Silnik Mechanika

Service
Sharan 1996 ➤
6-cyl. fuel injection engine, Mechanics
Engine ID AAA
Edition 06.1995
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Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg 00056605820

Sharan 1996 ➤
6-cyl. fuel injection engine, Mechanics - Edition 06.1995
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .n.A.G.. V. o. lk. s.w.a.ge. n. A. . . . . . . . . . . . . . .1
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1.3 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vo. lk. s.w.a. . . . . . . . . . . . . . . . o.e.s n. o.t . . . . . . . .2
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10 - Removing and installing engine . . . . . . . u.th.o . . . . . . . ............ . . . . . . . . .te.e o. .3
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1 Removing and installing engine . . . . . .............. . s.s . . . . . . . . . . . . . . . . . . . . . . . . .3
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1.1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
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1.2 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
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1.3 Securing engine to engine stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
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1.4 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
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1.5 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
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1.6 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
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1.7 Additional information and removal instructions for vehicles with air conditioner . . . . . . . . . .11
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
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1.1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.2 Removing and installing ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
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1.3 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
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1.4 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
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2 Removing and installing sealing flanges and flywheel/drive plate . . . . . . . . . . . . . . . . . . . .41
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2.1 Removing and installing sealing flanges and flywheel/drive plate . . . . . . . . . . . . . . . . . . . .41
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2.2 Renewing crankshaft oil seal - vibration damper end - . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
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2.3 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

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3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
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3.1 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
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4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
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4.1 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
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4.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
1.1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
1.3 Installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
1.4 Checking compressions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
2.1 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
2.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
2.3 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
2.4 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
2.5 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
2.6 Renewing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
2.7 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
1.1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
1.2 Dismantling and assembling oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
1.3 Dismantling and assembling oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
1.4 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Contents i
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19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
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1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
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1.1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
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1.2 Parts of cooling system body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
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1.3 Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
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1.4 Dismantling and assembling coolant thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . .106
1.5 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
1.6 Removing and installing radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
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1.7 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
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1.8 Checking coolant continued circulation pump and radiator fan run-on . . . . . . . . . . . . . . . .114
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
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1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
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1.1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
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1.2 Removing and installing fuel tank with its attachments and fuel filter, front wheel drive . . . .117 r
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Removing and installing fuel tank with its attachments and fuel filter, four wheel drive . . . .123
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1.4 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . .130
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1.5 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
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1.6 Adjusting throttle cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
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1.7 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
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1.8 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
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1.9 Servicing parts of the activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

1 Removing and installing parts of exhaust system, front wheel drive . . . . . . . . . . . . . . . . . .142
1.1 Removing and installing parts of exhaust system, front wheel drive . . . . . . . . . . . . . . . . . .142
1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments . . . . . . . . . . . . . . . . . .142
1.3 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
1.4 Removing and installing parts of exhaust system, four wheel drive . . . . . . . . . . . . . . . . . . . .146
1.5 Exhaust manifold, front exhaust pipe and catalyst with attachments . . . . . . . . . . . . . . . . . .147
1.6 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
1.7 Removing and installing front exhaust pipe and catalyst with attachments . . . . . . . . . . . . . .151
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
2.1 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
2.2 Checking exhaust gas recirculation valve with temperature sensor . . . . . . . . . . . . . . . . . . . .154
3 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
3.1 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
3.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
3.3 Removing and installing parts of the secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . .158
3.4 Checking combi-valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
3.5 Removing and installing combi-valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
ii Contents
Sharan 1996 ➤
00 - Technical data
1 - Technical data
1.1 - Technical data
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-> The engine number (3-letter engine code and (maximum) 6-digit serial number) is located next to the cylinder
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head on the cylinder block. It is found by looking downwards between the crankcase breather heater element
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Additionally there is a sticker on the cylinder head cover with "Engine code" and "Serial number".
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The engine code is also included on the vehicle data plate.
-> From model year 2000 ▸the engine number ("engine code" and "serial number") -arrow- is located next to
the vibration damper on the cylinder block. If more than 999 999 engines with the same engine code have been
produced, the first of the six digits is replaced with a letter.
1.1 - Technical data 1

Sharan 1996 ➤
Additionally there is a sticker on the intake manifold with "engine code" and "serial number".
1.3 - Engine data
Engine code AAA / AMY

Manufactured 06.95 ▸
Arrangement of cylinders VR1)
Cylinder angle 15°
Displacement ltrs. 2.8
Output kW at rpm 128/5800
Torque Nm at rpm 235/4200
(240/4200)2)
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2) Note: The future-orientated design of this engine with selective knock control permits the full use of high
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octane fuel. The figures given in brackets will be attained when using Super plus RON 98.
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Engine code AAA / AMY
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RON min. 95 unleaded
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Ignition system Motronic
Firing order 1-5-3-6-2-4
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Knock control x
Self-diagnosis x
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Lambda control x
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Catalyst x
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Exhaust gas recirculation system x
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Secondary air system x

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2 00 - Technical data
Sharan 1996 ➤

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

◆ Drip tray V.A.G 1306
◆ Fitting tool 3277 A
◆ Engine support 3395
◆ Engine/gearbox jack V.A.G 1383 A
◆ Grease G 000 100
(for vehicles with manual gearbox)
◆ V.A.G 1331 Torque wrench (5...50 Nm)
◆ Cable tie gen AG
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1.2 - Notes
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Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap
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must be disconnected. Obtain radio code first if necessary.

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- The engine is removed downwards together with the gearbox.
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- With the ignition switched off disconnect the battery earth strap.
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- All cable ties which are opened or cut open when removing engine, must be replaced in the same position
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- -> Remove air guide trim -1-.
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- Remove battery trim -2-.
1.1 - Removing and installing engine 3

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- Remove battery.
=> Electrical system; Repair group 27; Battery; Removing and installing battery Battery Removing and installing
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- -> Unbolt -arrows- battery trim with coolant expansion tank and lay to side, do not open coolant system.
- Remove ribbed belt => Page 33 .
- Disconnect intake hose from throttle valve control part.
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=> Repair group 24; Motronic injection and ignition system; Servicing injection part Motronic injection and ig‐
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- Remove spark plug connectors with tool 3277 A and unclip ignition cables:
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=> Repair group 28; Motronic injection and ignition system; Servicing ignition part Motronic injection and ignition
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- -> Remove H.T. cable guides -1-, -2- and -4-.

- Remove cover above intake manifold upper part -3-.
- Detach throttle cable and support bracket at throttle valve control part (do not remove retainer).
- Unclip fuel pipes on cylinder head cover.
- Mark fuel pipes and pull off fuel manifold.
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.
- Separate 42-pin connector (near ignition transformer).

- Pull vacuum hose off brake servo.
4 10 - Removing and installing engine

Sharan 1996 ➤
- Unbolt P.A.S. hydraulic pipes from engine support.
=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes Assembly over‐
view: vane pump, reservoir, hydraulic pipes
- Remove power assisted steering vane pump with bracket and secure to body with wire; hoses remain con‐
nected.
=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic lines; Removing and
installing vane pump on vehicles with VR6 engine Assembly overview: vane pump, reservoir, hydraulic lines
Removing and installing vane pump on vehicles with VR6 engine
- Remove front exhaust pipe => Page 142 , exhaust manifold, front exhaust pipe and catalyst with attach‐
ments.
- Remove secondary air pump fan ring with fan and motor => Page 110 , Removing and installing fan and
radiator
- Disconnect all electric wires from gearbox, alternator and starter and move clear.
- Disconnect all coolant, vacuum and breather hoses from engine.
Vehicles with manual gearbox

. Volkswagen AG
gen AG does
- Lever off pipe/hose from slave cylinder
Vol
ksw on gearbox:
a
not
by gu
d ara
ise nte
=> 5-Speed manual gearbox 006;
thor Repair group 30; Assembly overview; Hydraulics
eo and clutch release mech‐
anism Assembly overview Hydraulics
s au and clutch release mechanism ra
c
s
- Remove operating cable from gearbox:
ce
e
nl
pt
du
an
itte
y li
=> 5-speed manual gearbox 006; Repair group 34; Servicing selector mechanism; Removing and installing
erm
ab
operating cables Servicing selector mechanism Removing and installing operating cables
ility
ot p
wit
, is n
- Remove drive shafts:
h re
hole
spec
=> Running gear; Repair group 40; Servicing drive shafts; Removing and installing drive shafts. Servicing drive
es, in part or in w
shafts Removing and installing drive shafts.
t to the co
Vehicles with automatic gearbox
- Remove selector lever cable from gearbox:
rrectness of i
l purpos
=> Automatic gearbox 099; Repair group 37; Servicing selector mechanism; Dismantling and assembling se‐
lector mechanism Servicing selector mechanism Dismantling and assembling selector mechanism
nform
ercia
- Unbolt drive shafts from gearbox flange shaft and tie up.
m
at
=> Running gear; Repair group 40; Servicing drive shafts; Removing and installing drive shafts. Servicing drive
om
ion
shafts Removing and installing drive shafts.

