeve T10053 and bolt T10053/2 (M16 x 1.5 x 60).
Continuation for all seals
- -> Install crankshaft toothed belt sprocket and hold with counter-hold tool 3415.
- Tighten central bolt to 60 Nm and turn
90° (1/4 turn)
further (turning further can be done in several stages).
Note:
Thread and shoulder must be free of oil and grease.
- Install toothed belt and adjust timing => Page 60 .

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

Sharan 1996 ➤
2.3 - Removing and installing sealing flange -belt pulley end-
◆ 2080 A Fitting sleeve

◆ 3415 Counter-hold tool
◆ D176 404 A2 Silicone sealant
◆ Hand drilling machine with plastic brush insert
◆ Protective glasses
◆ Flat scraper
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Removing

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

- Cover seal with a clean rag.
- -> Remove sealant remains on sealing flange with a rotating plastic brush (wear protective goggles).
- Clean sealing surface, must be free of oil and grease.
Installing
Notes:
◆ Note the use by date of the sealant.
◆ The sealing flange must be installed within 5 minutes of applying the silicone sealant.
- -> Cut off tube nozzle at forward marking (nozzle approx. 3 mm ø).
- Apply silicone sealing compound, as shown, to clean sealing surface of the sealing flange. Sealing com‐
pound bead must be:
- 2...3 mm thick.
2.3 - Removing and installing sealing flange -belt pulley end- 39

Sharan 1996 ➤
- and run on inside of bolt holes -arrows-.
Notes:
◆ The sealing bead must not be thicker, otherwise excessive sealant may drip into the oil sump, the intake
pipe oil strainer may be blocked and it could also drip onto the sealing surface of crankshaft seal.
◆ Cover the sealing surface of the oil seal with a clean cloth before applying the sealant.
- Fit sealing flange immediately and lightly tighten all bolts.
Note:
Use guide sleeve from 2080A to fit sealing flange with the oil seal already installed.
- Tighten sealing flange securing bolts diagonally.
Tightening torque:15 Nm
- Remove excess sealant
- Install sump => Page 123 .
Note:
After installing, the sealant must be allowed to dry for approx. 30 minutes before engine oil is replenished.
- -> Install crankshaft toothed belt sprocket and hold with counter-hold tool 3415.
- Tighten new central bolt to 90 Nm and turn
90° (1/4 turn)
Note:
Thread and shoulder must be free of oil and grease.

Page 28 .
2.4 - Removing and installing drive plate
Sharan 1996 ➤
◆ VW 558 Retainer
◆ Hexagon bolt M8x45 and two M10 hexagon nuts
◆ Depth gauge
Loosening and tightening drive plate
- -> Secure counter-hold tool VW 558 to the drive plate with a hexagon bolt M8x45. Place two M10 hexagon
nuts between counter-hold tool and drive plate.
Position of counter-hold tool:

A - To loosen
B - To tighten
- Loosen drive plate bolts.
Installing drive plate

- -> Locate drive plate and packing plate with recesses -1-.
- Fit new bolts -3- and tighten to
2.4 - Removing and installing drive plate 41

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

Specification: 19.5...21.1 mm
Note:
Measured through hole in drive plate to milled surface of cylinder block.
If the specification is not attained:
- -> Remove drive plate again and fit shim -2-. Tighten bolts again to
30 Nm.
- Tighten bolts to 60 Nm and turn
90° (1/4 turn)
Sharan 1996 ➤
3 - Removing and installing crankshaft

3.1 - Removing and installing crankshaft
Notes:
◆ Before removing the crankshaft, ensure that a suitable surface is prepared to ensure that the sender wheel
(item 8 ) is not damaged or lies against any other item.
1 Oil pump with sprocket

◆ With pressure relief valve of 12 bar
◆ Before installing, check that both dowel sleeves for centralizing oil pump/cylinder head are fitted
=> Page 106
3.1 - Removing and installing crankshaft 43

Sharan 1996 ➤
2 15 Nm
3 Chain sprocket
◆ For oil pump drive
◆ Check for wear
4 Bearing caps 1, 2, 4 and 5
◆ For bearing cap without oil groove
◆ For cylinder block with oil groove
◆ Do not interchange used bearing shells (mark)
Vehicles 06.00 ▸
◆ Classification for ordering spare parts =>Page 47 , Fig. 1
5 65 Nm + 1/4turn (90 °) further
◆ Renew
◆ Threaded along complete length (screw)
◆ Tighten to 65 Nm when measuring radial clearance
Sharan 1996 ➤
6 Bearing cap
◆ Bearing cap 1: Pulley end
◆ Bearing cap 3 with recesses for thrust washers
◆ Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side
7 Bearing shell 3
◆ For bearing cap without oil groove
◆ For cylinder block with oil groove
◆ Do not interchange used bearing shells (mark)
Vehicles 06.00 ▸
◆ Classification for ordering spare parts =>Page 47 , Fig. 1
8 Sender wheel
◆ Renew
◆ For engine speed sender (G28)
◆ Can only be installed in one position. Holes are off-set

Sharan 1996 ➤
9 10 Nm + 1/4 turn (90 °) further

◆ Renew
10 Thrust washer
◆ For bearing 3 bearing cap
◆ Note fixing arrangement
11 Crankshaft
◆ Axial clearance new: 0.07...0.23 mm
Wear limit: 0.30 mm
◆ Check radial clearance with Plastigage
New: 0.01...0.04 mm
Wear limit: 0.15 mm
◆ Do not rotate the crankshaft when checking the radial clearance
◆ Crankshaft dimensions
=> Page 47
Sharan 1996 ➤
-> Fig. 1 Upper crankshaft bearing identification
Upper bearing shells of the proper thickness are allocated to the cylinder block at the factory. Colour markings
are used to identify the bearing shell thickness
Note:
Arrow points in direction of travel.
Letters on the lower sealing surface of the cylinder block identify which bearing thickness must be inserted at
which position
3.2 - Colour markings
Letter on Colour of bearing

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

dimension
Engine code Engine code AWC
AJH

Sharan 1996 ➤
Basic -0.022 -0.017 -0.022

dimension 54.00 54.00 47.80
-0.042 -0.037 -0.042
1st undersize -0.022 -0.017 -0.022
53.75 53.75 47.55
-0.042 -0.037 -0.042
2nd undersize -0.022 -0.017 -0.022
53.50 53.50 47.30
-0.042 -0.037 -0.042
3rd undersize -0.022 -0.017 -0.022
53.25 53.25 47.05
-0.042 -0.037 -0.042
4 - Dismantling and assembling pistons and conrods

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

Sharan 1996 ➤
Marking -A- faces towards pulley end
◆ Mark cylinder number -B-
5 30 Nm + 1/4 turn (90 °) further

◆ Renew
◆ Oil threads and contact surface
◆ To measure radial clearance tighten to 30 Nm but not further
6 Pressure relief valve, 27 Nm
◆ Opening pressure: 1.3...1.6 bar
7 Oil spray jet
◆ For piston cooling
Sharan 1996 ➤
8 Bearing shell
◆ Note installation position
◆ Do not interchange used bearing shells
◆ Ensure retaining lugs fit tightly in recesses
◆ Axial clearance
New: 0.10...0.31 mm
Wear limit: 0.40 mm
◆ Check radial clearance with Plastigage:
New: 0.01...0.05 mm
Wear limit: 0.12 mm
Do not rotate crankshaft when checking radial clearance
9 Cylinder block
◆ Checking cylinder bores
=>Fig. 4
◆ Piston and cylinder dimensions
=>Page 55
10 Conrod bolt
◆ Renew

Sharan 1996 ➤
11 Circlip
12 Piston pin
◆ If difficult to remove, heat piston to 60 °C
◆ Remove and install with drift VW 222a
Sharan 1996 ➤
-> Fig. 1 Checking piston ring gap
◆ Feeler gauges
Test sequence
- Push ring squarely from above down to approx. 15 mm from bottom end of cylinder.
Piston ring Gap

New Wear
limit
Compression rings mm 0.15...0.40 0.80
Oil scraper ring mm 0.25...0.50 1.0
-> Fig. 2 Checking ring to groove clearance
◆ Feeler gauges
Test sequence
- Clean ring groove before checking.
Piston ring Clearance

New Wear
limit
Compression rings mm 0.02...0.07 0.12

Sharan 1996 ➤
Piston ring Clearance

Oil scraper ring mm 0.02...0.06 0.12
-> Fig. 3 Checking piston
◆ Micrometer 75...100 mm
Test sequence
- Take measurement about 10 mm from lower edge of piston skirt and offset 90 °to piston pin axis.
Deviation from specification

max. 0.04 mm.
-> Fig. 4 Checking cylinder bores
◆ Internal dial gauge 50...100 mm
Sharan 1996 ➤
Test sequence
- Take measurements at right angles -A- and -B- at 3 positions.
Deviation from specification

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.
4.2 - Piston and cylinder dimensions
Honing dimension Piston - ø Cylinder bore - ø

Basic dimen. mm 80.9651) 81.010
1st oversize mm 81.4651) 81.510
1) Dimension without graphite coating (thickness 0.02 mm).

The graphite coating wears away.

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

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

=> Repair group 24; Servicing injection system; Removing and installing parts of injection system Servicing
injection system Removing and installing parts of injection system
Checking compression pressures => Page 75
56 15 - Cylinder head, Valve gear

Sharan 1996 ➤
1 Cap
◆ Renew seal if damaged
2 Gasket
◆ Renew if damaged
3 Connecting hose
◆ To crankcase breather pipe
4 Cylinder head cover
5 Cylinder head cover gasket
◆ Before installing, seal transition points between bearing cap and cylinder head as well as between chain
tensioner and cylinder head => Page 86 , fig. 4 and
6 Oil deflector
Above inlet camshaft
7 Cylinder head
◆ Check for distortion => Fig. 1
=> Page 68
◆ Reworking sealing surface
=> Page 85 , Fig. 1
◆ After replacing renew the complete coolant
8 Intake manifold gasket
1.1 - Removing and installing cylinder head 57

Sharan 1996 ➤
◆ Renew
9 Cylinder head gasket
◆ Metal gasket
◆ Renew
◆ If replaced renew the complete
coolant
Identification: Part No. must be readable from inlet side
10 Toothed belt
◆ Check for wear
◆ Do not kink
=> Page 60
11 Exhaust manifold gasket
◆ Renew
◆ Note fitting position
12 Cylinder head bolt
◆ Renew
◆ Sequence when loosening and tightening => Page 68 , Removing and installing cylinder head
13 10 Nm
14 Gasket

Sharan 1996 ➤
15 Breather housing
◆ To remove turn breather housing to left
-> Fig. 1 Checking cylinder head for distortion
◆ Straight edge
◆ Feeler gauges
Max. permissible distortion: 0.1 mm

Sharan 1996 ➤
1.2 - Removing, installing and tensioning toothed belts
◆ 10-222 A Support bracket

◆ 10-222 A/5 Legs
(Engine code AJH)
◆ 10-222 A/12 Shackle
(Engine code AWC)
◆ 10-222 A/14 and 10-222 A/15 Legs
(Engine code AWC)
◆ T10092 Tensioning bolt
◆ T40011 Locking pin
◆ D 000 600 A2 Locking fluid

◆ Bolts M8x35 Qty. 2 (engine code AWC)
Removing
- Note safety precautions before starting work => Page 182 .

Sharan 1996 ➤

- Remove battery.


- Remove air pipe between turbocharger and charge air cooler => Page 225 , Removing and installing parts
of charge air cooling: engine code AJH

- -> Remove the securing screws -arrows- for bracket for charge air system air pipe from the sump.

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

Sharan 1996 ➤
- -> Set camshaft sprocket to TDC No. 1 cylinder by turning the crankshaft. Mark on camshaft sprocket must
align with mark on cylinder head cover.
- -> Remove vibration damper/belt pulley.
- -> Fit engine support bracket 10-222 A with legs 10-222 A/5.
- Secure legs 10-222 A/5 using body bolts -arrows-.

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

Sharan 1996 ➤
- -> Assemble engine support bracket 10-222 A with legs 10-222 A/14 and 10-222 A/15 as shown.
- -> Bolt leg 10-222 A/14 to battery tray with bolts M8x35 -arrows-.
Tightening torque: 25 Nm
- -> Insert shackle 10-222 A/12 in lifting eye on right of cylinder head.
- Hook securing hook of engine support 10-222 A in shackle 10-222 A/12 and take up weight of engine.
- Remove pendulum support.
bar, wishbone

Sharan 1996 ➤
- -> Remove right assembly mounting securing bolts -1-.
- -> Remove bolts and nuts from engine mounting -arrows- and remove mounting complete.
- Lift the engine as far as is possible with the support bracket.
- Remove engine mounting from cylinder block and lift out upwards.
- Remove toothed belt guard centre and lower parts.
- -> Screw tensioning bolt T10092 into toothed belt tensioning element.
- Align pressure piston using pointed pliers or thin wire before tensioning. (Hole in pressure piston must align
with hole in housing.)
- Tension piston of tensioning element just enough that the piston can be locked with locking pin T40011.
- Remove toothed belt.
- Turn crankshaft back slightly.
Installing
Note:
When turning the camshaft the crankshaft must not be at TDC. Danger of damage to valves/piston crown.

Sharan 1996 ➤
A - Toothed belt completely removed
If toothed belt has only been removed from camshaft => Page 66 .
Conditions
• The pistons must not be positioned at TDC.
Work sequence
- -> Bring mark on camshaft in line with the mark on cylinder head cover.
- Place toothed belt on crankshaft pulley and coolant pump (observe DOR).
- Install centre and lower parts of toothed belt guard. (Insert securing bolts with locking fluid "D 000 600 A2".)
- Install vibration damper/belt pulley (fits in one position only).


Sharan 1996 ➤
- -> Turn crankshaft to TDC No. 1 cylinder.
- Install pendulum support:
bar, wishbone
- Install air pipe between turbocharger and charge air cooler => Page 225 , Removing and installing parts
of charge air cooling: engine code AJH.
- -> Install air pipe bracket on sump.

- Place toothed belt on the camshaft sprocket and tension => Page 67 .
B - Toothed belt only taken off camshaft sprocket
- -> Bring mark on camshaft in line with the mark on cylinder head cover.
- Turn crankshaft to TDC No. 1 cylinder.
- Place toothed belt on the camshaft sprocket and tension => Page 67 .

Sharan 1996 ➤
Tensioning toothed belt
Conditions
• The engine must not be more than warm to the touch.

• Engine is at TDC No. 1 cylinder.
Work sequence
- -> Tension toothed belt by pulling out locking pin T40011 and removing tensioning bolt T10092.
- Turn crankshaft two full turns and check whether camshaft and crankshaft marks align with their reference
points.
Continuation, installing toothed belt
- Install upper toothed belt guard.
AJH
- Install battery.

Sharan 1996 ➤
- Fit engine mounting to cylinder block.
- Install engine assembly mounting.
Tightening torque => Page 14 .
Page 28 .
1.3 - Removing and installing cylinder head
◆ 3070 Fitting tool with guide pins
◆ 3452 Tool or T10070 socket insert
◆ T10092 Tensioning bolt
◆ T40011 Locking pin

Sharan 1996 ➤
◆ VAS 5024 Spring-type hose clip pliers
Prerequisite
• The engine must be no more than warm to touch.
Work sequence
- With the ignition switched off disconnect battery earth strap.

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

- Seal the pipes so that the fuel system is not contaminated by dirt etc.
- -> Disconnect throttle cable at throttle valve control part cable disc and support bracket -arrows- (do not
remove locating clip on support bracket).
Note:
- Pull vacuum hose off combi-valve.
- -> Pull off 6-pin connector (grey) off EGR valve (N18) -arrow-.

Sharan 1996 ➤
Note:
- Pull vacuum hose off EGR valve.
- Remove intake manifold.
Note:
Seal the intake ports in cylinder head with a clean cloth.
- -> Remove air guide trim -1- and battery trim -2-.
- Remove the pipe for the crankcase breather.
- -> Remove the securing bolts from heat shield (exhaust side) -arrows-.
- -> Remove the three exhaust gas turbocharger/exhaust manifold securing bolts -1-.
- Now remove the lateral coolant hose connection on the cylinder head.

Sharan 1996 ➤
- Take toothed belt off camshaft toothed belt sprocket
=> Page 60 .
- Remove ignition coils with output stages:
=> Repair group 28; Servicing ignition; Removing and installing parts of ignition Servicing ignition Removing
and installing parts of ignition
- Remove cylinder head cover.
- -> Loosen cylinder head bolts using key 3452 or socket T10070 in the sequence given and then remove
completely.
Note:
Use tool 3452 or socket insert T10070 for Polydrive cylinder head bolts.
- Carefully lift cylinder head off.
Note:
To prevent dirt getting into the charge air system, cover the exhaust gas turbocharger with a clean cloth.

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

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

- Install ignition coils and tighten to
10 Nm.
- Adjusting accelerator cable =>Page 195 , Servicing accelerator mechanism.

- Interrogating and erasing fault memory:

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

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

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

Sharan 1996 ➤
-> Fuse holder for vehicles with engine code AJH.
-> Fuse holder for vehicles with engine code AWC.
Note:
Removing fuse No. 14 interrupts the voltage supply to the injectors.
- Remove spark plugs with spark plug socket and extension 3122B.
- Have a second mechanic operate the starter. (Also fully depress accelerator pedal in vehicles with engine
code AJH.)
- Check compressions with compression tester V.A.G 1763 and adapter V.A.G 1763/6.
Note:
Using the compression tester => Operating instructions.
- Operate starter until tester shows no further pressure increase.
Compression pressure:
New: 10...13 bar

Wear limit: 7.0 bar
Permissible difference between all cylinders:

max. 3 bar
- Install spark plugs with spark plug socket and extension 3122B and tighten to
30 Nm.
10 Nm.

Sharan 1996 ➤
2 - Servicing valve gear

2.1 - Servicing valve gear
Notes:
◆ Cylinder heads which have cracks between the valve seats or between valve seat inserts and the spark
plug thread can be used further without reducing service life, provided the cracks do not exceed a maximum
of 0.3 mm in width, or when no more than the first four spark plug threads are cracked.
◆ After installing new bucket tappets the engine must not be started for approx. 30 minutes (otherwise valves
will strike pistons), then turn crankshaft two rotations.
1.4 - Checking compression pressures 77

Sharan 1996 ➤
1 10 Nm
2 Inlet camshaft
◆ Checking axial clearance => Fig. 2
=> Page 96
◆ Checking radial clearance with plastigage
Wear limit: 0.1 mm
◆ Run-out: max. 0.01 mm
3 Drive chain
◆ Before removing mark D.O.R. (installation position)
=> Page 96 Removing and installing camshafts
4 10 Nm

Sharan 1996 ➤
5 Chain tensioner
◆ Only rotate engine with chain tensioner installed
◆ Secure with chain tensioner retainer 3366 before removing => Page 96 ; Removing and installing
camshafts
◆ Seal transition points between chain tensioner and cylinder head
=> Fig. 5
6 Bonded rubber mounting
◆ Renew=> Page 96 , Removing and installing camshafts
7 Cylinder head
=> Page 68
◆ Reworking valve seats
=> Page 87
◆ Reworking sealing surface
=> Fig. 1
◆ Sealing transition points
=> Fig. 4 and Fig. 5
2.1 - Servicing valve gear 79

Sharan 1996 ➤
8 Valves
◆ Do not rework only grinding-in is permitted
◆ Valve dimensions => Fig. 3
◆ Sodium-filled exhaust valves: Observe disposal instructions => Page 86
9 Oil seal
◆ Renewing=> Page 89
10 Hood
◆ For Hall sender
◆ When installing note fixing arrangement
11 Washer
◆ Conical
12 25 Nm

Sharan 1996 ➤
13 Hall sender (G40) housing

◆ Checking Hall sender:
=> Repair group 28; Servicing ignition; Checking Hall sender Servicing ignition Checking Hall sender
14 10 Nm
15 65 Nm
◆ Use counter-hold 3036 to loosen and tighten
16 Camshaft sprocket
The small web of the camshaft sprocket points outwards and the No. 1 Cyl. TDC marking is visible
17 Oil seal

Sharan 1996 ➤
18 Valve guide
◆ Checking => Page 102
19 Valve stem seal
20 Valve spring
◆ Removing and installing:
Cylinder head removed:
with valve spring depressor 3362 and thrust piece 3362/1
Cylinder head installed: => Page 103 , Renewing valve stem seals
21 Upper valve spring plate
22 Cotters
23 Bucket tappet
◆ Do not interchange
◆ With hydraulic valve clearance compensation
◆ Store with cam lobe contact surface downwards
◆ Before installing check camshaft axial clearance => Fig. 2
◆ Oil contact surface

Sharan 1996 ➤
24 Inlet camshaft bearing cap

◆ Observe installation position and installation sequence => Page 96 , Removing and installing cam‐
shafts
25 Double bearing cap
◆ Lightly coat contact surfaces with sealant "AMV 174 004 01" and observe installation position and in‐
stallation sequence => Page 96 , Removing and installing camshafts
◆ Seal transition points between double bearing cap and cylinder head
=> Fig. 4
26 Exhaust camshaft bearing cap
◆ Observe installation position and installation sequence => Page 96 , Removing and installing cam‐
shafts

Sharan 1996 ➤
27 Exhaust camshaft
◆ Checking axial clearance => Fig. 2
=> Page 96
◆ Checking radial clearance with plastigage
Wear limit: 0.1 mm
◆ Run-out: max. 0.01 mm

Sharan 1996 ➤
-> Fig. 1 Reworking cylinder head sealing surface
The dimension for reworking is measured through the holes for the cylinder head bolts
a = minimum 139.2 mm
-> Fig. 2 Checking camshaft axial clearance
◆ VW 387 Universal dial gauge bracket

◆ Dial gauge
Test sequence
Check with bucket tappets and chain removed and No. 2 and 4 bearing caps fitted.
Wear limit: max. 0.2 mm
-> Fig. 3 Valve dimensions
Note:
Valves must not be reworked. Only lapping-in is permitted.
Dimension Inlet valve Exhaust valve

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

Sharan 1996 ➤
α <° 45 45
Note:
Care must be taken when disposing of old sodium filled valves. They must be cut through in the centre of the
stem with a hacksaw. When doing this they must be perfectly dry (must not come into contact with water). The
valves prepared in this way can then be thrown into a bucket of water a maximum of ten at a time. When doing
this step back quickly because a sudden chemical reaction causes the sodium filling to burn. After this treatment,
the valves can be put in with the normal scrap.
-> Fig. 4 Sealing transition points between double bearing cap and cylinder head
◆ D 454 300 A2 Sealant
- Carefully apply a thin coat of sealant "D 454 300 A2" to both edges of sealing surfaces between double
bearing cap and cylinder head -arrows- using a small screwdriver.
-> Fig. 5 Sealing transition points between chain tensioner/cylinder head
- Carefully apply a thin coat of sealant "D 454 300 A2" to both edges of sealing surfaces between chain
tensioner/cylinder head -arrows- using a small screwdriver.

Sharan 1996 ➤
2.2 - Reworking valve seats
◆ Depth gauge
◆ Valve seat refacing tool
Work sequence
Notes:
◆ When repairing engines with leaking valves, it is not sufficient to replace or renew valve seats and valves.
It is also necessary to check the valve guides for wear. This particularly important on high mileage engines
=> Page 102 .
◆ The valve seats should only be reworked just enough to produce a perfect seating pattern. The maximum
permissible reworking dimension must be calculated before work is carried out. If the reworking dimension
is exceeded, the function of the hydraulic tappets can no longer be guaranteed and therefore the cylinder
head should be renewed.
- Remove camshafts => Page 96 .
The max. permissible reworking dimension is calculated as follows:
- 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.
- -> Measure distance between end of valve stem and upper edge of cylinder head.
- Calculate max. permissible reworking dimension from measured distance and minimum dimension.
Minimum dimension:
Outer inlet valves 34.0 mm
Centre inlet valve 33.7 mm
Exhaust valve 34.4 mm
Measured distance minus minimum dimension

= max. permissible reworking dimension.
Example:
- Measured distance 34.4 mm

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

Sharan 1996 ➤
*) The max. permissible reworking dimension is shown on illustrations for reworking valve seats as
dimension "b".
-> Reworking inlet valve seat
a = 26.2 mm ø
b = Max. permissible reworking dimension*
c = 1.5... 1.8 mm
Z = Cylinder head lower edge
α = 45 °valve seat angle
β = 30 °upper correction angle
γ = 60 °lower correction angle
*) Calculating max. permissible reworking dimension => Page 87 .
-> Reworking exhaust valve seat
a = 29.0 mm ø
b = Max. permissible reworking dimension*
c = Approx. 1.8 mm
Z = Cylinder head lower edge
α = 45 °valve seat angle
β = 30 °upper correction angle
γ = 60 °lower correction angle
*) Calculating max. permissible reworking dimension => Page 87 .

Sharan 1996 ➤
2.3 - Renewing camshaft oil seal
Removing and installing camshaft sprocket oil seal
Removing seal on Hall sender => Page 92
◆ 2085 Oil seal extractor

◆ 3036 Counter hold tool
◆ T10071 Puller
Removing oil seal on camshaft sprocket
2.3 - Renewing camshaft oil seal 89

Sharan 1996 ➤

=> Page 60 .
- -> Remove camshaft sprocket. Counter-hold sprocket with 3036 when loosening the bolt.

Sharan 1996 ➤
- -> Screw camshaft sprocket securing bolt -arrow- into camshaft onto stop by hand, to guide seal extractor.
- Unscrew inner part of oil seal extractor 2085 two turns (approx. 3 mm) out of the outer part and lock in
position with knurled screw.
- -> Lubricate threaded head of oil seal extractor, place it in position and exerting firm pressure screw it into
oil seal as far as possible.
- Loosen knurled screw and turn inner part of extractor against camshaft until oil seal has been extracted.
Installing
Note:
Introduction of PTFE oil seal (identifying characteristics: no annular spring, sealing lip wider). The sealing lip
of this oil seal must not be oiled or lubricated.
- Before installing, remove oil remains from camshaft journal with a clean cloth.
- -> Fit assembly tool T10071/1 onto camshaft journal.
- Slide oil seal over assembly tool onto camshaft journal.
- Remove assembly tool.

Sharan 1996 ➤
- -> Press seal in onto limit stop with press sleeve T10071/3 and bolt T10071/4.
- -> Install camshaft sprocket. When tightening camshaft sprocket bolt hold sprocket with counter-hold 3036.
Torque setting: 65 Nm
Removing seal on Hall sender
- -> Pull 3-pin connector off Hall sender -arrow-.

Sharan 1996 ➤

- Remove Hall sender housing.
- Remove washer and hood for Hall sender.
- -> Screw bolt 2085/1 into camshaft onto stop by hand, to guide seal extractor.
- Unscrew inner part of oil seal extractor 2085 two turns (approx. 3 mm) out of the outer part and lock in
position with knurled screw.
- -> Lubricate threaded head of oil seal extractor, place it in position and exerting firm pressure screw it into
oil seal as far as possible.
- Loosen knurled screw and turn inner part of extractor against camshaft until oil seal has been extracted.
Installing

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

- Slide oil seal over assembly tool onto camshaft journal.
- Remove assembly tool.
- -> Press seal in onto limit stop using press sleeve T10071/3. To do this, use bolt M8 x 60 -1-.
- Insert Hall sender hood into notch in inlet camshaft.
- Install washer (taper facing outwards) and tighten securing bolt to
25 Nm.
- Install housing for Hall sender and tighten to
10 Nm.
AJH
- Install upper toothed belt guard.
- -> Reconnect connector on Hall sender -arrow-.


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

◆ Irregular valve noises when starting engine are normal.
Test sequence
- Start engine and run until the radiator fan has switched on once.
- Increase engine speed to about 2500 rpm for approx. 2 minutes.
If the hydraulic tappets are still noisy, locate defective tappets as follows:
- Remove pressure hose between combi-valve and secondary air pump motor at combi-valve and unclip
pressure hose from retainers.
Note:

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

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

◆ 3036 Counter hold tool
◆ 3366 Retainer for chain tensioner
◆ AMV 174 004 01 Sealant
Removing

Sharan 1996 ➤

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

=> Page 60 .

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

Sharan 1996 ➤
- -> Clean drive chain and camshaft chain sprocket in area of arrows on bearing caps and mark installation
position with a coloured mark.
Notes:
◆ Do not mark chain with a centre-punch mark, notch or similar!
◆ The distance between both arrows or the coloured marks equals 16 rollers on the drive chain.
- -> Secure chain tensioner with retainer for chain tensioner 3366.
Note:
Hydraulic chain tensioner can be damaged if chain tensioner retainer is overtightened.
- -> First remove inlet and exhaust camshafts 3rd and 5th bearing caps.
- Remove double bearing cap.
- Remove both bearing caps at chain sprockets on inlet and exhaust camshafts.