c
in t
or
his
e
Vehicles with air conditioner

at
do
priv
- Observe additional information and removal instructions => Page 11 .

um
for
en
ng
t.
yi Co
op
Continuation for all vehicles C py
ht. rig
rig ht
- Fit engine support 3395 onto engine/gearbox jack V.A.G 1383 A . py by
co Vo
by lksw
cted agen
Prote AG.
1.2 - Notes on removing 5

Sharan 1996 ➤
- -> Fit engine support 3395 onto cylinder block and tighten securing nuts -1- to
40 Nm.
- Remove pendulum support.
=> Running gear; Repair group 40; Servicing front wheel mounting; I - Assembly overview, assembly carrier,
anti-roll bar, wishbone Servicing front wheel mounting I - Assembly overview, assembly carrier, anti-roll bar,
wishbone
- -> Unbolt assembly mounting, right securing bolts -1-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
- -> Unbolt assembly mounting, left securing bolts -A-.

un
pt
an
d
- Lower assembly carefully.

itte
y li
erm
ab
ility
Note:
ot p
wit
is n
h re
The assembly must be carefully guided when lowering, to prevent damage to the bodywork.
ole,
spec
t to the co
1.3 - Securing engine to engine stand

rrectne
When working on the engine, it should be secured to the engine stand support clamp VW 313 using the engine
ss
bracket 3269.
o
cial p
f inform

mer
atio
m
◆ Workshop crane V.A.G 1202 A

o
n
c
i
or
◆ Lifting tackle 2024 A

thi
te
◆ Extension 2024 A/1

sd
iva
o
r
(for vehicles with automatic gearbox)

p
cum
r
fo
◆ Engine bracket 3269

en
ng
t.
◆ Support clamp VW 313
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
Work sequence
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
- -> Pull 2 pin connector off intake air temperature sender -arrow-.
ility
ot p
- Remove intake manifold temperature sender from intake manifold upper part.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
- -> Attach lifting device 2024 A as follows and lift engine out of engine/gearbox jack using workshop crane.
f
en
ng
t.
yi Co
op
Vibration damper end:
C py
t. rig
gh
4th hole in hook at position 1
ht
pyri by
Vo
o
Flywheel end:
c by lksw
cted agen
4th hole in hook at position 6 Prote AG.
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 vibration damper.
◆ The holes in the hook rails are counted up from the hook.
1.3 - Securing engine to engine stand 7

Sharan 1996 ➤
- -> Attach lifting device 2024 A with extension 2024 A/1 as follows and lift engine out of engine/gearbox jack
using workshop crane.
Vibration damper end:

1st hole in extension at position 1
Flywheel end:
3rd hole in extension at position 6
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 vibration damper end.
◆ The holes in the hook rails are counted up from the hook.
Continuation for all vehicles
- Remove engine bracket 3395 from cylinder block.

- Fit engine bracket 3269 on cylinder block and tighten securing bolts to
40 Nm.
- Fit engine in support clamp VW 313 using workshop crane V.A.G 1202 A.
1.4 - Notes on installing
Work sequence olkswage es n
ot g
b yV ua
ed ran
Installation is carried out in the reverse sequence, when doing
horis this note the following: tee
ut or
a ac
ss
ce
le
un
pt
an
d
itte
- Check clutch release bearing in slave cylinder for wear, renew slave cylinder with release bearing if nec‐
y li
rm
ab
essary.
pe
ility
- Clean notched splines of input shaft and lightly grease with G 000 100.
ot
wit
, is n
h re
hole
spec
es, in part or in w
- Check whether the dowel sleeves for centralising engine/gearbox are in the cylinder block, install if neces‐
t to the co
sary.
- Insert all assembly mounting nuts and bolts by hand approx. 5...6 turns.
- Align assembly mountings stress-free by rocking.
rrectness of i
l purpos
Note:
Assembly mounting tightening torques

nform
mercia
=> Page 10 .
a
com
tion in
r
te o
- Install pendulum support:

thi
s
iva
do
r
rp
=> Running gear; Repair group 40; Servicing front wheel mounting; I - Assembly overview, assembly carrier,
um
fo
anti-roll bar, wishbone Servicing front wheel mounting I - Assembly overview, assembly carrier, anti-roll bar,
en
ng
t.
yi
wishbone
Co
Cop py
t. rig
gh ht
yri by
Vehicles with air conditioner cop Vo
by lksw
cted agen
Prote AG.
- Installing air conditioner compressor:

Sharan 1996 ➤
=> Heating, Air conditioning; Repair group 87; removing and installing compressor bracket removing and in‐
stalling compressor bracket
- Connect pipe/hose on slave cylinder and secure with clip:

swage es n
=> 5-Speed manual gearbox 006; by VRepair group 30; Assembly overview;
olk ot g
u hydraulics and clutch release mech‐
anism Assembly overview hydraulics
ir se
d and clutch release mechanismarante
ho eo
aut ra
- Attach operating cable
ss to gearbox, adjust if necessary: c
ce
e
nl
pt
du
=> 5-Speed manual gearbox 006; Repair group 34; Servicing selector mechanism; Removing and installing
an
itte
y li
operating cables Servicing selector mechanism Removing and installing operating cables
erm
ab
ility
ot p
- Install drive shafts.
wit
, is n
h re
hole
=> Running gear; Repair group 40; Servicing drive shafts; Removing and installing drive shafts Servicing drive
spec
shafts Removing and installing drive shafts
es, in part or in w
t to the co
rrectness of i
- Install selector cable on gearbox, adjust if necessary:
l purpos
=> Automatic gearbox 099; Repair group 37; Servicing selector mechanism Servicing selector mechanism
nf
ercia
orm
m
atio
m
- Install P.A.S. vane pump with bracket:

o
n in
or c
thi
e
=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes; Removing and
t
sd
iva
o
installing vane pump for vehicles with VR6 engine. Assembly overview: vane pump, reservoir, hydraulic pipes
r
rp
cu
o
m
Removing and installing vane pump for vehicles with VR6 engine.
f
en
ng
t.
yi Co
op py
- Install front exhaust pipe => Page , exhaust manifold, front exhaust pipe and catalyst with attachments.
t. C rig
gh ht
- Install secondary air pump fan ring with fan and motor => Page 110 , Removing and installing radiator and
yri
p by
co Vo
fan.
by lksw
cted agen
- Filling with coolant => Page 109
Prote AG.
- Adjusting throttle cable => Page 131

- Electrical connections and routing:
=> Current flow diagrams, Electrical fault finding and Fitting locations
- Install ribbed belt => Page 33 .