Sharan 1996 ➤
- Remove chain tensioner securing bolts.
- Remove inlet and exhaust camshaft 2nd and 4th bearing caps using alternate and cross-over sequence.
- Remove chain tensioner for inlet and exhaust camshafts and retainer for chain tensioner 3366.
Installing
Notes:
◆ When installing the camshafts the cams for No. 1 Cyl. must point upwards.
◆ When installing the bearing caps, ensure that the cap markings can be read from the inlet side of the cylinder
head.
- Fit drive chain onto both camshafts relevant to the coloured markings.
Notes:
◆ -> If a new drive chain is used, the distance between notches -A- and -B- in camshafts must be 16 rollers
of the drive chain.
◆ The illustration shows where on the sprockets the 1st and 16th rollers must be placed.
◆ Notch -A- is offset slightly to the inside relative to chain roller -1-.
.
- -> Renew bonded rubber seal for chain tensioner and lightly coat hatched area with sealant "D 454 300 A2".
- Slide chain tensioner between drive chain.
- Oil running surfaces of both camshafts.
- Place camshafts with drive chain and chain tensioner in cylinder head.
- Tighten chain tensioner to
10 Nm
(take note of dowel sleeves).

Sharan 1996 ➤
- -> Tighten inlet and exhaust camshaft 2nd and 4th bearing caps using alternate and cross-over sequence
to
10 Nm
- -> Install both bearing caps at chain sprockets of inlet and exhaust camshafts. Check camshafts for correct
positioning -arrows- and tighten bearing caps to
10 Nm
(note dowel sleeves).
- Remove retainer for chain tensioner 3366.
- -> Coat hatched area of double bearing cap lightly with sealant "AMV 174 004 01", install and tighten to
10 Nm
- Install remaining bearing caps and tighten to
10 Nm

Sharan 1996 ➤
- -> Install camshaft sprocket (narrower shoulder facing outwards and TDC mark visible) and tighten securing
bolt to
65 Nm
(use counter-hold tool 3036).
- -> Recheck position of camshafts relative to one another -arrows-.

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

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

◆ Dial gauge
Test sequence
- -> 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.
- Determine rock.
Wear limit: 0.8 mm
If rock tolerance is exceeded:
- Replace cylinder head.

Sharan 1996 ➤
2.7 - Replacing valve stem seals
(with cylinder head installed)
◆ 3122 B Spark plug spanner

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

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

- Remove the bucket tappets and place them with the contact surface downwards. When doing this ensure
that the tappets are not interchanged.
- Remove spark plugs with spark plug socket and extension 3122B.
- Set piston of appropriate cylinder to "bottom dead centre".
- -> Screw pressure hose VW 653/3 into the spark plug thread.
- Insert thrust piece 3362/1 in valve spring depressor 3362.
- Mount valve spring depressor 3362 with securing bolts screwed in on cylinder head.
- Position fitting tool for compressing valve springs to one of the following positions
outer inlet valves: lower position,
centre inlet valve: upper position,
exhaust valve: lower position

Sharan 1996 ➤
- Connect pressure hose to compressed air system supplying

at least 6 bar
and remove valve springs.
- -> Pull off valve stem seals with valve stem seal puller 3364.
Installing
- -> To prevent damage to the new valve stem seals, place plastic sleeve -A- on valve stem.
- Oil sealing lip of valve stem seal -B- insert in fitting tool 3365 and carefully push into valve guide.
- Install spark plugs with spark plug socket and extension 3122B and tighten to
30 Nm.
- Install camshafts => Page 96 .
2.7 - Replacing valve stem seals 105

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

1.1 - Removing and installing parts of the lubrication system
Notes:
◆ If large quantities of metal shavings or small metal particles are found in the engine oil during an engine
repair this can be due to partial seizure of crankshaft or conrod bearings. In this case it is not only necessary
to thoroughly clean the oil passages, but also to replace the oil cooler and oil filter to prevent subsequent
damage.
◆ The oil level must not be above the max. mark - danger of damage to catalyst!
Marking => Page 112 , Fig. 1
Dismantling and assembling oil filter bracket

=> Page 113 .
Checking oil pressure => Page 126 .
Engine oil specifications:
Use engine oil fulfilling VW standard 500 00, 501 01 or 501 02. Only in exceptional cases: Multi-grade or single-
grade oils according to API-SF or SG.
Note:
You can also use engine oil fulfilling VW standard 503 00. This engine oil is appropriate for extended service
intervals (ESI).
Dismantling and assembling oil filter bracket

=> Page 118 .
Checking oil pressure and oil pressure switch => Page 128
Engine oil specificationswith long-life service
New VW standard (specially developed, ageing resistant)

First filling: VW standard: 503 00 (VW TL 52 173)
Note:
Engines are filled at the factory with oil meeting VW standard 503 00. This engine oil is matched to long service
intervals. However, you can also use the engine oils listed below.
Engine oils conforming to VW standard 500 00, 501 01 or 502 00 can be used furthermore. The oil must then
be changed every 12 months or every 15,000 km and the service interval display must be programmed corre‐
spondingly. Procedure:
=> Maintenance manual
106 17 - Lubrication
Sharan 1996 ➤
Oil system capacity1):
with oil filter 4.5 ltrs.
1) Up-to-date figures:
=> Exhaust emissions test binder
1 15 Nm
2 Sealing flange
D 176 404 A2
=> Page 38
3 Chain tensioner with tensioning rail, 15 Nm
◆ Check for wear
◆ When installing, pretension spring and fit
4 Chain sprocket
◆ For oil pump drive
◆ Check for wear
1.1 - Removing and installing parts of the lubrication system 107

Sharan 1996 ➤
5 Cylinder block
=> Page 48
6 Dipstick
◆ The oil level must not be above the max. mark!
◆ Markings => Fig. 1
7 Guide
◆ For dipstick
◆ Secured to intake manifold with bracket
8 Guide tube
9 Oil spray jet
◆ For piston cooling
10 Pressure relief valve, 27 Nm
◆ Opening pressure: 1.3...1.6 bar
11 Suction pipe
◆ Clean strainer if soiled
12 O-ring
Sharan 1996 ➤
◆ Renew
13 Baffle plate
14 Sump
D 176 404 A2
=> Page 123
15 15 Nm
◆ Loosen and tighten with jointed wrench 3185
◆ Remove with socket extension 3249
16 Oil level/temperature sender (G266)
◆ Only vehicles with engine code AWC
◆ Black 3-pin connector
17 Seal
◆ Renew
◆ Oil before assembling

Sharan 1996 ➤
18 10 Nm
19 20 Nm
20 Bracket
◆ For air pipe between charge air cooler and turbocharger => Page 228 , Removing and installing parts
of charge air cooling: engine code AWC
21 Oil drain plug, 30 Nm
◆ Renew plug with attached seal
22 Gasket
◆ Renew
23 Oil return pipe
◆ From turbocharger
=> Page 223 , item 24
Sharan 1996 ➤
24 Oil pump
◆ With pressure relief valve of 12 bar
◆ Before installing, check that both dowel sleeves for centralizing oil pump/cylinder head are fitted
25 Chain sprocket
◆ For oil pump
◆ Check for wear
26 25 Nm
27 Roller chain
◆ Check for wear
28 Dowel sleeves
◆ Check for tight fit

Sharan 1996 ➤
-> Fig. 1 Markings on oil dipstick
1- max. mark
2- min. mark
a- Area above hatched field up to max. mark: Do not replenish with engine oil!
b- Oil level within hatched field: can be replenished with engine oil
c- Area from min. mark up to hatched field: replenish with max. 0.5 ltr. of engine oil!
Sharan 1996 ➤
1.2 - Dismantling and assembling oil filter bracket: engine code AJH
Notes:
◆ All hose connections secured by spring-type or tensioning clips.

◆ Tensioning clips are always to be replaced with spring-type clips.
1 O ring
◆ Fit onto shoulder of pipe
2 Connecting pipe
3 T-piece
◆ With non-return valve
4 Connecting hose
◆ To connection on intake manifold
1.2 - Dismantling and assembling oil filter bracket: engine code AJH 113
Sharan 1996 ➤
5 Pipe/hose assembly
◆ For crankcase breather
6 Retaining clip
7 0.25 bar oil pressure switch (F22), 25 Nm
◆ Identification: blue
◆ If sealing ring is leaking nip open and replace.
◆ Identification: black
9 Oil supply pipe
◆ To turbocharger
=> Page 219 , item 5
Sharan 1996 ➤
10 Banjo bolt, 30 Nm
11 Seal
◆ Renew
12 Oil temperature sender (G8)
◆ For oil temperature gauge
◆ Tighten to 10 Nm
13 15 Nm + 1/4 turn (90 °) further
◆ Renew
14 Seal
◆ Renew
◆ Oil before installing
◆ Fit into groove on oil cooler
Sharan 1996 ➤
15 Oil cooler
◆ Coat area outside oil seal contacting oil filter bracket with sealant "AMV 188 100 02"
◆ See note
=> Page 106
16 25 Nm
17 Oil filter
◆ Observe change intervals
◆ Loosen with strap wrench
◆ Tighten by hand
◆ Observe installation instructions on oil filter
◆ With pressure relief valve approx. 4 bar
Sharan 1996 ➤
19 Sealing plug, 40 Nm
20 Spring
◆ For pressure relief valve, approx. 4 bar
21 Piston
22 Gasket
◆ Renew
23 Non-return valve, 8 Nm
Sharan 1996 ➤
1.3 - Dismantling and assembling oil filter bracket: engine code AWC
Notes:
◆ All hose connections secured by spring-type or tensioning clips.

◆ Tensioning clips are always to be replaced with spring-type clips.
1 O ring
◆ Fit onto shoulder of pipe
2 Connecting pipe
3 T-piece
4 Connecting hose
◆ To connection low on intake manifold
Sharan 1996 ➤
5 Pipe/hose assembly
6 Retaining clip
8 Oil supply pipe
◆ To turbocharger
9 Banjo bolt, 30 Nm
10 Seal
◆ Renew
◆ Identification: black
1.3 - Dismantling and assembling oil filter bracket: engine code AWC 119
Sharan 1996 ➤
12 15 Nm + 1/4 turn (90 °) further

◆ Renew
13 Seal
◆ Renew
◆ Oil before installing
◆ Fit into groove on oil cooler
14 Oil cooler
◆ Coat area outside oil seal contacting oil filter bracket with sealant "AMV 188 100 02"
◆ See note
=> Page 106
15 25 Nm
Sharan 1996 ➤
16 Oil filter
◆ Observe change intervals
◆ Loosen with strap wrench
◆ Tighten by hand
◆ Observe installation instructions on oil filter
◆ See note
=> Page 106
◆ With pressure relief valve approx. 4 bar
19 Spring
20 Piston
1.3 - Dismantling and assembling oil filter bracket: engine code AWC 121
Sharan 1996 ➤
21 Gasket
◆ Renew
22 Non-return valve
◆ Insert in oil filter bracket (is no longer screwed into oil filter bracket)
Sharan 1996 ➤
1.4 - Removing and installing sump
◆ 3185 Jointed extension socket wrench
◆ 3249 Socket
◆ D176 404 A2 Silicone sealant
◆ Hand drill with plastic brush
◆ Flat scraper
Removing

- Drain engine oil.
Note:
Observe disposal regulations!
- Detach the oil return pipe for the exhaust gas turbocharger from the sump.
- Remove the securing screw for the air pipe bracket from the sump.
1.4 - Removing and installing sump 123

Sharan 1996 ➤
- -> Pull 3-pin connector off oil level/temperature sender (G266) -1-.
- Detach turbocharger oil return pipe -2- from sump.
- -> Remove the securing screws -arrows- for bracket for charge air system air pipe from the sump.
- Loosen oil sump bolts using jointed extension socket wrench 3185. (Remove using socket 3249.)
- Remove sump, it may be necessary to release sump by tapping lightly with a rubber head hammer.
- Remove sealant residue on cylinder block with a flat scraper.
- -> Remove sealant residue on the sump with a rotating brush, e.g. a hand drill with a plastic brush (wear
eye protection).
- Clean sealing surface, must be free of oil and grease.
Installing
Notes:
◆ Note the use by date of the sealant.
Sharan 1996 ➤
◆ Sump must be installed within 5 minutes of applying silicone sealing compound.
- -> Cut off tube nozzle at forward marking (nozzle approx. 3 mm ø).
- Apply silicone sealing compound, as shown, to clean sump sealing surface. Sealing compound bead must
be.
- 2...3 mm thick.
- and run on inside of bolt holes -arrows-.
Note:
The sealing compound bead must not be thicker, otherwise excess sealing compound will enter the sump and
may block the oil suction pipe strainer.
- -> Apply silicone sealing bead as shown to the clean sealing surface of the sump. (The illustration shows
the position of the sealant bead on the cylinder block).
- Install sump immediately and tighten all sump bolts lightly.
Note:
After installing sump the sealant must be allowed to dry for approx. 30 minutes before engine oil is replenished.
- Tighten sump bolts to
15 Nm.
- Tighten sump/gearbox bolts to
40 Nm.

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

Sharan 1996 ➤
20 Nm.
1.5 - Checking oil pressure and oil pressure switch: engine code AJH
◆ V.A.G 1342 Oil pressure tester

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

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

At
0.15...0.35 bar
the LED must go out. Otherwise renew 0.25 bar oil pressure switch (F22).
=> Page 114 , item 7 .
- Connect diode test lamp to 1.4 bar oil pressure switch (F1) -A-.
At
1.2...1.6 bar
The LED must light up. Otherwise renew oil pressure switch.
=> Page 114 , item 8 .
Check oil pressure
- Check oil pressure at different speeds:

2 000 rpm: at least 2.0 bar
Above 2 000 rpm: maximum 7.0 bar.
If the specifications are not obtained:
- Rectify mechanical damage, e.g. bearing damage.

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

7.0 bar
If the specification is exceeded:
- Check oil galleries.

- If necessary, replace oil filter bracket with pressure relief valve
=> Page 111 , item 24
1.5 - Checking oil pressure and oil pressure switch: engine code AJH 127
Sharan 1996 ➤
1.6 - Checking oil pressure and oil pressure switch: engine code AWC
◆ V.A.G 1342 Oil pressure tester

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

Note:
Functional check and servicing the optical and acoustic oil pressure warning:
Sharan 1996 ➤
Checking oil pressure switch
- -> Remove oil pressure switch (F1) and screw into tester.
- Screw tester into the oil filter bracket in place of the oil pressure switch.
- Connect brown wire of tester to earth (-).
- Connect diode test lamp V.A.G 1527 B using auxiliary cables from V.A.G 1594 A to battery positive (+) and
oil pressure switch.
LED must not light up.
If the LED lights up:
- Renew oil pressure switch (F1) .

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

At
1.2...1.6 bar pressure
the LED must light up; otherwise renew oil pressure switch (F1) => Page 119 , item 11 .
Check oil pressure
- Check oil pressure at different speeds:

2 000 rpm: 2.7...4.5 bar
Above 2 000 rpm: maximum 7.0 bar.
If the specifications are not obtained:
- Rectify mechanical damage, e.g. bearing damage.

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

7.0 bar
If the specification is exceeded:
- Check oil galleries.

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

1.1 - Removing and installing parts of cooling system
Warning!
cramped conditions:
Notes:
◆ 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.
◆ Assembly tool VAS 5024 or hose clip pliers V.A.G 1921 are recommended for fitting 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).
Perform cooling system leakage test with cooling system tester V.A.G 1274 and adapters V.A.G 1274/8 and
V.A.G 1274/9.
Parts of cooling system body side =>Page 131 .
Parts of cooling system engine side => 138 .
Coolant hose connection diagram =>Page 148 .
Test cooling system leakage using cooling system tester V.A.G 1274 and adapters V.A.G 1274/1 A and V.A.G
1274/7.
Parts of cooling system body side =>Page 134 .
Parts of cooling system engine side => 142 .
Coolant hose connection diagram =>Page 150 .
Draining and filling with coolant=> Page 152 .
Coolant mixture ratios => Page 152 , draining and filling with coolant
130 19 - Cooling system

Sharan 1996 ➤
1.2 - Parts of cooling system body side: engine code AJH
1 Rubber mounting
2 Upper coolant hose
◆ Check securely seated
◆ Coolant hose connection diagram =>Page 148
3 Radiator
=>Page 156
◆ After replacing renew entire coolant
4 Radiator fan thermo-switch (F18), 35 Nm
◆ For electric fan
◆ Switching temperatures:
Stage 1
on: 92...97 °C
off: 84...91 °C
Stage 2
on: 99...105 °C
off: 91...98 °C
1.2 - Parts of cooling system body side: engine code AJH 131
Sharan 1996 ➤
5 Connector
◆ Black, 3 pin
◆ For radiator fan thermo switch
6 10 Nm
7 Reinforcing strip
8 Connector
◆ Black
◆ For right radiator fan (V35)
9 Retaining clip
◆ Check seated securely
10 Right radiator fan (V35)
=>Page 156
11 Fan ring
12 Rubber grommet

Sharan 1996 ➤
13 Washer
14 Rubber washer
15 Bush
16 Connector
◆ Black
◆ For left radiator fan (V7)
17 Left radiator fan (V7)
=>Page 156
18 Securing bracket
◆ For lower coolant hose
19 Lower coolant hose
20 Air intake ducting
21 Rubber bush
1.2 - Parts of cooling system body side: engine code AJH 133
Sharan 1996 ➤
1.3 - Parts of cooling system body side: engine code AWC
1 Rubber mounting
2 Radiator
=>Page 156
◆ After replacing renew entire coolant
3 10 Nm
4 Radiator fan thermo-switch (F18), 35 Nm
◆ Switching temperatures:
Stage 1
on: 92...97 °C
off: 84...91 °C
Stage 2
on: 99...105 °C
off: 91...98 °C

Sharan 1996 ➤
5 Connector
◆ Black, 3 pin
◆ For radiator fan thermo switch
6 Rubber bush
7 Bracket
◆ For charge air cooler
8 Air ducting
9 9 Nm
10 Right radiator fan (V35)
◆ With fan ring
◆ Only vehicles with optional equipment
=>Page 156
11 Bracket
◆ For lower coolant hose
1.3 - Parts of cooling system body side: engine code AWC 135
Sharan 1996 ➤
12 Left radiator fan (V7)

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

Sharan 1996 ➤

1.3 - Parts of cooling system body side: engine code AWC 137
Sharan 1996 ➤
1.4 - Parts of cooling system engine side: engine code AJH
1 15 Nm
2 To turbocharger
3 Coolant circulation pump (V50)
◆ Checking =>Page 162
5 O-ring
◆ Renew
6 Connection
7 To heat exchanger
8 To rear heat exchanger
◆ Location: In rear left wheel housing

Sharan 1996 ➤
9 Retaining clip
10 Coolant temperature sender (G62)
◆ Blue, 4 pin
◆ With coolant temperature gauge sender (G2)
◆ For engine control unit
◆ If necessary release pressure in cooling system before removing
◆ Checking:
11 Connector
12 Air conditioner cut-off thermo switch (F163) and radiator fan 3rd speed thermo switch (F165)
◆ Brown, 4 pin
◆ On vehicles with air conditioning:
=> Heating, air conditioning; Repair group 87
◆ A plug is fitted on vehicles without air conditioner
13 10 Nm
◆ 2-pin
◆ On vehicles with air conditioning
=> Heating, air conditioning; Repair group 87
1.4 - Parts of cooling system engine side: engine code AJH 139
Sharan 1996 ➤
15 Bracket
16 To top of radiator
18 Oil cooler
=>Page 113 , Dismantling and and assembling oil filter bracket: engine code AJH
19 From rear heat exchanger
◆ Location: In rear left wheel housing
20 20 Nm
21 Coolant pipe
22 Cap
◆ Check with cooling system tester V.A.G 1274 and adapter V.A.G 1274/9
◆ The pressure relief valve must open at a pressure of 1.4 ...1.6
23 Seal
◆ Note installation position on cap

Sharan 1996 ➤
24 Expansion tank
◆ Carry out leak test of cooling system with cooling system tester V.A.G 1274 and adapter V.A.G1274/8
◆ Observe markings
=> Page 152 , Draining and filling coolant
25 From heat exchanger

26 Connection, 30 Nm
◆ For coolant supply pipe/hose
27 Coolant supply pipe
◆ For turbocharger
28 Coolant pump
=> Page 159
29 Toothed belt
◆ Check for wear
◆ Do not kink
=> Page 60
1.4 - Parts of cooling system engine side: engine code AJH 141
Sharan 1996 ➤
1.5 - Parts of cooling system engine side: engine code AWC
1 Bracket
◆ For coolant circulation pump
3 10 Nm
4 To heat exchanger
5 Connector
◆ Black, 2-pin
◆ Coolant temperature sender
6 Retaining clip

Sharan 1996 ➤
7 Connector
◆ Black, 2-pin
◆ For coolant shortage indicator sender
8 Cap
◆ Note installation position of seal in cap
◆ Renew seal if damaged
◆ Check with coolant system tester V.A.G 1274 and adapters V.A.G 1274/1A and V.A.G 1274/7
◆ The pressure relief valve must open at a pressure of 1.4 ...1.6
9 Expansion tank
◆ Perform leak test of cooling system with cooling system tester V.A.G 1274 and adapter V.A.G1274/7
◆ Observe markings
=> Page 152 , Draining and filling coolant
1.5 - Parts of cooling system engine side: engine code AWC 143
Sharan 1996 ➤
10 From heat exchanger

11 O-ring
12 20 Nm
13 Coolant pipe
◆ From bottom of radiator
◆ To top of radiator

Sharan 1996 ➤
16 Oil cooler
=>Page 118 , Dismantling and assembling oil filter bracket: engine code AWC
17 15 Nm
18 Connection
◆ For thermostat
19 O-ring
◆ Renew
=> Page 161
◆ Observe installation position,
=> Page 161 Removing and installing thermostat
Sharan 1996 ➤
21 Connection, 30 Nm
◆ For coolant supply pipe/hose
23 Coolant pump
=> Page 159
24 Toothed belt
◆ Check for wear
◆ Do not kink
=> Page 60
25 Coolant return pipe

Sharan 1996 ➤

◆ Black, 2-pin
◆ For engine control unit
◆ Checking:
27 Connection
Sharan 1996 ➤
1.6 - Coolant hose connection diagram: engine code AJH
1 Cylinder block/cylinder head

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

Sharan 1996 ➤
10 Radiator
12 Oil cooler
14 Coolant pump
1.6 - Coolant hose connection diagram: engine code AJH 149

Sharan 1996 ➤
1.7 - Coolant hose connection diagram: engine code AWC
15 Turbocharger
16 Connection
18 Heating system heat exchanger
19 Expansion tank
20 Coolant pipe
21 Gearbox oil cooler
◆ Only on vehicles with automatic gearbox
23 Radiator

Sharan 1996 ➤

25 Oil cooler
26 Coolant pump/coolant thermostat
27 Cylinder head/cylinder block
1.7 - Coolant hose connection diagram: engine code AWC 151

Sharan 1996 ➤
1.8 - Draining and filling cooling system
◆ T10007 Refractometer
◆ VAS 5024 Assembly tool for spring-type clamps
Not illustrated:
◆ VAS 6096 Cooling system charging
Draining

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

Sharan 1996 ➤
- Pull the bottom hose off the radiator.
- -> Pull out retaining clip -arrow- for lower coolant hose and remove coolant hose from quick-release coupling
on radiator.
- -> To drain coolant from engine also remove coolant hose from oil cooler -arrow-.
Note:
Observe disposal regulations!
Filling
Notes:
◆ Only use coolant additive G 12 in accordance with TL VW 774 F.

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

Sharan 1996 ➤
◆ If for climatic reasons a greater frost protection is required, the amount of G 12 can be increased, but only
up to 60 % (frost protection to about -40 °C), as otherwise frost protection is reduced again and cooling
effectiveness is also reduced.
◆ The refractometer T10007 is recommended for determining the current anti-freeze density.
◆ 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 122) Water2)

equipment to propor‐
tion1)
one -25 °C 40 % 2.8 ltr. 4.2 ltr.
heat ex‐ -35 °C 50 % 3.5 ltr. 3.5 ltr.
changer
two -25 °C 40 % 3.6 ltr. 5.4 ltr.
heat ex‐ -35 °C 50 % 4.5 ltr. 4.5 ltr.
changers
two -25 °C 40 % 3.8 ltr. 5.8 ltr.
heat ex‐ -35 °C 50 % 4.8 ltr. 4.8 ltr.
changers
and addi‐
tional water
heater
1) The amount of anti-freeze must not exceed 60 %; frost protection and cooling effect will decrease if
amount of anti-freeze is too high.
2) The amounts of coolant given in table refer to vehicles with manual gearbox. For vehicles with automatic
gearbox the amounts of G12 and water both increase by approx. 0.1 ltr.
Work sequence
With cooling system charging unit VAS 6096
- Screw adapter V.A.G 1274/7 or 8 onto expansion tank.

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

Sharan 1996 ➤
- -> Install lower coolant hose and secure with retaining clamp -arrow-.
- -> Push coolant hose onto oil cooler connection and secure with a spring-type clamp.
- Turn off heater control.
- Press top radiator hose down.
- -> Fill with coolant slowly up to max. mark on expansion tank. Filling takes approx. 5 minutes.
- Start engine and run at increased idling speed (about 2500 rpm) while filling expansion tank up to MAX.
marking with coolant.
With and without cooling system charging unit VAS 6096
- Fit cap to expansion tank cap.

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

Sharan 1996 ➤
Warning !
Steam can be released when removing the cap from the expansion tank. Cover cap with a cloth and open
carefully.
- Install noise insulation tray.
1.9 - Removing and installing radiator
◆ VAS 5024 Assembly tool for spring-type clips
Removing

Sharan 1996 ➤
- Pull upper coolant hose off radiator.

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

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

Additional information and removal work on vehicles with air conditioner
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, Exterior; Repair group 66; Trims; Removing and installing radiator grille with frame
Trims Removing and installing radiator grille with frame
- Removing left headlight:
1.9 - Removing and installing radiator 157

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

- Remove condenser from cooler.
- Secure condenser to body so that refrigerant pipes/hoses are not stressed.
Installing
- Electrical connections and routing:
- Check headlight adjustment and adjust if necessary:
=> Maintenance
- Installing radiator grille with frame:
=> General body repairs, Exterior; Repair group 66; Trims; Removing and installing radiator grille with frame
Trims Removing and installing radiator grille with frame

Sharan 1996 ➤
1.10 - Removing and installing coolant pump
Notes:
◆ Always renew seals and gaskets.
◆ The lower part of the toothed belt guard need not be removed.
◆ The toothed belt should be left in position on the crankshaft sprocket.
◆ Cover toothed belt with a cloth to protect it from coolant before removing coolant pump.
Removing
- Drain coolant => Page 152

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

Sharan 1996 ➤
- Take toothed belt off coolant pump toothed belt sprocket => Page 60 , Removing, installing and tensioning
toothed belt.
- -> Unscrew coolant pump securing bolts -1- and remove coolant pump -2-.
Installing
- Moisten new O-ring with coolant.

- Insert coolant pump into cylinder block and tighten securing bolts.
Note:
The coolant pump plug faces downwards.

- Install ribbed belt => Page 28 .

Sharan 1996 ➤
1.11 - Removing and installing thermostat
Removing
Note:
Always renew gaskets and sealing rings.
- Drain coolant => Page 152
1.11 - Removing and installing thermostat 161

Sharan 1996 ➤
- -> Pull coolant hose off connecting flange -3-.

- Unbolt securing bolts -4- of connecting flange -3- and remove connecting flange -3- with thermostat -1-.
Installing
- Moisten new O-ring -2- with coolant.