- Install intake hose with air cleaner:
- Match engine electronics control unit to immobilizer:
=> Repair group 24; Motronic injection and ignition system; Matching engine electronics control unit to immo‐
bilizer Motronic injection and ignition system Matching engine electronics control unit to immobilizer
- Interrogate fault memory:
=> Repair group 01; Self-diagnosis; Interrogating and erasing fault memory Self-diagnosis Interrogating and
erasing fault memory
- Check idling speed and ignition timing:
=> Repair group 24; Motronic injection and ignition system; Checking idling speed Motronic injection and ignition
system Checking idling speed
1.4 - Notes on installing 9

. Volkswagen AG
gen AG d
Sharan 1996 ➤ olks
wa oes
not
yV gu
6-cyl. fuel injection
ised b engine, Mechanics - Edition 06.1995
ara
n r tee
ho
ut or
- Check headlight adjustment
ss
a and adjust if necessary: ac
ce
le
un
pt
=> Maintenance booklet
an
d
itte
y li
erm
ab
ility
ot p
wit
1.5 - Tightening torques
is n
h re
ole,
spec
Bolted connec‐ Tightening torque
t to the co
tion
Intake manifold temperature sender 10 Nm
to intake manifold upper part
rrectne
Engine to gear‐ M7 10 Nm
box
ss
M8 20 Nm
o
cial p
f in
M10 60 Nm
form
mer
M12 80 Nm
atio
om
Starter to engine and gearbox 45 Nm
n
c
i
or
n thi
Front exhaust pipe to exhaust mani‐ 40 Nm
te
sd
a
fold
iv
o
pr
cum
r
fo
Front exhaust pipe to catalyst 25 Nm
en
ng
t.
yi
Hydraulic pipe to engine support 35 Nm
Co
Cop py
t. rig
Drive shafts to flanged shafts (vehi‐ 80 Nm
gh ht
pyri by
cles with automatic gearbox)
o Vo
by c lksw
cted agen
Prote AG.
1.6 - Assembly mountings
Tightening torques
(Bolts oiled)
-> Assembly mounting, right:
A = 55 Nm
B = 60 Nm

Sharan 1996 ➤
. Volkswage
-> Assembly mounting,
ksw
agleft
en AGon vehiclesn Awith
G do manual gearbox:
es n
ol ot g
yV ua
db ran
A=55 Nm oris e
tee
B=110 Nmau
th or
ac
C=100s Nm
s
ce
D1)=20 Nm + 90°(1/4 turn) further
e
nl
pt
du
an
itte
y li
1) Always renew bolt
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
-> Assembly mounting, left on vehicles with automatic gearbox:

te
sd
iva
o
r
rp
cu
A = 55 Nm
o
m
f
en
ng
B = 110 Nm
t.
yi Co
op
C = 60 Nm C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.7 - Additional information and removal instructions for vehicles with air conditioner
Warning!
The air conditioning system refrigerant circuit must not be opened.
Note:
The opening of the refrigerant circuit can only be carried out in workshops, which have trained personnel and
the necessary range of tools and workshop equipment.
To facilitate removing and installing the engine without opening the refrigerant circuit:
- Remove retaining clamp(s) from refrigerant pipes.
1.6 - Assembly mountings 11

Sharan 1996 ➤
- Remove alternator:
=> Electrical system; Repair group 27; Alternator with ribbed V-belt; 6-Cyl. injection engine Alternator with
ribbed V-belt 6-Cyl. injection engine
- Removing air conditioner compressor:
stalling compressor bracket gen AG
. Volkswagen AG
d wa oes
olks not
yV gu
- Secure air conditioner compressor to body so that edthe refrigerant
b hoses/pipes are relieved.
ara
nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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

1.1 - Dismantling and assembling engine
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
te
Notes:
a
do
priv
cum
for
◆ When stripping and assembling the engine it should be secured to the engine frame with engine bracket
en
ng
t.
yi
3269.
Co
Cop py
◆ If when repairing an engine, metal shavings or large quantities of small metal particles -caused, for example,
t. rig
gh ht
yri
by partial seizure of crankshaft and conrod bearings- are found in engine oil, to prevent consequential dam‐
p by
co Vo
lksw
age, apart from thoroughly cleaning oil passages, it is necessary to renew all oil spray jets, the oil non-return
by
cted agen
Prote
valve and the oil cooler.
AG.
I =>Page 14
1.1 - Dismantling and assembling engine 13

Sharan 1996 ➤
II =>Page 20
III =>Page 26
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Part I
1 Camshaft chain sprocket

◆ Removing and installing
=> Page 77 , removing and installing camshafts
2 Sender wheel
◆ For Hall sender (G40)
◆ Contact surface of timing chain and sender wheel must be dry when installing
=> Page 77 , Removing and installing camshafts
3 100 Nm
◆ Oil bolt head contact surface when installing
◆ To remove and install counter-hold with 24 mm open jaw spanner on camshaft => Page 77 , removing
and installing camshafts
4 Pivot pin, 25 Nm
◆ For tensioning plate item 7
5 Seal
14 13 - Crankshaft group
Sharan 1996 ➤
◆ Renew
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
6 Chain tensioner, 30 Nm
ab
pe
ility
◆ For camshaft chain item 9

ot
wit
, is n
◆ Up to engine number:
h re
AAA 217000 with oil drilling for double chain

hole
spec
◆ Bleed before installing

es, in part or in w
=> Fig. 3
t to the co
◆ From engine number:

AAA 217001 without oil drilling => Fig. 2
◆ Only rotate engine when chain tensioner is installed
rrectness of i
7 Tensioning plate
l purpos
◆ For camshaft chain item 9

AAA 217000 for double chain
nform
ercia

m
AAA 217001 for single chain

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

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
8 Sprocket
agen
Prote AG.
◆ For single chain Pos. 15

◆ Installing => Page 35 , adjusting valve timing
9 Camshaft chain
◆ Mark D.O.R. before removing (installation position)
=> Fig. 1
AAA 217000 double chain
AAA 217001 single chain
10 100 Nm
11 Sprocket
AAA 217001 for single chain
12 10 Nm
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
13 Chain tensioner with tensioning plate

◆ For single chain Pos. 15 spec
es, in part or in w
t to the co
◆ Before installing release locking spline in chain tensioner with a small screwdriver and press tensioning
plate against chain tensioner
◆ Only rotate engine with chain tensioner installed
rrectness of i
14 Crankshaft sprocket
◆ Integral part of crankshaft
l purpos
◆ Ground down tooth aligned with main bearing joint = TDC No. 1 Cyl.
=> Page 35 , adjusting valve timing
nform
ercia
15 Single chain
m
◆ Mark D.O.R. before removing (installation position)

at
om
io
=> Fig. 1
n
c
in t
r

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

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
16 Guide rail
◆ For single chain Pos. 15
◆ Remove together with single chain
=> Page 35 , adjusting valve timing
17 Locating pin without collar, 25 Nm
◆ For guide rail item 16
18 Locating pin with collar, 25 Nm
◆ For guide rail item 21
19 20 Nm
◆ Insert with locking fluid "D6"
20 20 Nm
21 Guide rail
◆ For double chain item 9
22 10 Nm
23 Thrust washer
24 Intermediate shaft
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b
-> Fig.1 Marking
rise single and double chains
d ara
nte
o eo
- Mark single
aut and double chains before removing (e.g. with
h
r a paint, arrow pointing in D.O.R.).
ss c
ce
le
Notes:
un
pt
an
d
◆ From engine number AAA-217001 camshaft drive single chains only are installed.
itte
y li
erm
Therefore the chain tensioner has no oil drilling and must not be bled => Fig. 2 .
ab
ility
◆ The single chain with new chain tensioner must only be installed in conjunction with a suitable tensioning
ot p
wit
plate.
is n
h re
◆ Do not mark chain with a punch mark, notch or similar!

ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
-> Fig. 2 Camshaft chain tensioner

en
ng
t.
yi
◆ The chain tensioner -A- with oil drilling (arrow) must only be installed with the double chain.
Co
op py
◆ The chain tensioner -B- must only be installed with the single chain.
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
-> Fig. 3 Bleeding double chain chain tensioner
- Push a piece of wire (ø0.8 mm) through the hole of the pressure piston -arrow- up to ball valve and press
pressure piston and housing together onto stop.
Note:
If the pressure piston moves out again, repeat bleeding procedure.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Part II
1 5 Nm
l purpos
2 Cover
◆ Over intake manifold upper part
nf
ercia
or
3 25 Nm
m
m
atio
m
4 H.T. cable guide

o
n in
or c
5 Rear left support

thi
te
sd
a
◆ Between intake manifold upper part and cylinder head

iv
o
r
rp
◆ With engine earth connection

cu
o
m
f
en
ng
6 Support bracket
t.
yi Co
op
◆ For accelerator cable C py
t. rig
gh ht
7 Cap pyri by
Vo
co lksw
by
cted agen
Prote AG.
Sharan 1996 ➤
8 Gasket
◆ Renew if damaged
9 Crankcase breather valve
◆ Arrow on heater element points to intake hose
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
10 10 Nm
11 Cylinder head cover
=> Page 66
12 O-Ring
◆ Renew
◆ Coat with oil before assembling and insert in camshaft sprocket cover Pos. 13
13 Camshaft sprocket cover
◆ Can be removed and installed with cylinder head fitted
◆ Coat sealing surfaces with AMV 188 001 02
◆ If only the camshaft sprocket cover has been removed, prepare cylinder head gasket for assembly
=> Page 66 , Fig. 2

Sharan 1996 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
◆ For double chain
erm
ab
ility
ot p
=> Page 20 , Fig. 3

wit
, is n

AAA 217001 without oil drilling => Fig. 2 h re
hole
◆ Only turn engine with chain tensioner installed spec

es, in part or in w
t to the co
15 Seal
◆ Renew
16 Bracket
rrectness of i
◆ For 42-pin connector and pump for coolant continued circulation

l purpos
17 Ignition transformer (N152)*

◆ Checking:
nform
ercia
=> Repair Group 28; Servicing ignition part Servicing ignition part
m
at
om
ion
c
18 Bracket
in t
or
his
e
◆ For electric wires

at
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e
19 Thermostat housing
t
sd
iva
o
r
◆ Dismantling and assembling => Page 107

rp
cu
o
m
f
en
ng
20 O-ring
t.
yi Co
op
◆ Renew C py
ht. rig
rig ht
21 Cylinder head gasket py by
co Vo
by lksw
◆ Renew Prote
cted AG.
agen
◆ If replaced renew the complete
coolant
22 Cylinder head
=> Page 58
coolant
23 Cylinder head bolt
◆ Renew
◆ Note sequence when loosening and tightening
=> Page 67 , installing cylinder head

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
24 Lifting eye
C py
ht. rig
rig ht
◆ Secondary air inlet valve (N112) secured by bracket to lifting eye => Page 158 , Removing and installing
py by
co Vo
parts of secondary air system
by lksw
cted agen
Prote AG.
25 Intake manifold - lower part
26 Gasket for intake manifold lower part
◆ Renew
27 Ribbed belt tensioner
◆ Removing and installing ribbed belts => Page 33
28 Cylinder head cover gasket
◆ Note fitting position
29 Bracket
◆ For fuel pipes
AG. Volkswagen AG d
agen
olksw
oes
not Sharan 1996 ➤
yV gu
6-cyl.
ed b fuel injection engine, Mechanics ara
nte - Edition 06.1995
ris
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
30 Gasket for intake manifold upper part

◆ Renew
31 Intake manifold upper part
◆ First tighten intake manifold lower part, then the two rear supports, Pos. 5 and 33
32 Vacuum hose
◆ From brake servo
33 Rear right support

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Part III
1 10 Nm
2 Oil pump drive cover
3 O-ring
◆ Renew
◆ Oil before assembling
4 Oil pump drive
5 Cylinder block
◆ Removing and installing sealing flange and flywheel/drive plate => Page 41
◆ Removing and installing crankshaft => Page 48
◆ Dismantling and assembling pistons and conrods
=> Page 51
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
7 Thrust washer
8 10 Nm
nf
ercia
orm
9 Knock sensor 2 (G66)
m
atio
m
◆ Checking:
o
n in
or c
thi
te
sd
=> Repair Group 01; Self-diagnosis; Interrogating fault memory Self-diagnosis Interrogating fault memory
iva
o
r
rp
cu
o
m
f
10 20 Nm
en
ng
t.
yi Co
◆ Tightening torque influences the function of the knock sensor Cop py
t. rig
gh
11 O-ring
ht
pyri by
Vo
o
by c
lksw
cted agen
Prote AG.
12 Engine speed sender (G28)
◆ Checking:

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
13 Gasket
◆ Before fitting gasket coat sump flange/cylinder block flange with "D2"
14 Coolant pipe
◆ To thermostat housing
=>Page 23 , Pos. 19
=> Page 102 , parts of cooling system - engine side
15 O-ring
◆ Renew
16 Oil pump
◆ Coat oil pressure pipe on cylinder block and oil pump housing with AMV 188 001 02
17 25 Nm
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
18 10 Nm
s
iva
do
◆ Renew
r
rp
cum
fo

en
ng
t.
yi
19 Seal
Co
Cop py
t. rig
◆ Renew pyri
gh by
ht
20 Oil drain plug, 30 Nm

o Vo
by c lksw
cted agen
21 15 Nm
Prote AG.
22 Sump
◆ Clean sealing surface before installing
23 Oil cooler cover, 25 Nm
24 Oil cooler
◆ Coat contact area outside the seal with AMV 188 100 02
◆ Ensure clearance to adjacent components
◆ See note
=> Page 13

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
25 Oil filter housing
C py
ht. rig
rig ht
◆ Dismantling and assembling py by
co Vo
=> Page 90
by lksw
cted agen
Prote AG.
26 Gasket
◆ Renew
◆ Oil before installing
27 Vibration damper
◆ Removing and installing ribbed belt => Page 33
28 120 Nm + 1/4 turn (90 °) further
◆ Renew
◆ Counter-hold with 3273 to loosen and tighten =>Fig. 1
29 Coolant pump
◆ Check for ease of movement
=> Page 111
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
30 20 Nm
p
cum
for
31 Pulley
en
ng
t.
yi Co
◆ For coolant pump Cop py
t. rig
32 25 Nm
gh ht
pyri by
Vo
co
◆ Use V.A.G 1590 to loosen and tighten
by lksw
cted agen
Prote
◆ Modify water pump spanner V.A.G 1590
AG.
=> Page 106 , Fig. 1

33 60 Nm
34 Guide tube
◆ Secure with bolt to inlet manifold lower part
35 Right engine bracket
36 Dipstick
◆ The oil level must not be above the max. mark!

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
37 Oil non-return valve, 5 Nm

◆ Clean if badly soiled
◆ See note
=> Page 13
Sharan 1996 ➤
-> Fig.1 To loosen and tighten the securing bolt hold vibration damper with counter-hold tool 3273
Notes:
◆ Renew securing bolt.

◆ When tightening the securing bolt the crankshaft must not turn.
1.2 - Removing and installing ribbed belt
◆ Hexagon bolt M8x80
Note: AG. Volkswagen AG d

agen oes
olksw not
V gu
When installing the beltiseensure
db
y
it is correctly seated in the pulley.ara
nte
or eo
th
u ra
Removing ss a c
ce
le
un
pt
- Remove air cleaner upper part complete with air mass meter (G70):
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
- Disconnect solenoid valve 1 (N80) with retaining ring from air cleaner lower part => Page 139 , Servicing
spec
activated charcoal filter system.
es, in part or in w
t to the co
- Remove air cleaner lower part.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
- -> Screw a M8x80 bolt in tensioner threaded hole -A- until the ribbed belt is no longer under tension.
t. rig
gh ht
pyri by
Vo
co lksw
by
Note: cted agen
Prote AG.
Only screw bolt in until the ribbed belt can be removed, otherwise the tensioner housing can be damaged.
- Remove ribbed belt.
Installing
Note:
Before fitting the ribbed belt ensure that all sub-assemblies (alternator, air conditioner compressor, vane pump)
are tight.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Sharan 1996 ➤ autho eo
ra
6-cyl. fuel injection engine, Mechanics - Edition 06.1995 ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
- -> Fit ribbed belt.
yi Co
op
- Remove M8 bolt from the tensioner!
C py
t. rig
gh
- Install air cleaner lower part:
ht
pyri by
Vo
co lksw
by
cted agen
Prote
=> Repair group 24; Motronic injection and ignition system; Servicing injection pump Motronic injection and
AG.
ignition system Servicing injection pump
- Connect solenoid valve 1 (N80) with retaining ring to air filter lower part.
- Install air cleaner upper part complete with air mass meter (G70).
- Start engine and check belt running.
Note:
Engines with an air conditioner compressor are fitted with a double ribbed belt.
1.3 - Checking valve timing
◆ Camshaft setting bar 3268
Test sequence
- -> Set crankshaft to TDC No. 1 Cyl. marks -arrow- by turning crankshaft on the vibration damper securing
bolt in engine D.O.R.:
AG. Volkswagen AG d
agen oes Sharan 1996 ➤
olksw not
yV gu
6-cyl.
ed b fuel injection engine, Mechanicsara
nte
- Edition 06.1995
ris
tho eo
- Remove cylinder head coverau => Page 66 ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f
- -> The camshaft jig 3268 must locate in both shaft grooves.
inform
mer
Note:
atio
om
n
c
i
This condition only occurs every 2nd TDC position.
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
1.4 - Adjusting valve timing

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
(Timing chains removed) Prote
cted AG.
agen
◆ Counter-hold tool VW 558