- Fit connecting flange -3- with thermostat -1- into engine block.
- Tighten securing bolts -4-.
1.12 - Checking coolant circulation pump

Sharan 1996 ➤
◆ V.A.G 1594 A Auxiliary test set
◆ Current flow diagram
Check conditions
• -> Fuse No. 18 must be OK (for vehicles with engine cold AJH).
• -> Fuse No. 16 must be OK (for vehicles with engine code AWC).
Test sequence
- -> Remove the securing nuts -arrows- for the heat shield for the coolant circulation pump (V50), from the
bulkhead.
- Pull the heat shield forward slightly.
- Pull 2-pin connector off coolant circulation pump (V50).
1.12 - Checking coolant circulation pump 163

Sharan 1996 ➤
- -> Pull 2-pin connector off continued coolant circulation pump (V51) -arrow- .
Functional check
- -> Connect contacts of coolant circulation pump (V50) or continued coolant circulation pump (V51) to battery
using adapter cables from V.A.G 1594 A.
Pump must run.
If pump does not run:
- Replace pump.
If pump runs:
Checking activation
- Switch ignition off and on again.
- -> Connect diode test lamp V.A.G 1527 B to disconnected connector for coolant circulation pump (V50) or
continued coolant circulation pump (V51) using adapter cables from V.A.G 1594 A

Sharan 1996 ➤
LED must light up.
Note:
This check must be performed within 3 minutes of switching ignition off.
If the LED does not light up:
- Locate and rectify open circuit using current flow diagram:
1.12 - Checking coolant circulation pump 165

Sharan 1996 ➤
20 - Fuel supply system
1 - Removing and installing parts of fuel supply system

1.1 - Removing and installing parts of fuel supply system
Notes:
◆ Hose connections are secured with either spring-type or clamp-type clips.

◆ Always replace clamp-type clips with spring-type clips.
◆ Fuel hoses in engine compartment must only be secured with spring-type clips. The use of clamp or screw-
type clips is not permissible.
Removing and installing fuel tank with attachments and fuel filter: engine code AJH => Page 167 .
Removing and installing fuel tank with attachments and fuel filter: engine code AWC => Page 175 .
Observe safety precautions=> Page 182 .
Observe rules for cleanliness => Page 183 .
Observe crash fuel shut-off: engine code AWC => Page 186 .
Servicing accelerator mechanism: engine code AJH => Page 195
Adjusting throttle cable: engine code AJH => Page 197
Electronic power control (EPC): engine code AWC => Page 199 .
Activated charcoal filter system => Page 204 .
166 20 - Fuel supply system

Sharan 1996 ➤
1.2 - Removing and installing fuel tank with attachments and fuel filter: engine code AJH
Note:
After all repairs to the fuel supply unit or the fuel gauge sender unit have been carried out, ensure the the supply
or return flow hoses do not make contact with the fuel tank (pump noises may be transferred).
1 Cap
2 Seal
◆ If damaged only replace together with cap
3 Retaining ring
4 Rubber cup
167
Sharan 1996 ➤
5 Gravity valve
◆ To remove valve unclip upwards out of filler neck
◆ Check valve for through-flow
valve vertical: open,
valve tilted 45 °: closed
6 O-ring
7 Vent valve
◆ Cannot be removed; renew together with filler neck => item 17
◆ Checking =>Page 174 , Fig. 2
8 Pressure retaining valve
◆ For fuel tank venting
◆ Checking => Page 174 , Fig. 3

Sharan 1996 ➤
9 Return line
◆ Blue
◆ Clipped onto fuel tank
◆ From fuel return pipe on fuel rail
=> Repair group 24; Servicing injection system; Dismantling and assembling fuel rail and injectors Servicing
injection system Dismantling and assembling fuel rail and injectors
10 Union nut, 75 Nm
◆ Remove and install with spanner 3217
11 Connector
◆ Black, 4 pin
◆ For fuel gauge sender (G) and fuel pump (G6)
12 Flange
◆ Note fitting position on fuel tank => Page 174 , Fig. 1
◆ Underside marked with "V" and "R" for supply and return hoses
169
Sharan 1996 ➤
13 Supply hose
14 Sealing ring
◆ When installing, insert seal "dry" into fuel tank opening
◆ Moisten with fuel only when installing flange item 12
15 Return hose
16 6 Nm
17 Filler neck
◆ With expansion tank and vent valve

Sharan 1996 ➤
18 Vent pipe
◆ To junction piece between activated charcoal filter and solenoid valve 1 for activated charcoal filter
=>Page 206 , Servicing parts of activated charcoal filter system: engine code AJH
19 Grommet
20 Retaining ring
21 Non-return valve
◆ Check for freedom of movement
22 Vent pipe
23 25 Nm
24 Fuel tank
◆ Support with engine and gearbox jack V.A.G 1383 A when removing
171
Sharan 1996 ➤
25 Securing strap
◆ Note differing length
26 20 Nm
27 Bracket
◆ For fuel filter
28 Supply line
◆ Black
◆ To fuel supply pipe on fuel rail:
=> Repair group 24; Servicing injection system; Dismantling and assembling fuel rail and injectors Servicing
injection system Dismantling and assembling fuel rail and injectors
29 Fuel filter
◆ Installation position: Arrow points in through-flow direction
30 Fuel gauge sender (G)

Sharan 1996 ➤
31 Fuel delivery unit

=> Page 183
◆ Checking fuel pump
=> Page 187
32 Strainer
173
Sharan 1996 ➤
-> Fig. 1 Installation position of fuel delivery unit flange
Marking on the flange must align with marking on the fuel tank -arrows-.
Note:
After installing fuel delivery unit flange, check that the supply, return and breather pipes are still clipped onto
the fuel tank.
-> Fig. 2 Checking vent valve
Valve in rest position: Closed
Valve pushed in direction of arrow: Open
-> Fig. 3 Checking pressure retaining valve
From the gravity valve direction the pressure retaining valve is open in both directions of flow -arrow -1-.
From junction piece for activated charcoal filter and solenoid valve 1, it permits flow in one direction only -arrow
2-.

Sharan 1996 ➤
1.3 - Removing and installing fuel tank with attachments and fuel filter: engine code AWC
Notes:
◆ Following all work on fuel delivery unit or fuel gauge, ensure that the fuel supply and return hoses do not
touch the fuel tank (transmission of pump noise).
◆ Fuel pump relay (J17)
=> Page 182 , Fig. 4 .
1 Cap
2 Securing clip
3 Seal
4 Retaining ring
1.3 - Removing and installing fuel tank with attachments and fuel filter: engine code
AWC 175
Sharan 1996 ➤
5 Rubber cup
6 Gravity valve
◆ To remove valve unclip upwards out of filler neck
◆ Check valve for through-flow
valve vertical: open,
valve tilted 45 °: closed
7 O-ring
8 Vent valve
◆ Cannot be removed, replace together with filler neck => item 14
◆ Checking =>Page 181 , Fig. 2
9 Pressure retaining valve
◆ For fuel tank venting
◆ Checking => Page 182 , Fig. 3

Sharan 1996 ➤
10 Return line
◆ Blue
◆ From fuel return pipe on fuel rail
11 Supply line
◆ Black
◆ To fuel manifold
12 Connector
◆ Black, 4 pin
◆ For fuel gauge sender (G) and fuel pump (G6)
13 6 Nm
14 Filler neck
◆ With expansion tank and vent valve
AWC 177
Sharan 1996 ➤
15 Vent pipe
◆ To junction piece between activated charcoal filter and solenoid valve 1
=>Page 209 , Servicing parts of activated charcoal filter system: engine code AWC
16 Grommet
17 Retaining ring
18 Vent pipe
19 Non-return valve
◆ Check for freedom of movement
20 25 Nm
21 Fuel tank
◆ Support with engine and gearbox jack V.A.G 1383 A when removing

Sharan 1996 ➤
22 Securing strap
◆ Note differing length
23 20 Nm
24 Bracket
◆ For fuel filter
25 Supply line
◆ Black
◆ To fuel supply pipe on fuel rail:
26 Fuel filter
◆ Fitting position: Arrow points in direction of flow
27 Union nut, 75 Nm
◆ Remove and install with spanner 3217
AWC 179
Sharan 1996 ➤
28 Fuel delivery unit

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

Sharan 1996 ➤
-> Fig. 1 Installation position of fuel delivery unit flange
Marking on sender must align with the marking on fuel tank -arrows-.
Blue or blue marked return pipe -1- to connection with identification -R-.
Black supply pipe -2- to connection with identification -V-.
Note:
After installing fuel delivery unit flange, check that the supply, return and breather pipes are still clipped onto
the fuel tank.
-> Fig. 2 Checking vent valve
Valve in rest position: Closed
Valve pushed in direction of arrow: Open
AWC 181
Sharan 1996 ➤
-> Fig. 3 Checking pressure retaining valve
From the gravity valve direction the pressure retaining valve is open in both directions of flow -arrow -1-.
From junction piece for activated charcoal filter and solenoid valve 1, it permits flow in one direction only -arrow
2-.
-> Fig.4 Fuel pump relay (J17)
-Relay position 21-
The relay is located on the lower relay carrier of the multi-function unit.
Notes:
◆ If tools are necessary to pull relays or control units out of the relay plate, first disconnect battery earth strap.
◆ Before disconnecting battery earth strap obtain code for radios with anti-theft coding.
1.4 - Safety precautions when working on the fuel supply system
Warning!
cramped conditions:
When removing and installing the fuel gauge sender or fuel pump (fuel delivery unit) from a full or partly full fuel
tank the following must be observed:
Warning!
◆ Before commencing work, switch on exhaust extraction system and place an extraction hose close to the
sender opening in the fuel tank to extract escaping fuel fumes.
If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displace‐
ment greater than 15 m3/h can be used.
◆ Prevent skin contact with fuel! Wear fuel-resistant gloves!

Sharan 1996 ➤
◆ For reasons of safety, remove fuse No. 14 from fuse holder before opening the fuel system because the
fuel pump can be activated by the driver's door contact switch.
1.5 - Rules for cleanliness
When working on the fuel supply/injection system, pay careful attention to the following "5 rules":
◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
◆ Carefully cover opened components or seal, if the repair cannot be carried out immediately.
◆ Only install clean components:
Only unpack replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
◆ When the system is open:
Do not work with compressed air if this can be avoided.
Do not move vehicle unless absolutely necessary.
1.6 - Removing and installing fuel delivery unit
◆ 3217 Ring nut spanner
1.4 - Safety precautions when working on the fuel supply system 183
Sharan 1996 ➤
Removing

- With the ignition switched off disconnect battery earth strap.
- Remove cover from fuel delivery unit.
- Pull 4-pin connector and supply and return pipes off flange.
Warning!
Note:
- Remove union nut with union nut tool 3217.
- Pull flange and seal out of the opening in fuel tank.

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

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

◆ -> Note installation position of fuel delivery unit flange:
The marking on flange must align with marking on fuel tank -arrows-.
◆ -> When the fuel delivery unit is correctly installed the fuel gauge sender float points in direction of travel A:
◆ -> Note installation position of fuel delivery unit flange:

The marking on flange must align with marking on fuel tank -arrows-.
1.7 - Removing and installing fuel gauge sender: engine code AWC
Removing
- Removing fuel delivery unit
1.6 - Removing and installing fuel delivery unit 185

Sharan 1996 ➤
=> Page 183 .
- -> Release and pull off the terminals for wires -3- and -4-.
- Lift retaining tabs -1- and -2- with a screwdriver and pull fuel gauge sender out downwards -arrows-.
Installing
- Insert fuel gauge sender in the guides on the fuel delivery unit and push up until it engages.
- Installing fuel delivery unit
=> Page 183 .
1.8 - Crash fuel shut-off: engine code AWC
Function
Vehicles with an airbag are fitted with a crash fuel shut-off system. It reduces the danger of a fire in a crash as
the fuel pump is switched off via the fuel pump relay.
Simultaneously this system provides improved starting characteristics for the engine.
When the door is opened the fuel pump is activated for 2 seconds to build-up the pressure in fuel system.
When opening the fuel system:
- Check activation of fuel pump relay using current flow diagram and V.A.G 1466 A:

Sharan 1996 ➤
1.9 - Checking fuel pump
◆ 3217 Union nut spanner

◆ V.A.G 1318 Pressure tester
◆ V.A.G1318/17 Adapter
◆ V.A.G 1318/11 Adapter
◆ V.A.G 1318/16 Adapter
1.9 - Checking fuel pump 187

Sharan 1996 ➤
◆ V.A.G 1348 Fuel quantity comparison meter

◆ V.A.G 1466 Test system
◆ V.A.G 1715 Multimeter
◆ VAS 5024 Assembly tool for spring-type clip
◆ Measuring container

Sharan 1996 ➤
Check conditions
• Fuse No. 14 must be OK.
-> Fuse holder for vehicles with engine code AJH.
-> Fuse holder for vehicles with engine code AWC.

Note:
Note description of function of crash fuel shut-off for vehicles with engine code AWC=>Page 186 .
Checking function and voltage supply
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.
- Remove cover from fuel delivery unit.

- Briefly operate starter. Fuel pump must be
heard to run.
- Switch off ignition.
If the fuel pump does not run:
- -> Separate the 6-pin connector -arrow- left behind the battery.

Sharan 1996 ➤
- -> Connect remote control V.A.G 1348/3A to contact 2 of connector and battery positive (+) using adapter
cable V.A.G 1348/3-2 and adapter cable from V.A.G 1594 A.
- -> Pull 2-pin connector from cylinder No. 1 injector -arrow-.
- -> Connect remote control V.A.G 1348/3A to contact 1 of connector and battery positive (+) using adapter
cable V.A.G 1348/3-2 and adapter cable from V.A.G 1594 A.

- Operate remote control.
Fuel pump runs:

- Check activation of fuel pump relay using current flow diagram and V.A.G 1466 A:
Fuel pump does not run:
- Pull 4-pin connector off flange of fuel delivery unit.

Sharan 1996 ➤
- -> Connect diode test lamp V.A.G 1527 B with auxiliary cables from V.A.G 1594 A to the outer contacts of
the connector.
- Operate remote control.
LED must light up
LED does not light up:
- Locate and eliminate open circuit using current flow diagram:
LED lights up (voltage supply OK.):
- Remove union nut with union nut tool 3217.

- Check that the electrical wires between flange and fuel pump are connected.
If no open circuit can be found:
- Fuel pump defective, renew fuel delivery unit =>Page 183 , Removing and installing fuel delivery unit.
Checking delivery rate
Check conditions
• Voltage supply OK.

• Remote control V.A.G 1348/3A connected.
Test sequence
- Remove filler cap from fuel tank filler neck.