◆ Hexagon bolt M8x20 with hexagon nut
◆ Torque wrench V.A.G 1332 (40 - 200 Nm)
1.3 - Checking valve timing 35

Sharan 1996 ➤
Work sequence
AG. Volkswagen AG d
Engine removed lksw
agen oes
not
o
byV gu
ara
d
Install single chain and chain tensioneroris with tensioning plate:
e nte
eo
h
aut ra
c
- -> Set/check position of crankshaft
ss
to intermediate shaft.
ce
e
Ground down tooth on crankshaft sprocket -B-
nl
pt
du
must align with the main bearing joint (TDC No. 1 Cyl.).
an
itte
y li
- Install pin without collar for guide rail -2- and tighten to
erm
ab
25 Nm.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
- -> Install guide rail -2- with single chain -1- and both sprockets -3- and -4- (note D.O.R. of single chain =>
Page 19 , Fig. 1 )
The marking on single chain sprocket -4-
must align with the notch -C- or -D- on the
thrust washer.
- Release locking spline in chain tensioner with a small screwdriver -A-.
- Press chain tensioner against tensioner plate and tighten chain tensioner to
10 Nm.
- Tighten flywheel to crankshaft with 3 old bolts and counter-hold with VW 558.
- Secure drive plate to crankshaft with 3 old bolts.
Sharan 1996 ➤
- -> Secure counter-hold tool VW 558 behind the drive plate with a hexagon bolt M8x20.
- -> Tighten intermediate shaft sprockets 3 and 4

100 Nm.
- Remove flywheel/drive plate and check position of crankshaft to intermediate shaft.
Install double chain and chain tensioner with tensioning plate:
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
- -> Locate camshafts with camshaft jig 3268.

spec
- Install tensioning plate pivot pins and tighten to

25 Nm.
t to the co
- Install tensioning plate for chain tensioner (camshaft chain).

- Install locating pin with collar for guide rail and tighten to
25 Nm.
rrectne
Note:
ss o
cial p
With cylinder head removed:

inform
mer
atio
- Installing cylinder head =>Page 67 .

om
n
c
i
or
- Place guide rail on locating pin. Insert short securing bolt with locking fluid "D6" and tighten both bolts to
thi
te
sd
a
20 Nm.
iv
o
pr
- Place camshaft chain on intermediate shaft. (Note D.O.R. of chain

um
r
fo
=> Page 19 , Fig. 1 ).

en
ng
t.
yi
- Fit camshaft sprocket and chain to camshaft for cylinder bank 2, 4 and 6 (short camshaft) and tighten by
Co
Cop py
hand.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.4 - Adjusting valve timing 37

Sharan 1996 ➤
- Fit camshaft sprocket (with sender wheel for Hall sender) and chain to camshaft for cylinder bank 1, 3 and
5 and tighten by hand.
Notes:
◆ Contact surface of timing chain and sender wheel must be dry when installing.
◆ Oil head contact surface of bolts when installing.
- Remove camshaft jig 3268.
- Tighten securing bolts for camshaft sprockets to

100 Nm.
-> Note:
Only counter-hold with 24 mm open jaw spanner on the camshaft -arrow-. The camshaft jig must not be fitted
when tightening/loosening the sprockets.
- Coat sealing surface of sealing flange with AMV 188 001 02 and install. Tighten securing bolt to
10 Nm.
- Replace sealing flange oil seal
=> Page 41 , removing and installing sealing flange and flywheel/drive plate.
- Prepare cylinder head gasket for assembly
=> Page 66 , Fig. 2
- Coat camshaft sprocket cover sealing flange with AMV 188 001 02.
- Oil O-ring (=> Page 21 , Pos. 12 ) and insert in camshaft sprocketagcover. n AG. Volkswagen AG do
w e
- Install camshaft cover, insert all securing bolts and tighten lightly. olks es n
ot g
yV
- First tighten M8 securing bolt to d b ua
ran
ir se
25 Nm tho tee
or
then M6 securing bolts to au ac
ss
10 Nm.
ce
e
nl
- Install chain tensioner for camshaft chain and tighten to

pt
du
an
30 Nm.
itte
y li
erm
ab
ility
ot p
Notes:
wit
, is n
h re
◆ If the chain tensioner has been pulled apart (for double chain), bleed chain tensioner before installing
hole
=>Page 20 , Fig. 3
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Sharan 1996 ➤
◆ Only turn engine with chain tensioner installed! Otherwise single or double chain will jump over!
- Turn crankshaft two full turns in engine D.O.R. and check valve timing => Page 34 .
Engine installed, cylinder head removed
bolt in engine D.O.R.:
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
-> If the TDC No. 1 Cyl. setting is correct it is possible to see a notch on the intermediate shaft sprockets -
es, in part or in w
arrow-.
t to the co
If the notch cannot be seen:
rrectness of i
- Turn crankshaft one full turn in engine D.O.R.
l purpos
Note:
nform
ercia
If the crankshaft is turned with the cylinder head removed, a 2nd mechanic should guide the double chain by
m
a
hand to prevent it jamming.
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

- Prepare cylinder head gasket for assembly
=> Page 66 , Fig. 2
- Install cylinder head => Page 67
- Place guide rail on locating pin. Insert short securing bolt with locking fluid "D6" and tighten bolts to
20 Nm.
- Fit camshaft sprocket and chain to camshaft for cylinder bank 2, 4 and 6 (short camshaft) and tighten by
hand.
- Install camshaft sprocket (with sender wheel for Hall sender) and chain on camshaft for cylinder bank 1, 3
and 5 and tighten by hand.
Notes:
◆ Contact surface of timing chain and sender wheel must be dry when installing.
1.4 - Adjusting valve timing 39

Sharan 1996 ➤
◆ Oil head contact surface of bolts when installing.
- Remove camshaft jig 3268.

- Tighten securing bolts for camshaft sprockets to
100 Nm.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
-> Note:
t to the co
Only counter-hold with 24 mm open jaw spanner on the camshaft -arrow-. The camshaft jig must not be fitted
when tightening/loosening the sprockets.
rrectness of i
- Coat sealing surface of sealing flange with AMV 188 001 02.
l purpos
- Oil O-Ring (=> Page 21 , Pos. 12 ) and insert in camshaft sprocket cover.
- Install camshaft cover, insert all securing bolts and tighten lightly.
nform
ercia
- First tighten M8 securing bolt to

25 Nm
m
a
com
t
then M6 securing bolts to
ion in
10 Nm.
r
te o
thi
- Install chain tensioner camshaft chain and tighten to
s
iva
30 Nm.
do
r
rp
cum
fo
en
g
Notes:
n
t.
yi Co
Cop py
t. rig
gh
◆ If the chain tensioner has been pulled apart, bleed chain tensioner before installing
ht
pyri by
Vo
=>Page 20 , Fig. 3
o
by c lksw
cted agen
◆ Only turn engine with chain tensioner installed! Otherwise single or double chain will jump over! Prote AG.
- Turn crankshaft two full turns in engine D.O.R. and check valve timing => Page 34 .
AG. Volkswagen AG d
agen oe
ksw Sharan s1996 gu ➤
ol not
byV ara
6-cyl. fuel injection engine,
rised
Mechanics - Edition 06.1995 nte
ho eo
ut ra
2 - Removing and installing sealing flanges and flywheel/drive plate s a c
s
ce
e
nl
pt
du
an
2.1 - Removing and installing sealing flanges and flywheel/drive plate
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Notes:
◆ For repairs to the clutch:
=> 5 Speed manual gearbox 006; Repair group 30; servicing clutch servicing clutch
◆ The sealing flange (Pos. 7 ) can be removed and installed with the cylinder head fitted.
◆ When stripping and assembling the engine it should be secured to the engine frame with engine bracket
3269.
1 100 Nm + 1/4 turn (90 °) further

◆ Renew
◆ Counter-hold with 3273 to loosen and tighten =>Page 44 , replacing crankshaft oil seal, vibration
damper end
2.1 - Removing and installing sealing flanges and flywheel/drive plate 41

Sharan 1996 ➤
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spec
es, in part or in w
t to the co
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2 Vibration damper
nform
ercia
3 10 Nm
4 Oil seal
m
at
om
io
◆ Renewing => Page 44

n
c
in t
or
5 Sealing flange
his
ate
do
riv
◆ Coat sealing surfaces with

p
cum
AMV 188 001 02

for
en
ng
t.
6 Cylinder block
yi Co
op py
◆ Removing and installing crankshaft => Page 48
t. C rig
gh ht
yri
◆ Dismantling and assembling pistons and conrods p by
co Vo
=> Page 51
by lksw
cted agen
Prote AG.
7 Sealing flange
◆ Coat sealing surfaces with
AMV 188 001 02
Sharan 1996 ➤
AG. Volkswagen AG d
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nl
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
8 Oil seal
◆ Remove with 2086
◆ Only for coil spring seal: Oil sealing lip and pull in with press sleeve 2003/3
◆ PTFE version of oil seal
◆ Identification: no inner coil spring
◆ Do not additionally oil or grease the oil seal sealing lip
◆ Before installing, remove oil remains from crankshaft journal with a clean cloth
◆ Install over sleeve 2003/2A
◆ Pull in onto stop with press sleeve 2003/1
9 Flywheel/drive plate
◆ To remove and install counter-hold with VW 558
◆ Removing and installing drive plate =>Page 46
2.1 - Removing and installing sealing flanges and flywheel/drive plate 43

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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V gu
d by ara
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or eo
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aut ra
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un
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10 60 Nm + 1/4 turn (90 °) further

erm
ab
◆ Renew
ility
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wit
11 25 Nm
is n
h re
ole,
12 Bracket
spec
◆ For coolant hose

t to the co
2.2 - Renewing crankshaft oil seal - vibration damper end -

rrectness o

cial p
f inform
mer
◆ Retainer 3273
atio
◆ Oil seal extractor 3203

om
◆ Pressure sleeve 3266

c
i
or
◆ Torque wrench V.A.G 1332 (40 - 200 Nm)

thi
te
sd
iva
o
pr
Removing
um
r
fo
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ng
t.
yi Co
op
- Remove ribbed belt => Page 33 . C py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Sharan 1996 ➤
- -> Remove vibration damper. To do this lock vibration damper with 3273.
- Unscrew inner part of oil seal extractor 3203 three turns (approx. 4 mm) out of the outer part and lock with
knurled screw.
- Lubricate threaded head of oil seal extractor, 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
AG. Volkswagen AG d
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Note:
h re
hole
spec
-> A PTFE seal (Teflon) -2- has been introduced gradually to replace the coil spring seal -1-. The seal has a
es, in part or in w
t to the co
wider sealing lip. PTFE seals are fitted free of oil or grease.
If a PTFE seal is installed then only such a seal may be used as a spare part.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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Cop py
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- Before installing, remove oil remains from crankshaft journal with a clean cloth. cted agen
Prote AG.
- -> Place guide sleeve T10053/1 at front onto crankshaft journal and carefully slide seal over guide sleeve
as far as possible onto crankshaft journal.
- Remove assembly tool.
2.2 - Renewing crankshaft oil seal - vibration damper end - 45

Sharan 1996 ➤
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spec
es, in part or in w
t to the co
- -> Press oil seal in onto stop with press sleeve from 3266. To do this use an old vibration damper securing
bolt.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
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Cop py
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Vo
co lksw
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cted agen
Prote
- -> Install vibration damper and lock with counter-hold tool 3273.
AG.
- Tighten new securing bolt to 100 Nm and then turn

1/4 turn (90°)
further.
Notes:
◆ Renew securing bolt.

◆ When tightening the securing bolt the crankshaft must not turn.
2.3 - Removing and installing drive plate
◆ Counter-hold tool VW 558

◆ Hexagon bolt M8x20 with hexagon nut
◆ Depth gauge
◆ Straight edge
Sharan 1996 ➤
Loosening and tightening drive plate
- -> Secure counter-hold tool VW 558 behind the drive plate with a hexagon bolt M8x20.
Installing drive plate

- Fit drive plate on crankshaft.
. Volkswagen AG
gen AG d
- Insert at least 3 old securing bolts and tighten Vol
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not
30 Nm. d by gu
ara
- -> Check dimension -a- through the three rise holes for securing the torque converter using
nte
a straight edge and
tho eo
depth gauge and calculate average. au ra
c
- Compare average with specification ss (measured distance + thickness of straight edge).
ce
e
Specification: 15.7 ... 16.5 mm

nl
pt
du
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erm
If the specification is not attained:

ab
ility
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spec
es, in part or in w
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nf
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orm
m
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om
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c
- -> Remove drive plate again and fit appropriate shim -1-.
or
thi
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sd
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If the specification is attained:

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- Fit drive plate using new securing bolts and tighten to 60 Nm then turn
t.
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op
1/4 turn (90°) C py
t. rig
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Vo
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cted agen
Prote AG.
2.3 - Removing and installing drive plate 47

Sharan 1996 ➤
further. agen
AG. Volkswagen AG d
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V gu
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3 - Removing and installing crankshaft ss aut ra
c
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nl
pt
du
3.1 - Removing and installing crankshaft
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note:
When stripping and assembling the engine it should be secured to the engine frame with engine bracket 3269.
1 Bearing cap
◆ Bearing cap 1: Vibration damper end
◆ Bearing cap 5 with recesses for thrust washers
◆ Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side
2 30 Nm + 1/2 turn (180°) further
◆ Renew
◆ 2 x 90°further is permitted
n AG. Volkswagen AG do Sharan 1996 ➤
wage es n
yV
olks 6-cyl. fuel injection ot g engine, Mechanics - Edition 06.1995
d b ua
ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3 Bearing shells 1 ... 7

◆ For bearing cap without oil groove
◆ For cylinder block with oil groove
◆ Do not interchange used bearing shells (mark)
4 Thrust washer
◆ For bearing cap 5
◆ Note fixing arrangement
5 Crankshaft
◆ Axial clearance new: 0.07...0.23 mm
Wear limit: 0.30 mm
◆ Check radial clearance with Plastigage
New: 0.02...0.06 mm
Wear limit: 0.10 mm
◆ Do not rotate the crankshaft when checking the radial clearance
◆ Crankshaft dimensions:
Main journal:
59.958 ... 59.978 mm
Crankshaft journal:
53.958 ... 53.978 mm
reworking is not permitted
3.1 - Removing and installing crankshaft 49

lkswage es n
o ot g
byV ua
d ran
Sharan 1996 ➤ ho
ir se tee
t or
au Mechanics - Edition 06.1995 ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
6 Sender wheel
◆ For engine speed sender (G28)
◆ Renew
7 10 Nm + 1/4 turn (90 °) further
◆ Renew
8 Thrust washer
◆ For cylinder block, bearing 5
◆ Note fixing arrangement
9 Oil spray jet
◆ For crankshaft bearings 2...7
◆ For piston cooling
◆ Opening pressure: 2.0 bar
=> Page 89 , Fig. 1
◆ See note
=> Page 13
Sharan 1996 ➤
4 - Dismantling and assembling pistons and conrods

4.1 - Dismantling and assembling pistons and conrods
AG. Volkswagen AG d
agen oes
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V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
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Prote AG.
Note:
When stripping and assembling the engine it should be secured to the engine frame with engine bracket 3269.
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 Piston
◆ Checking => Fig. 3
◆ Mark installation position to conrod and cylinder number
◆ High point of piston crown faces to centre of cylinder block
◆ Install with piston fitting tool 3278
4.1 - Dismantling and assembling pistons and conrods 51

Sharan 1996 ➤
=> Fig. 5
AG. Volkswagen AG d
agen oes
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au ra
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3 Conrod
an
d
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◆ Only renew as a set

rm
ab
pe
ility
◆ Mark cylinder number -B-

ot
◆ Installation position:
wit
, is n
h re
Marks -A- must be above one another

hole
spec
4 Conrod bearing cap

es, in part or in w
◆ Note installation position

t to the co
5 30 Nm + 1/4 turn (90 °) further

◆ Renew
rrectness of i
◆ Oil threads and contact surface

◆ To measure radial clearance tighten to 30 Nm but not further
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Sharan 1996 ➤
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d ran
ir se tee
tho
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a ac
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un
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an
d
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ab
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ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
6 Bearing shell
◆ Note installation position
rrectness of i
◆ Do not interchange used bearing shells