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

Sharan 1996 ➤
Warning!
Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release
pressure by carefully loosening the connection.
- Connect pressure gauge V.A.G 1318 to the fuel supply pipe using adapter 1318/10.
- Fit hose V.A.G 1318/16 onto the adapter V.A.G 1318/11 on the pressure gauge and hold hose in a measuring
container.
- Open the pressure gauge shut-off tap. The lever then points in the direction of flow -A-.
- Operate remote control V.A.G 1348/3A and slowly close cut-off tap, until pressure gauge shows
3 bar.
From this point on do not move position of cut-off tap.
- Empty the measuring container.
- The quantity of fuel delivered by the fuel pump is dependent upon battery voltage. Therefore connect the
multimeter with adapter cables from V.A.G 1594 A to the vehicle battery.
- Operate remote control for
30 seconds
and measure battery voltage
- -> Compare the quantity of fuel delivered with specification.
*) Minimum delivery cm3/30 seconds
**) Voltage at fuel pump with engine stopped and pump running (approx. 2 volts less than battery voltage).
Example:
During the test a voltage of 12.2 volts is measured at the battery. As the voltage at the pump is approx. 2 volts
less than the battery voltage then this will equate to a minimum delivery of 550 cm3/30 s.
If the minimum delivery rate is not attained:
- Check the fuel pipes for possible restrictions (kinks) or blockages.

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

- Reconnect all disconnected fuel pipes.
- -> Connect multimeter V.A.G 1715 to wire -arrow- for contact 1 of 4-pin connector using the pick-up clamp.
- Start the engine and run at idling speed.
- Measure the current draw of the fuel pump.
Specification: max. 8 amps.
Note:
If the fuel system malfunction is intermittent, you can perform the check during a test drive with the help of a
2nd person.
If the current draw is exceeded:

Sharan 1996 ➤
Checking fuel pump non-return valve
Test conditions
• Remote control V.A.G 1348/3A is still connected.

• Pressure gauge V.A.G 1318 is still connected.
Note:
With this check the fuel supply pipe connections from the fuel delivery unit to the point at which the pressure
gauge V.A.G 1318 is connected will be checked for leaks at the same time.
Test sequence
- -> Close pressure gauge shut-off tap (lever at right angles to throughflow direction - position -B-).
- Separate remote control at short intervals, until a pressure of
Approx. 3 bar
has built up.
- If pressure builds up too high, lower excess pressure by carefully opening the shut-off tap.
Warning!
Danger of spray when opening the shut-offtap, hold container over the free connection of the pressure gauge.
- Watch pressure drop on gauge. After 10 minutes the pressure must not drop below
2.5 bar.
If the pressure drops further:
- Check pipe connections for leaks.
If no fault is detected in the wiring:

Sharan 1996 ➤
2 - Accelerator mechanism: engine code AJH

2.1 - Accelerator mechanism: engine code AJH
2.2 - Servicing accelerator mechanism

1 Accelerator cable
◆ Adjusting => Page 197
◆ Do not reuse damaged accelerator cable, replace
2 Cable cam
◆ On throttle valve control part
3 Retainer
◆ Adjusting throttle cable => Page 197
4 Support bracket
◆ For accelerator cable
2.1 - Accelerator mechanism: engine code AJH 195

Sharan 1996 ➤
5 Kickdown switch (F8)

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

Sharan 1996 ➤
2.3 - Adjusting throttle cable
Work sequence
- -> Adjust accelerator cable by moving the retainer -arrow- at the support bracket, so that the full throttle
position is attained at the throttle valve control part.
◆ V.A.G 1526 A Hand multimeter
2.3 - Adjusting throttle cable 197

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◆ V.A.G 1594 A Auxiliary test set

◆ Distance piece 13 mm
Work sequence
- -> Clamp distance piece -1-,

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

Sharan 1996 ➤
- -> Connect hand multimeter V.A.G 1526 A with aux. cables from V.A.G 1594 to kick-down switch.
- Check resistance at switch.
Specification: ∞ω
- Slowly move accelerator pedal in direction of full throttle.
Shortly after the kick-down pressure point the resistance must drop to 0 ω.
At this point the accelerator pedal must be just off the stop.
3 - Electronic power control (EPC): engine code AWC

3.1 - Electronic power control (EPC): engine code AWC
3.2 - Function of EPC system
With the EPC system the throttle valve is not operated by a cable. There is no mechanical connection between
accelerator and throttle valve.
The position of the accelerator is transmitted to the engine control unit by two accelerator position senders
(variable resistors together in a housing) which are connected to the accelerator pedal.
The position of the accelerator (drivers requirement) is the main input value for the engine control unit.
The throttle valve is operated over the complete revolution and load range by an electric motor (throttle valve
positioner) in the throttle valve control part.
The throttle valve is operated by the throttle valve positioner which is controlled by the engine control unit.
When the engine is not running and the ignition is switched on the engine control unit moves the throttle valve
exactly as prescribed by the accelerator pedal position sender. This means that when the accelerator is de‐
pressed halfway the throttle valve positioner opens the throttle valve by the same amount, the throttle is then
approximately half open.
When the engine is running (under load) the engine control unit can open or close the throttle valve independ‐
ently of the accelerator pedal position sender.
This means that the throttle valve can already be completely open even though the accelerator pedal is de‐
pressed half way.
After evaluating the torque requirements of various components (e.g. air conditioning, automatic gearbox, ABS/
ESP and so on), the engine control unit calculates the optimal throttle valve opening angle for the respective
situation.
This also gives vastly improved consumption and exhaust emission levels at certain load conditions.
It is incorrect to believe that the "EPC" is comprised of one or two components only. The EPC is a system,
which is comprised of all components which have an influence, control or monitor the position of the throttle
2.3 - Adjusting throttle cable 199

Sharan 1996 ➤
valve, e.g. the accelerator pedal position sender, the throttle valve control unit, the EPC warning lamp, the
engine control unit.
3.3 - Servicing parts of electronic power control (EPC)
1 Bracket
2 Connector
◆ Black, 6-pin
3 10 Nm
4 Accelerator pedal position sender (G79)
◆ Not adjustable
◆ The accelerator pedal position passes the position of the pedal on to the engine control unit

Sharan 1996 ➤
3.4 - Checking accelerator pedal position sender
◆ V.A.G 1526 Hand multimeter

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

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Check conditions
• -> The fuses must be OK.

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

Rapid data transfer HELP
Select function XXX
- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.

Read measured value block
Input display group number XXX
- Press keys 0, 6 and 2 for the "Display group number 62" and confirm entry with Q key.

(1...4 = Display zones)
Read measured value block 62
1 2 3 4
- Check specification of sender 1 (G79) at idling speed limit stop in display zone 3.
Specification: 6...96 %
- Check specification of sender 2 (G185) at idling speed limit stop in display zone 4.
Specification: 3...48 %
Note:
The engine control unit calculates the voltage values of the angle sender in percent relative to 5 Volt and displays
these as a percentage figure (5 Volt supply voltage equates to 100 %).
- Operate the accelerator pedal slowly until fully depressed and observe the angle sender figures in display
zones 3 and 4:
The percent figures in display zone 3 must rise evenly. The tolerance range of 6...96 % is not covered
completely.
The percent figures in display zone 4 must rise evenly. The tolerance range of 3...48 % is not covered
completely.

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

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
If the display does not indicate as described:
- Check accelerator pedal position sender voltage supply and wiring connections =>Page 203 .
Checking voltage supply and wiring to control unit
- Pull 6-pin connector off accelerator pedal position sender.

- Switch ignition on.
- -> Connect multimeter to measure voltage at the following contacts of the connector using adapter cables
from V.A.G 1594 A
Contact 1 + earth
Contact 1 + 5
Contact 2 + earth
Contact 2 + 3
Specification: minimum 4.5 V
If no voltage is present:
- Remove battery.
- -> Connect test box V.A.G 1598/31 to control unit wiring harness. The engine control unit remains discon‐
nected.
3.4 - Checking accelerator pedal position sender 203

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- -> Check wiring for open circuit between test box and 6-pin connector using current flow diagram.
Contact 1+ socket 72
Wire resistance: max. 1.5 ω
- Additionally check wires for short to one another, to vehicle earth and to battery positive.
If no fault is detected in the wiring:
- Renew accelerator pedal position sender

- On vehicles with automatic gearbox the gearbox control unit must be matched additionally:
=> Self-diagnosis for automatic gearbox 09B - 5-speed; Repair group 01; Performing self-diagnosis; Initiating
basic setting Performing self-diagnosis Initiating basic setting
4 - Activated charcoal filter system

4.1 - Activated charcoal filter system
4.2 - Function
Depending upon the air pressure and ambient temperature, fuel vapour will form above the level of fuel in the
tank.
The activated charcoal filter system prevents these HC emissions escaping to the atmosphere.
Fuel vapours pass through a gravity valve (which closes at an angle of 45 °) located at the highest point in the
tank and through a pressure retention valve into the activated charcoal filter in limited quantities.
The activated charcoal stores these vapours like a sponge.

Sharan 1996 ➤
When the Lambda control is active when driving (engine warm), the activated charcoal filter solenoid valve
(N80), also called regeneration valve), is activated (pulsed) from engine control unit depending upon load and
engine speed. The opening period is dependent on the input signals.
During the purging procedure (regeneration of activated charcoal), the intake manifold vacuum draws fresh air
through the vent opening on the activated charcoal filter. The fuel vapours stored in the activated charcoal and
fresh air are fed in pulses for combustion.
The pressure retention valve prevents fuel vapours from being drawn from the tank when the activated charcoal
filter solenoid valve (N80) is open and intake manifold vacuum is present. It thus ensures that the evacuation
of the activated charcoal filter has priority.
With no voltage (e.g. wiring open circuit), the activated charcoal filter solenoid valve (N80) is closed and the
activated charcoal filter will not be purged.
Notes:
◆ Hose connections are secured with either spring-type or clamp-type clips.

Servicing parts of the activated charcoal filter system: engine code AJH=> Page 206 .
Servicing parts of the activated charcoal filter system: engine code AWC => Page 209 .
Checking activated charcoal filter solenoid valve 1: engine code AWC => Page 212 .
Checking fuel tank breather: engine code AJH => Page 214 .
Checking fuel tank breather: engine code AWC => Page 215 .
4.2 - Function 205

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4.3 - Servicing parts of the activated charcoal filter system: engine code AJH
1 Connections
2 Bracket
◆ For activated charcoal filter
3 Junction piece
4 Vent pipe
◆ From pressure retaining valve on fuel tank
=> Page 167 , Removing and installing fuel tank with attachments and fuel filter: engine code AJH
5 Activated charcoal filter
◆ Location: in front right wheel housing
◆ Remove wheel housing liner to remove

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

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4.4 - Servicing parts of the activated charcoal filter system: engine code AWC
1 Connector
2 Bracket
◆ For activated charcoal filter
3 Junction piece
4 Vent pipe
=> Page 175 , Removing and installing fuel tank with attachments and fuel filter: engine code AWC
◆ Location: in front right wheel housing
◆ Remove wheel housing liner to remove
4.4 - Servicing parts of the activated charcoal filter system: engine code AWC 209
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6 10 Nm
7 Junction piece
8 Vent pipe
◆ Black with white markings
◆ To upper connecting pipe on fuel rail:
9 Non-return valve
◆ For activated charcoal filter system
◆ Grey connection faces junction piece -item 7 -
10 Vent pipe
engine code AWC:
=>Page 236
11 Air cleaner lower part

Sharan 1996 ➤

13 Connector
◆ Green, 2-pin
◆ For activated charcoal filter solenoid valve 1 (N80)
14 Vent pipe
◆ To atmosphere
◆ Secured to body
15 O-ring
4.4 - Servicing parts of the activated charcoal filter system: engine code AWC 211
Sharan 1996 ➤
4.5 - Checking activated charcoal filter solenoid valve 1: engine code AWC
In a no-current situation the solenoid valve is closed.
Checking activation:
◆ V.A.G 1551 Fault reader
Note:
The vehicle system tester V.A.G 1552 can be used instead of the fault reader V.A.G 1551, however a print-out
is not possible.
◆ V.A.G 1551/3 Cable
Test conditions

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

Select function XXX
- Press keys 0 and 8 for the "Read measured value block" function and confirm entry with Q key.

- Press keys 0, 7 and 0 for "Display group number 70" and confirm entry with Q key.

1 2 3 4
- Press key 4 for the "Basic setting" function ("Tank venting valve diagnosis" will be initiated)
Note:
The engine must not be loaded during this diagnosis because the diagnosis will be interrupted and will not be
started again until the engine is revved-up.

System in basic setting 70
1 2 3 4
When the diagnosis is initiated by the engine control unit, the display in display zone 4 jumps from "Test OFF"
to "Test ON".
- Run engine at idling speed until the specification "TVV OK" is displayed in display zone 4.
Note:
TVV stands for tank vent valve (activated charcoal filter solenoid valve 1).
If the specification "TVV OK" is obtained:
- Press ⇒key.
If "TVV not OK" appears in display zone 4:
- Initiate the final control diagnosis and activate the activated charcoal filter solenoid valve 1 (N80):
4.5 - Checking activated charcoal filter solenoid valve 1: engine code AWC 213
Sharan 1996 ➤
4.6 - Checking fuel tank breather: engine code AJH
◆ V.A.G 1368 Vacuum tester
◆ V.A.G 1390 Hand vacuum pump
Test sequence
- -> Pull breather pipe/hose -5- from activated charcoal filter -1- off the throttle valve control part -3-.
- Connect hand vacuum pump V.A.G 1390 to pipe/hose -5-.
- Pull breather pipe/hose -4- from fuel tank off activated charcoal filter and connect to -connection A- of vacuum
tester V.A.G 1368.
- Connect vacuum tester V.A.G 1368 -connection B- to breather pipe/hose -2-.
- Set vacuum tester to position -B-.
- Initiate final control diagnosis and select activated charcoal filter solenoid valve 1 (N80):
- Operate hand vacuum pump V.A.G 1390 several times.
Vacuum must not

Sharan 1996 ➤
build up.
If vacuum builds up:

- Check breather connection -6- on activated charcoal filter -1- for soiling, clean if necessary.
If vacuum does not build up:
- -> Connect hand vacuum pump V.A.G 1390 to vacuum tester V.A.G 1368 -connection B-.
- Set vacuum tester to -A/B- position.
Vacuum must build up.

- Check pressure retaining valve => Page 174 , Fig. 3
- Check pipe/hose -1- from fuel tank for blockage.
4.7 - Checking fuel tank breather: engine code AWC
◆ V.A.G 1368 Vacuum tester
4.6 - Checking fuel tank breather: engine code AJH 215

Sharan 1996 ➤
Test sequence
- -> Pull breather pipe/hose -3- off activated charcoal filter solenoid valve 1 -1-.
- Connect vacuum tester V.A.G 1368 -connection A- to activated charcoal filter solenoid valve 1 -1-.
- Connect hand vacuum pump V.A.G 1390 to vacuum tester V.A.G 1368 -connection B-.
- Set vacuum tester to -A/B- position.
- Initiate final control diagnosis and select activated charcoal filter solenoid valve 1 (N80):

Vacuum must not
build up.
If vacuum builds up:
- Check breather pipe/hose -4- on activated charcoal filter for soiling and clean if necessary.
- -> Plug breather hose/pipe -arrow- from activated charcoal filter.

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

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

Sharan 1996 ➤
- -> Check vent hose/pipe -2- on fuel tank for leaks.
4.7 - Checking fuel tank breather: engine code AWC 217

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

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

◆ Charge air system must be free of leaks.
◆ Renew self-locking nuts.
Removing and installing turbocharger with attachments => Page 219 .
Removing and installing parts of charge air cooler:

Engine code AJH => Page 225 .
Removing and installing parts of charge air cooler:

Engine code AWC => Page 228 .
Overview of turbocharging:
Overview of turbocharging:
Checking charge pressure system:

Checking charge pressure system:

218 21 - Charging
Sharan 1996 ➤
1.2 - Removing and installing turbocharger and attachments
1 Exhaust manifold
2 Gasket
◆ Renew
3 Seal
◆ Renew
4 Connection, 30 Nm
5 From oil filter bracket
◆ On vehicles with engine code AJH:
◆ On vehicles with engine code AWC:
6 Oil supply pipe
1.2 - Removing and installing turbocharger and attachments 219

Sharan 1996 ➤

8 Coolant return pipe
9 Connection, 35 Nm
10 Washer
11 25 Nm
12 Vacuum hose
◆ To charge pressure control solenoid valve (N75)
engine code AJH:
=>Page 233
engine code AWC:
=>Page 236
220 21 - Charging
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14 From cylinder block
16 10 Nm
17 Vacuum hose
◆ To charge pressure control solenoid valve (N75)
engine code AJH:
=>Page 233
engine code AWC:
=>Page 236

Sharan 1996 ➤
19 Spacer sleeve
◆ Only vehicles with manual gearbox
20 Support
◆ Between turbocharger and cylinder block
21 From air cleaner
engine code AJH:
=>Page 233
engine code AWC:
=>Page 236
22 To charge air cooler
engine code AJH:
=>Page 233
engine code AWC:
=>Page 236
23 Plug, 15 Nm
222 21 - Charging
Sharan 1996 ➤
24 Oil return pipe

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

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27 Front exhaust pipe

28 35 Nm
◆ Renew
◆ Coat threads and bolt head seating surface with "G 052 112 A3"
224 21 - Charging
Sharan 1996 ➤
1.3 - Removing and installing parts of charge air cooling: Engine code AJH
1 Intake hose
◆ From air filter
2 Pressure regulating valve
3 From crankcase breather
4 From charge pressure control solenoid valve (N75)
engine code AJH:
=>Page 233
5 Air pipe
◆ Secured to cylinder head cover
1.3 - Removing and installing parts of charge air cooling: Engine code AJH 225
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6 From activated charcoal filter solenoid valve 1 (N80)

engine code AJH:
=>Page 233
7 Air hose
◆ To turbocharger
engine code AJH:
=>Page 233
8 Air hose
engine code AJH:
=>Page 233
9 To throttle valve control part
10 Air pipe
226 21 - Charging
Sharan 1996 ➤
11 Bracket
◆ For air pipe
12 25 Nm
13 Bracket
14 10 Nm
16 Vacuum hose/pipe
engine code AJH:
=>Page 233
17 Overrun shut-off valve
1.3 - Removing and installing parts of charge air cooling: Engine code AJH 227
Sharan 1996 ➤
1.4 - Removing and installing parts of charge air cooling: engine code AWC
1 Intake hose
◆ From air filter
2 10 Nm
4 Connecting hose
◆ From crankcase breather pipe
5 Vacuum hose
◆ From charge pressure limitation solenoid valve (N75)
engine code AWC:
=>Page 236
228 21 - Charging
Sharan 1996 ➤
6 Air pipe
◆ Secured to cylinder head cover
7 Vent pipe
◆ With connecting piece
◆ For non-return valve in activated charcoal filter system
engine code AWC:
=>Page 236
8 Air hose
◆ Note assembly markings
◆ To turbocharger
engine code AWC:
=>Page 236
9 Air hose
◆ To throttle valve control part (J338)
1.4 - Removing and installing parts of charge air cooling: engine code AWC 229
Sharan 1996 ➤
10 Vent hose
◆ From EGR valve (N18)
engine code AWC:
=>Page 236
11 Air pipe
12 O-ring
13 Charge pressure sender (G31)
14 6 Nm
15 Air pipe
16 Bracket
=> Page 240
230 21 - Charging
Sharan 1996 ➤
18 Air hose
◆ Note assembly markings
19 Bracket
◆ For air pipe -item 21 -
20 20 Nm
21 Air pipe
◆ Adjust longitudinally in bracket -item 19 - so that air pipe is not installed under tension
22 Vent hose
engine code AWC:
=>Page 236
1.4 - Removing and installing parts of charge air cooling: engine code AWC 231
Sharan 1996 ➤
24 Air pipe
◆ From turbocharger
engine code AWC:
=>Page 236
25 25 Nm
26 Bracket
◆ Secured to cylinder block
27 25 Nm
◆ Renew
28 Bracket
◆ Secured to sump
232 21 - Charging
Sharan 1996 ➤
1.5 - Overview of turbocharging: engine code AJH

3 Vent pipe
=> Page 168 , Item 8
4 Crankcase breather pressure regulating valve
1.5 - Overview of turbocharging: engine code AJH 233

Sharan 1996 ➤
5 Non-return valve
◆ Gray connection faces junction piece
7 Turbocharger
8 Pressure unit
◆ For charge pressure control valve
◆ Integral part of turbocharger cannot be replaced
9 Charge pressure limitation solenoid valve (N75)
234 21 - Charging
Sharan 1996 ➤
10 Cylinder head
11 Throttle valve control part (J338)
13 Crankcase breather
14 Fuel pressure regulator
15 Intake manifold
16 Air mass meter (G70)
17 Air cleaner housing
1.5 - Overview of turbocharging: engine code AJH 235

Sharan 1996 ➤
1.6 - Overview of turbocharging: engine code AWC

3 Vent pipe
236 21 - Charging
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5 Non-return valve
◆ Gray connection faces junction piece
7 Turbocharger
8 Charge pressure limitation solenoid valve (N75)
◆ Vacuum hoses on solenoid valve=> Fig. 1
1.6 - Overview of turbocharging: engine code AWC 237

Sharan 1996 ➤
9 Pressure unit
◆ For charge pressure control valve
◆ Integral part of turbocharger cannot be replaced
10 EGR valve (N18) with potentiometer for exhaust gas recirculation (G212)
◆ Check potentiometer for exhaust gas recirculation =>Page 281
◆ Check EGR valve (N18):
11 Cylinder head
12 Throttle valve control part (J338)
13 Charge pressure sender (G31)
238 21 - Charging
Sharan 1996 ➤
15 T-piece
16 Crankcase breather
17 Fuel pressure regulator
18 Intake manifold
19 Air mass meter (G70)
20 Air cleaner housing
1.6 - Overview of turbocharging: engine code AWC 239

Sharan 1996 ➤
-> Fig. 1 Vacuum hoses on charge pressure control solenoid valve (N75)
1- From charge pressure control vacuum unit
=> Page 220 , item 12
2- To intake hose
3- From connection on turbocharger
=> Page 221 , item 17
1.7 - Rules for cleanliness
When working on the exhaust gas turbocharger, pay careful attention to the following "5 rules":
◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
◆ Carefully cover opened components or seal, if the repair cannot be carried out immediately.
◆ Only install clean components:
Only unpack replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
◆ When the system is open:
Do not work with compressed air if this can be avoided.
Do not move vehicle unless absolutely necessary.
1.8 - Safety precautions
Warning!
cramped conditions:
Observe following if test and measuring instruments are required during a test drive:
◆ Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this
location.
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.
1.9 - Removing and installing charge air cooler: engine code AWC
240 21 - Charging
Sharan 1996 ➤
◆ VAS 5024 Spring-type hose clip pliers

◆ Hand drill
◆ Drill, 14 mm ø
Removing

- Removing front bumper:
=> General body repairs, exterior, Repair group 63; Front bumper, Removing and installing front bumper
- Remove retainer for lower coolant hose.

- -> Unbolt P.A.S. hydraulic pipe/hose -1- from lock carrier -arrows-.
- -> Drill holes in lock carrier at the marked positions -arrows- (use14 mm ødrill).
1.9 - Removing and installing charge air cooler: engine code AWC 241
Sharan 1996 ➤
- Remove charge air cooler securing bolts and remove charge air cooler.
Installing
- Tighten securing bolts on charge air cooler and hydraulic pipe/hose.
2 - Checking charge air system: engine code AJH

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

◆ V.A.G 1397 A Turbocharger tester
Check conditions
• No faults must be stored in fault memory
• Engine oil temperature min. 60 °C
• No leaks on intake and exhaust systems.
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.
Observe applicable safety precautions when carrying out a road test => Page 240 .
242 21 - Charging
Sharan 1996 ➤
- -> Pull off connecting hose between intake manifold and overrun shut-off valve at intake manifold and con‐
nect turbocharger tester V.A.G 1397 A using T-piece.
- Select measuring range l.
Notes:
◆ Operation of turbocharger tester =>operating instructions.
◆ The pipes/hoses must be connected so that there is no leakage.
◆ If boost pressure is measured whilst driving, it is necessary for safety reasons, for a second person to operate
the turbocharger tester.
◆ Ensure that the pressure hose is not trapped between the bonnet and the body.
- Measuring charge pressure at full throttle:
Accelerate with full throttle from 2000 rpm in 3rd gear

or in 2nd driving range.
- At 3000 rpm press the memory button "M" on turbocharger tester.

Specification: (absolute pressure)
1.300 ... 1.400 bar
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 shaft mounting for charge pressure regulating valve in turbocharger for ease of movement.
When corroded together, renew turbocharger.
If the charge pressure is not attained:

- Check charge pressure control solenoid valve (N75) =>Page 243 .
2.3 - Checking charge pressure control solenoid valve
◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715
◆ Adapter set V.A.G 1594
Test conditions
• Carry out final control diagnosis
• Ignition switched off.
Test sequence
2.2 - Checking charge pressure regulation 243

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

2.4 - Checking pressure unit for charge pressure regulating valve
Test conditions
Test sequence
- -> Pull connector -1- off charge pressure control solenoid valve (N75) -2-.
- -> 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 control valve lever -1- for ease of movement. When corroded together, renew tur‐
bocharger.
If the operating rod does not move, even though the lever is free to move:
244 21 - Charging
Sharan 1996 ➤
- Turbocharger defective. Renew turbocharger => Page 219 , Removing and installing turbocharger with
attachments.
2.5 - Checking overrun shut-off valve
Test conditions
• Reduced performance or load change judders
Test sequence
Note:
The overrun shut-off valve is located before the turbocharger. It is opened by vacuum pressure during the
overrun phase and at idling speed.
- -> Connect hand vacuum pump V.A.G 1390 to vacuum connection on overrun valve.
- Operate hand vacuum pump.
Overrun valve must open in direction of arrow.
- Operate vent valve on hand vacuum pump.
Overrun valve must close.
Overrun valve does not open or close, renew valve.
2.4 - Checking pressure unit for charge pressure regulating valve 245
Sharan 1996 ➤
Note:
The overrun shut-off valve connections are secured with screw-type clips.
3 - Checking charge pressure system: engine code AWC

3.1 - Checking charge pressure system: engine code AWC
3.2 - Checking charge pressure regulation
Note:
is not possible.
Check conditions
246 21 - Charging
Sharan 1996 ➤
Test sequence
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select engine electronics control unit with
"Address word" 01. Connecting fault reader and selecting engine control unit:
fault reader

Select function XXX
- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.

- Press keys 1, 1 and 4 for "Display group number 114" and confirm entry with Q key.

1 2 3 4
- Check duty cycle of charge pressure control solenoid valve (N75) in display zone 4 (at full throttle between
1 800...2 300 rpm) during a test drive or on a rolling road.
Specification: 5.0...95.0 %
Observe applicable safety precautions when carrying out a road test => Page 240 .
If the specification is obtained:
- Change to display group 115 as follows:

V.A.G 1551: Press key 3
V.A.G 1552: Press key ↑

1 2 3 4
- Check actual charge pressure value in display zone 4 at full throttle.
On rolling road
In 3rd gear or in 2nd driving range
During test drive
Vehicles with manual gearbox
- Accelerate in 2nd gear with full throttle.
Vehicles with automatic gearbox.
- Manually select 4th driving range and accelerate vehicle from low speed with full throttle (without kickdown;
gearbox does not downshift).
- At engine speed between 1 800...2 300 rpm, press the print button and read off actual charge pressure value
in display zone 4.
Specification: 1 350 ... 1 750 mbar
- Compare actual charge pressure value with specified charge pressure value in display zone 3
3.2 - Checking charge pressure regulation 247

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

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

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

=> Page 240 , Fig. 1 .
- Check pressure unit for charge pressure regulating valve is securely mounted on turbocharger.
- Check vacuum unit => Page 253 .
If the charge pressure is not attained:
- Check charge pressure sender (G31) => Page 250

- Check charge pressure control solenoid valve (N75) => Page 248 .
- Check vacuum unit => Page 253 .
attachments.
3.3 - Checking charge pressure control solenoid valve
◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715
◆ Adapter set V.A.G 1594
Check conditions
248 21 - Charging
Sharan 1996 ➤
Test sequence
- -> Unbolt heat shield from bulkhead -arrows-.

- Pull 2-pin connector off charge pressure control solenoid valve (N75) -arrow-.
- Pull solenoid valve out of bracket (hoses remain connected).
- -> Check resistance of charge pressure control solenoid valve between contacts.
Specification: 25.0...35.0 ω(at room temperature)
If the specification is not obtained:
- Replace charge pressure control solenoid valve (N75).
3.3 - Checking charge pressure control solenoid valve 249

Sharan 1996 ➤
If the specification is obtained:
- Check specifications in measured value blocks for charge pressure control:

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

250 21 - Charging
Sharan 1996 ➤
Check conditions
• Self-diagnosis has detected a fault with the charge pressure sender:
Checking voltage supply and wiring to control unit

- -> Pull 4-pin connector off charge pressure sender (F31) -arrow-.
- -> Connect multimeter to measure voltage to contacts 1 (earth) and 3 (positive) of connector for charge
pressure sender using adapter cables from V.A.G 1594 .
- Switch on ignition.
Specification: min. 4.5 V
3.4 - Checking charge pressure sender 251

Sharan 1996 ➤
- Remove battery.
nected.
- -> Check wiring for open circuit between test box and 4-pin connector using current flow diagram:
Contact 1 test box socket 108
If no wiring fault is detected and voltage was present between contacts 1 + 3:
- Check the functions => Page 252
- Renew engine control unit:
=> Repair group 24; Engine control unit; Renew engine control unit Engine control unit Renew engine control
unit
Checking function
- Connect the test box V.A.G 1598/31 to engine control unit wiring harness and to engine control unit.
- Connect battery.
- -> Reconnect 4-pin connector to charge pressure sender (G31) -arrow-.