◆ The lugs on the bearing shells must fit tightly in the recesses
l purpos
◆ Axial clearance
New: 0.05...0.31 mm
Wear limit: 0.40 mm
nform
ercia
◆ Check radial clearance with Plastigage:

m
New: 0.02...0.07 mm
a
com
tio
Wear limit: 0.10 mm

n in
r
Do not rotate crankshaft when

te o
thi
checking radial clearance

s
iva
do
r
7 Cylinder block
rp
cum
fo
en
g
◆ Checking cylinder bores

n
t.
yi Co
=>Fig. 4 Cop py
. rig
◆ Piston and cylinder dimensions
t
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=>Page 57 cop Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
8 Piston pin
◆ If difficult to remove, heat piston to 60 °C
◆ Remove and install with drift VW 222a
9 Circlip
-> Fig. 1 Checking piston ring gap

- Push ring squarely from above down to approx. 15 mm from bottom end of cylinder. To do this use a piston
without rings.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
e o Sharan 1996 ➤
ris
ho
ut
ss 6-cyl.
a fuel injection engine, Mechanics - Edition
ra
c 06.1995
ce
e
nl
pt
Piston ring Gap
du
an
itte
y li
New Wear
erm
ab
limit
ility
ot p
wit
Compression ring mm 0.20...0.40 1.0
, is n
h re
Tapered stepped ring mm 0.20...0.40 1.0
hole
spec
Oil scraper ring mm 0.25...0.50 1.0
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
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m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
-> Fig. 2 Checking ring to groove clearance
Clean groove before check.
Piston ring Clearance

New Wear
limit
Compression ring mm 0.02...0.07 0.15
Tapered stepped ring mm 0.03...0.06 0.15
Oil scraper ring mm 0.02...0.06 0.15

Sharan 1996 ➤
-> Fig. 3 Checking piston
Measure pistons approx. 6 mm from the lower edge of skirt, at 90 ° to the piston pin axis.
Deviation from nominal dimension

max. 0.04 mm
lkswage es n
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ility
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wit
, is n
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es, in part or in w
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-> Fig. 4 Checking cylinder bores
rrectness of i
◆ Measure bores at 3 locations in both directions -A- across the engine and -B- in line with crankshaft.
l purpos
◆ Use internal dial gauge 50...100 mm.

◆ Deviation from nominal dimension
max. 0.08 mm
nform
ercia
Note:
m
a
com
tion in
r
Measuring the cylinder bores must not be done when the cylinder block is mounted on a repair stand with
te o
thi
adapter bracket 3269, as incorrect measurements would then be possible.

s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Sharan 1996 ➤
-> Fig.5 Installing pistons with piston fitting tool 3278
Note:
If a new fitting tool (funnel) is used to install the pistons, first pass piston with oiled piston rings twice through
the tool and then if necessary remove the resulting metal shavings. Only then install piston with piston rings.
- Oil tool and push piston in by hand. High point of the piston crown must face to the lug on the fitting tool -
arrow-.
- Hold tool (with piston inserted) on upper edge and press piston in with both thumbs.
- Push piston in until it protrudes approx. 15 mm from the lower edge of the fitting tool.
- Place piston in appropriate cylinder bore. Lug on fitting tool -arrow- must face to centre of cylinder block.
- Hold fitting tool tight against cylinder block and push piston in.
4.2 - Piston and cylinder dimensions
Honing Piston-ø Cylinder bore-ø

dimension
Basic dimen. mm 80.985 81.01
1st oversize mm 81.485 81.51
2nd oversize mm 81.985 82.01
AG. Volkswagen AG d
agen oes
olksw not
V gu
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or eo
h
aut ra
ss c
ce
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un
pt
an
d
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rm
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pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
AG. Volkswagen AG d
ksw
agen oes
not
Vol
by gu
15 - Cylinder head, Valve gear

ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
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rm
ab
1 - Removing and installing cylinder head
pe
ility
ot
wit
, is n
h re
1.1 - Removing and installing cylinder head
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Checking compressions
=> Page 68
Notes:
◆ When installing an exchange cylinder head with fitted camshaft, the contact surfaces between bucket tappet
and cam must be oiled after installation.
◆ The plastic protectors fitted to protect the open valves must only be removed immediately before fitting the
cylinder head.
58 15 - Cylinder head, Valve gear

Sharan 1996 ➤
. Volkswagen AG
gen AG d
◆ When replacing
Vol
ksw the cylinder head the ecomplete
a o s
not coolant must be renewed.
y gu
db ara
ise nte
1 5 Nmtho
r eo
2 Cover au ra
c
ss
ce
◆ Above intake manifold upper part
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
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f
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
3 25 Nm
4 H.T. cable guide
5 Rear left support
◆ With engine earth connection
6 Support bracket
◆ For accelerator cable
7 Cap
8 Gasket
9 Cylinder head cover
=> Page 66
10 10 Nm
11 Bracket
1.1 - Removing and installing cylinder head 59

Sharan 1996 ➤
◆ For electric wires and exhaust gas recirculation valve
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
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rm
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ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
12 O-Ring a
com
tion in
◆ Renew
r
te o
◆ Oil before fitting and insert in the camshaft sprocket cover Pos. 13
thi
s
iva
do
13 Camshaft sprocket cover

r
rp
cum
fo
◆ Can be removed and installed with cylinder head fitted

en
ng
t.
◆ Coat sealing surfaces with AMV 188 001 02
yi Co
op
◆ If only the camshaft sprocket cover has been removed, prepare cylinder head gasket for assembly
C py
t. rig
gh
=> Fig. 2
ht
pyri by
Vo
co
14 Spacer ring
by lksw
cted agen
Prote AG.
15 O-ring
◆ Renew

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
16 Hall sender (G40)

nf
ercia
or
◆ Checking:
m
m
atio
om
n in
or c
thi
te
sd
a
iv
o
r
rp
cu
◆ For double chain

o
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f
en
ng

t.
yi Co
op
=>Page 20 , Fig. 3 C py
t. rig
gh
ht
pyri by
AAA 217001 without bleeder hole
co Vo
by lksw
cted agen
◆ Only turn engine with chain tensioner installed Prote AG.
18 Seal
◆ Renew
19 Bracket
◆ For 42-pin connector and pump for continued coolant circulation
20 Ignition transformer (N152)*
◆ Checking:
=> Repair Group 28; Servicing ignition part Servicing ignition part

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
21 Bracket
or c
thi
e
◆ For electric wires

t
sd
iva
r
rp
cu
o

f
en
ng
t.
yi Co
23 O-ring Cop py
ht. rig
◆ Renew rig ht
py by
o Vo
24 Cylinder head gasket
by c lksw
cted agen
Prote AG.
◆ Renew
coolant
25 Cylinder head
◆ Check for distortion => Fig. 1
◆ Installing => Page 67
coolant

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
26 Cylinder head bolt
in t
or
his
te
◆ Renew
a
do
riv

p
cum
or

f
en
ng
t.
yi
27 Lifting eye
Co
Cop py
ht. rig
◆ Secondary air inlet valve (N112) secured by bracket to lifting eye => Page 158 , Removing and installing rig ht
py by
parts of secondary air system co Vo
by lksw
cted agen
28 Intake manifold - lower part Prote AG.
29 Intake manifold lower part gasket

◆ Renew
30 Ribbed belt tensioner
◆ Removing and installing ribbed belt => Page 33

Sharan 1996 ➤
wage
n AG. Volks-waEdition
gen AG 06.1995
doe
ks s no
Vol t gu
d by ara
e nte
ris
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
31 Cylinder head cover gasket

32 Bracket
◆ For fuel pipes
33 Intake manifold upper part gasket
◆ Renew
34 Intake manifold temperature sender (G72), 10 Nm
◆ Checking:
35 Intake manifold upper part

◆ First tighten intake manifold lower part, then the two rear supports, items 5 and 36

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
36 Rear right support
l purpos
◆ With bracket for fuel pipes nform

mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
-> Fig. 1 Checking cylinder head for distortion
Max. permissible distortion: 0.1 mm

AG. Volkswagen AG d
agen oes
olksw not
yV gu
Sharan 1996 ed b ➤ ara
nte
ris
6-cyl.uthfuel injection engine, Mechanics - Edition
o eo
ra
06.1995
s a c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
-> Fig.2 Preparing cylinder head gasket for assembly