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

=> Page 230 , item 13 .
3.5 - Checking pressure unit for charge pressure regulating valve
Check conditions
Test sequence
- -> Remove heat shield from bulkhead -arrows-.

- Pull 2-pin connector off charge pressure control solenoid valve (N75) -arrow-.
3.4 - Checking charge pressure sender 253

Sharan 1996 ➤
- -> Start engine and raise to maximum speed by quickly operating throttle. The operating rod -1- for charge
pressure regulating valve must
move.
If the operating rod does not move:
attachments.
3.6 - Checking overrun shut-off valve
Test conditions
• Reduced performance or load change judders
254 21 - Charging
Sharan 1996 ➤
Test sequence
Note:
The overrun shut-off valve is located before the turbocharger. It is opened by vacuum pressure during the
overrun phase and at idling speed.
- -> Connect hand vacuum pump V.A.G 1390 to vacuum connection on overrun valve.
Overrun valve must open in direction of arrow.
- Operate vent valve on hand vacuum pump.
Overrun valve must close.
Overrun valve does not open or close, renew valve.
Note:
The overrun shut-off valve connections are secured with screw-type clips.
3.6 - Checking overrun shut-off valve 255

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

1.1 - Removing and installing parts of exhaust system
Notes:
◆ After working on the exhaust system, ensure that the system is not under stress, and that it has sufficient
clearance to the bodywork. If necessary, loosen clamps and align silencer and exhaust pipe so that sufficient
clearance to the bodywork is maintained and the supports are evenly loaded.
◆ Renew self-locking nuts.
◆ Components marked with * will be checked by self-diagnosis:
256 26 - Exhaust system

Sharan 1996 ➤
1.2 - Front exhaust pipe and catalyst with attachments
1 Seal
◆ Renew
2 25 Nm
◆ Renew
3 Front exhaust pipe
4 Catalyst
5 To front silencer
6 Markings
◆ For push-in depth catalyst/front silencer => Fig. 1
1.2 - Front exhaust pipe and catalyst with attachments 257

Sharan 1996 ➤
7 Lambda probe 2 after catalyst (G130)*, 50 Nm

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

Sharan 1996 ➤
9 Heat shield
10 10 Nm
11 Securing clip
12 Lambda probe 1 before catalyst (G39)*, 50Nm
◆ Remove and install with Lambda probe open ring spanner set 3337
◆ Grease only the threads with "G 052 112 A3"; "G 052 112 A3" must not get into the slots on the probe
body
=> Repair group 24; Checking functions; Checking Lambda control Checking functions Checking Lambda con‐
trol
=> Repair group 24; Checking functions; Checking Lambda probe and Lambda regulation before catalyst
Checking functions Checking Lambda probe and Lambda regulation before catalyst

Sharan 1996 ➤
13 Connector
◆ For Lambda probe 1 before catalyst (G39) and Lambda probe heater (Z19)
Vehicles with engine code AJH:
◆ Black, 4-pin
Vehicles with engine code AWC:
◆ Black, 6-pin
◆ Contacts gold plated
14 From turbocharger
15 Retaining ring

Sharan 1996 ➤
-> Fig.1 Insertion depth of catalyst/front silencer
- Push catalyst pipe into the front silencer pipe up to appropriate mark.
Vehicles with manual gearbox: mark -S-

Vehicles with manual gearbox: mark -A-

Sharan 1996 ➤
1.3 - Silencer with mountings
Note:
Align the exhaust system longitudinally so that the dimensions -a- and -b- are maintained.
1 Catalyst
◆ => Page 257 , item 4
2 Markings
◆ For insertion depth of catalyst/front silencer => Page 261 , Fig. 1
3 Clamp
4 Retaining ring
◆ Note fitting position
5 Front silencer
6 Rear silencer

Sharan 1996 ➤
7 Dimension -b- = approx. 50 mm

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

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

Sharan 1996 ➤
2.2 - Function
The secondary air system blows air in behind the exhaust valve during a cold start. This produces an oxygen
rich exhaust gas, causing afterburning and reducing the heating-up phase of the catalyst. Activation is per‐
formed by the Motronic control unit (J220) via the secondary air pump relay (J229) to secondary air inlet valve
(N112, change-over valve) and combi-valve.
2.3 - Removing and installing parts of the secondary air system
Notes:
◆ Components marked with an * are checked by the self-diagnosis:
◆ Components marked with ** are checked by the final control diagnosis:
=> Repair Group 01; Self diagnosis; Final control diagnosis Self diagnosis Final control diagnosis

Sharan 1996 ➤
◆ Secondary air pump relay (J299)** =>Page 268 , Fig. 1
1 O ring
◆ Renew
2 Connection
3 Combi-valve
4 Air channel
◆ In cylinder head
5 10 Nm
6 Secondary air inlet valve (N112)*/**
7 Retainer
◆ For secondary air inlet valve
◆ Bolted to bulkhead
8 Connector
◆ Black, 2-pin
9 To intake pipe
10 Non-return valve
◆ White connection faces towards secondary air inlet valve (N112)
11 To vacuum reservoir
2.3 - Removing and installing parts of the secondary air system 265
Sharan 1996 ➤
12 Intake hose
◆ Ensure seated tightly
◆ Press together at front to release
◆ From air cleaner housing
=> Repair group 24; Servicing injection system; Dismantling and assembling air cleaner Servicing injection
system Dismantling and assembling air cleaner
13 Secondary air pump motor (V101)**

14 Connector
◆ Black, 2-pin
◆ For secondary air pump motor
15 Bracket
◆ Secured to lock carrier
16 Pressure hose
17 Washer

Sharan 1996 ➤
18 Rubber bush
19 Bush
20 Connection
◆ For combi-valve
21 Gasket
◆ Renew
22 5 Nm
Sharan 1996 ➤
-> Fig.1 Secondary air pump relay (J299)** -arrow 1-
◆ With fuse S 130 arrow -2-
Notes:
2.4 - Checking combi-valve
Check conditions
• Vacuum pipes and hose connections must be free of leaks.
• Vacuum pipes not blocked/kinked.
Test sequence

Sharan 1996 ➤
- Pull off vacuum hose from combi-valve to secondary air inlet valve (N112).
- -> Connect hand vacuum pump V.A.G 1390 to vacuum hose to combi-valve.
Note:
Do not use compressed air during the following check!
- -> Detach vacuum hose at air cleaner upper part -arrow- and pressurise slightly by blowing into hose.
Combi-valve must be closed.
Note:
To release, press together the buttons on the hose coupling.

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

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

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

Sharan 1996 ➤
3 Combi-valve
4 O-ring
5 Pressure hose
6 EGR valve (N18)*/** with potentiometer for exhaust gas recirculation (G212)*
◆ Check potentiometer for exhaust gas recirculation =>Page 281
7 Connector
◆ Grey, 6-pin
Sharan 1996 ➤
8 Vent hose
◆ To air pipe
=> Page 230 , item 11
9 25 Nm
10 10 Nm
11 15 Nm
12 Retaining clip
13 Connecting pipe
14 Connector
◆ Black, 2-pin
15 Bracket
◆ Secured to cylinder block

Sharan 1996 ➤
16 Rubber bush
17 Secondary air pump motor (V101)**
18 Intake hose
◆ From air cleaner housing
=> Repair group 24; Servicing injection system; Dismantling and assembling air cleaner Servicing injection
system Dismantling and assembling air cleaner
19 Connection
◆ With mounting for combi-valve and EGR valve (N18)
Sharan 1996 ➤
-> Fig.1 Secondary air pump relay (J299)** -relay position 22-
The relay is located on the lower relay carrier of the multi-function unit.
Notes:
3.4 - Checking secondary air pump motor
Note:
is not possible.

Sharan 1996 ➤
Check conditions

• Fuse for secondary air pump relay (J299) OK.
• The suction hose for secondary air pump is not blocked or kinked
Test sequence

- -> Detach the pressure hose -arrow- from the secondary air pump motor.
Note:
- Activate the secondary air pump relay (J299) via the final control diagnosis.
The secondary air pump motor must run in intervals and air must exit from outlet connection.
If the motor runs, but little or no air exits:
- Proceed with final control diagnosis until completed.

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

Sharan 1996 ➤
3.5 - Checking combi-valve
Check conditions
• Hose connections must be free of leaks.
Test sequence
Note:
Do not use compressed air during the following check!

- -> Detach the pressure hose -arrow- from the secondary air pump motor.
Note:
- Blow gently into pressure hose of combi-valve.

Combi-valve must remain closed.
- Blow hard into pressure hose of combi-valve.
Combi-valve must open.
If the combi-valve does not open, or is permanently open:
- Replace the combi-valve

=> Page 271 , item 3 .

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

4.1 - Exhaust gas recirculation system: engine code AWC
Warning!
cramped conditions:
Notes:
◆ The function and control of the exhaust gas recirculation system is checked by the self-diagnosis of the
Motronic control unit (J220).
◆ Pulsed control makes every conceivable valve position possible.
◆ The cone shaped plunger in the (electric) EGR valve ensures that various cross sectional openings are
possible at different plunger lifts.
4.1 - Exhaust gas recirculation system: engine code AWC 277

Sharan 1996 ➤
4.2 - Servicing parts of exhaust gas recirculation system
Notes:
1 Air channel
2 Gasket
◆ Renew

Sharan 1996 ➤
3 Combi-valve
◆ Secondary air system
=>Page 269 , Secondary air system: engine code AWC
4 O-ring
5 Pressure hose
◆ From secondary air pump motor => Page 273 , item 17
6 EGR valve (N18)*/** with potentiometer for exhaust gas recirculation (G212)*
◆ Check potentiometer for exhaust gas recirculation (G212) =>Page 281
4.2 - Servicing parts of exhaust gas recirculation system 279

Sharan 1996 ➤
7 Connector
◆ Grey, 6-pin
8 Vent hose
◆ To air pipe
=> Page 230 , item 11
9 25 Nm
10 15 Nm
11 Retaining clip
12 Connecting pipe
13 10 Nm
14 Connection
◆ With mounting for combi-valve and EGR valve (N18)

Sharan 1996 ➤
4.3 - Checking potentiometer for exhaust gas recirculation

4.3 - Checking potentiometer for exhaust gas recirculation 281

Sharan 1996 ➤
Check conditions

Test sequence
- -> Pull off 6-pin connector (grey) off EGR valve (N18) -arrow-.
- -> Connect multimeter to measure voltage between contacts 2 (positive) and 4 (earth) of connector using
adapter cables from V.A.G 1594 A.
- Switch on ignition.
Specification: min. 4.5 V

Sharan 1996 ➤
- Remove battery.
nected.
- -> Check wiring for open circuit between test box and 6-pin connector using current flow diagram.
Contact 2 and test box socket 98
- Connect test box V.A.G 1598/31 to engine control unit as well and reconnect 6-pin connector to EGR valve.
- Install battery.
- Connect the fault reader V.A.G 1551 (V.A.G 1552). Then switch ignition on and select engine control unit
with the "Address word" 01.
fault reader
- Initiate final control diagnosis and select EGR valve (N18):
- Connect diode test lamp V.A.G 1527 B to socket 100 of test box and earth using adapters from V.A.G 1594.
The LED must flash.
- Proceed with final control diagnosis until completed.
- Depending on conditions, renew following components:
LED flashes:
- Renew EGR valve (N18) with potentiometer (G212) => Page 279 , item 6 .
4.3 - Checking potentiometer for exhaust gas recirculation 283

Sharan 1996 ➤
- Re-adapt engine control unit:
=> Repair group 24; Engine control unit; Adapting engine control unit to throttle valve control part and EGR
valve Engine control unit Adapting engine control unit to throttle valve control part and EGR valve
If no wiring fault is detected and the LED does not flash:
- Renew engine control unit:
=> Repair group 24; Engine control unit; Renew engine control unit Engine control unit Renew engine control
unit

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Service

Service Department. Technical Information

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

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

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

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

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

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166

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

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

1.2 - Engine number

1.3 - Engine data

Engine code AJH AWC

Volkswagen Technical Site: http://vwts.ru http://vwts.info

1.1 - Technical data 1

Catalyst yes yes

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

Engine code AJH AWC

10 - Removing and installing engine

1 - Removing and installing engine

◆ 2024 A Lifting tackle

1.1 - Removing and installing engine 3

◆ V.A.G 1306 Drip tray

1.2 - Notes on removing

4 10 - Removing and installing engine

- -> Remove air duct trim -1-.

Vehicles with engine code AJH

Vehicles with engine code AWC

1.2 - Notes on removing 5

- Unclip fuel hoses from bracket.

Vehicles with engine code AJH

Press buttons on hose couplings to do this.

Vehicles with engine code AWC

Press buttons on hose couplings to do this.

Vehicles with 5-speed manual gearbox 006

- Pull pipe/hose off slave cylinder on gearbox:

- Remove operating cable from gearbox:

6 10 - Removing and installing engine

- Remove drive shafts:

Vehicles with 6-speed manual gearbox 02N

- Remove operating cable from gearbox:

- Remove drive shafts:

Vehicles with automatic gearbox 099 - 4-speed

- Remove selector lever cable from gearbox:

Vehicles with automatic gearbox 09B - 5-speed

- Remove selector lever cable from gearbox:

- Unbolt drive shafts at gearbox flanged shaft and tie up.

Vehicles with air conditioner

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

Continuation for all vehicles

- Remove ribbed belt => Page 28 .

- Unbolt P.A.S. hydraulic pipe at right engine bracket.

1.2 - Notes on removing 7

- Bring lock carrier into service position:

- Remove pendulum support.

- -> Unbolt assembly mounting, right securing bolts -1-.

Vehicles with engine code AJH

8 10 - Removing and installing engine

To remove securing bolts use ladder VAS 5085.