- Remove old sealant from 3 mm holes in the cylinder head gasket -arrows-.
nform
ercia
- Fill 3 mm holes in the cylinder head gasket with sealant AMV 188 001 02.
m
a
com
tio
Note:
n in
r
With the cylinder head installed the holes are only half visible.
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
1.2 - Removing and installing cylinder head cover
yi Co
Cop py
ht. rig
rig ht
by
Special tools, testers and auxiliary items copy Vo
by lksw
◆ Fitting tool 3277 A cted agen
Prote AG.
Removing
- Remove air cleaner upper part:
- Pull connectors off throttle valve control part, heater element, air mass meter and intake manifold temper‐
ature sender.
- Pull crankcase breather valve off cylinder head cover and breather hose to activated charcoal filter solenoid
valve 1 off intake manifold upper part.
Attention!
The breather hose must not come into contact with other components.
- Remove intake hose with air mass meter from the throttle valve control part.
- Remove spark plug connectors with H.T. cables:

Sharan 1996 ➤
- -> Removing H.T. cable guides -1- and -2-.
- Detach throttle cable and support bracket at throttle valve control part (do not remove retainer).
- Mark coolant hoses from throttle valve control part, pull off and seal (first release pressure from cooling
system).
- Pull vacuum hose from secondary air inlet valve off junction piece between fuel pressure regulator and intake
manifold upper part.
- Pull vacuum hose off brake servo.
- Unclip fuel pipes from cylinder head cover.
- Detach dipstick guide tube on intake manifold lower part.
- Remove earth connection from rear left support.
- Remove rear left and right supports between intake manifold upper part and cylinder head.
- Detach pipe from exhaust gas recirculation valve at intake manifold upper part.
- Remove intake manifold upper part with throttle valve control part (note position of dowel sleeves when
installing).
Note:
Seal intake ports with clean cloth.
- Remove cylinder head cover.
Installing
Install in reverse order.
Notes:
◆ Replace cylinder head cover gasket if damaged.

◆ Replace intake manifold upper part gasket.
◆ First secure intake manifold upper part to intake manifold lower part, then the two rear supports (=>Page
58 , items 5 and 36 ).
- Adjusting throttle cable => Page 131

- If necessary top-up coolant => Page
en AG. V
109
olkswagen AG
ag does
ksw not
y Vol gu
b ara
ed nte
oris eo
1.3 - Installing
au
th
cylinder head ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m

com
tion in
◆ Crankshaft setting bar 3268

r
te o
thi
s
iva
do
Work sequence
r
rp
cum
fo
en
g
n
t.
yi Co
op
bolt in engine D.O.R.: C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.2 - Removing and installing cylinder head cover 67

Sharan 1996 ➤
Note:
This condition only occurs every 2nd TDC position.
wage es n
- -> Place cylinder head gasket on. Vol
ks ot g
by ua
Observe position of centralizing sleeves in cylinder ed block (hole 12 and 20. ran
ris
- Place cylinder head on. utho
tee
or
- Insert cylinder head bolts and tighten byss ahand. ac
- Tighten cylinder head in four stages in sequence shown as follows:
ce
le
un
pt
- 1. Tighten initially with torque wrench:

an
d
itte
Stage I = 40 Nm
y li
erm
ab
Stage II = 60 Nm
ility
ot p
- 2. Turn further with normal spanner:

wit
Stage III = 1/4 turn (90 °)

is n
h re
Stage IV = 1/4 turn (90 °)

ole,
spec
Notes:
t to the co
◆ Loosening cylinder head: Reverse sequence.

◆ Pulling-down cylinder head after repairs is not necessary.
rrectness o
1.4 - Checking compressions

cial p
f inform
mer
atio
m

o
n
c
i
or
n thi
e
◆ Compression tester V.A.G 1381 or V.A.G 1763

t
sd
va
◆ Spark plug spanner 3122 B

i
o
pr
cum
r

fo
en
ng
t.
yi Co
op py
Test conditions t. C rig
gh ht
pyri by
Vo
o
by c
• Engine oil temperature at least 30 °C.
lksw
cted agen
Prote AG.

Sharan 1996 ➤
Test sequence
- Remove spark plug connectors with tool 3277 A and unclip ignition cables:
- Remove spark plugs with spark plug spanner 3122 B.

- -> Remove ignition cable guide -2-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
- -> Pull 5 pin connector off ignition transformer -arrow-.

- Fully open throttle valve.

t to the co
- Check compressions with compression tester V.A.G 1381 or V.A.G 1763.
Note:
rrectne
Using the compression tester => Operating instructions.

ss o
cial p
- Operate starter until tester shows no further pressure increase.

inform
mer
Compression pressure:
atio
om
n
c
i
or
New: 10...13 bar

thi
te
sd
a
Wear limit: 7.5 bar

iv
o
pr
cum
r
fo
Permissible difference between all cylinders: 3 bar

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.4 - Checking compressions 69

Sharan 1996 ➤
2 - Servicing valve gear

2.1 - Servicing valve gear
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Note:
l purpos
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 0.5
mm in width.
nform
mercia
1 Bearing cap
com
tion in
◆ Installation position => Fig. 2

r
te o
thi
◆ Installation sequence
s
iva

do
r
rp
cum
2 20 Nm
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
3 Camshafts
spec
◆ Checking axial clearance => Fig. 1

t to the co

=> Page 77
◆ Checking radial clearance with plastigage
rrectne
Wear limit: 0.1 mm

◆ Run-out: max. 0.01 mm
s
4 Camshaft sprocket
s o
cial p

in
=> Page 77 , Removing and installing camshafts

form
mer
5 Sender wheel
atio
om
◆ For Hall sender (G40)

n
c
i
or
◆ When installing contact surface on timing chain and sender wheel must be dry
thi
te
sd

iva
o
r

p
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.1 - Servicing valve gear 71

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
6 100 Nm
◆ To remove and install counter-hold with 24 mm OJ spanner on camshaft
rrectness of i
=>Page 77 , removing and installing camshafts
l purpos
◆ Oil bulkhead contact surface when installing

7 Cylinder head height
nf
◆ Minimum height: a = 139.5 mm

ercia
orm
8 Cylinder head
m
atio
m
◆ See note
o
n in
c
=> Page 70
or
thi
e
◆ Reworking valve seats

t
sd
iva
=> Page 76
o
r
rp
cu
o
9 Valves
f
en
ng
t.
yi Co
◆ Do not rework only grinding-in is permitted Cop py
◆ Valve dimensions => Fig. 3
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
10 Valve guide
o
r
rp
cu
o
◆ Checking => Page 81

f
en
ng
t.
◆ Renewing => Page 82
yi Co
op py
◆ Service version with collar
. C rig
ht ht
rig
11 Valve stem seal
py by
co Vo
by lksw
◆ Renewing=> Page 82
cted agen
Prote AG.
12 Valve springs
◆ Removing and installing:
Cylinder head
removed: with 2037
installed: => Page 82 , renewing valve stem seals
13 Valve spring plate
14 Valve cotters

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
15 Bucket tappet
t to the co
◆ Do not interchange
◆ With hydraulic valve clearance compensation
◆ Store with cam lobe contact surface downwards
rrectne
◆ Before installing check camshaft axial clearance => Fig. 1

◆ Oil contact surface
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
-> Fig. 1 Camshafts, checking axial clearance
Wear limit: max. 0.15 mm
Check with bucket tappets removed and with first and last bearing caps fitted to appropriate camshaft.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
-> Fig. 2 Fitting position of camshaft bearing caps
rrectness of i
l purpos
The bearing cap identification must be readable from the exhaust side of the cylinder had and the arrow pointing
to vibration damper end.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
-> Fig. 3 Valve dimensions
Note:
Valves must not be reworked. Only lapping-in is permitted.
Dimension Inlet valve Exhaust valve

øa mm 39.0 34.20
øb mm 6.97 6.95
c mm 105.95 106.95
α <° 45 45

Sharan 1996 ➤
AG. Volkswagen AG d
agen
2.2 - Reworking valve seats
oes
olksw not
y V gu
d b ara
rise nte
tho eo
Notes: s au ra
c
s
◆ When repairing engines with leaking valves, it is not always sufficient to rework or renew valve seats and
ce
le
un
pt
valves. It is also necessary to check the valve guides for wear. This is particularly important on high mileage
an
d
itte
y li
engines. rm
ab
◆ The valve seats should only be reworked just enough to produce a perfect seating pattern. The maximum
pe
ility
permissible reworking dimension must be calculated before reworking commences. If the reworking dimen‐
ot
wit
, is n
sion is exceeded, the function of the hydraulic tappets can no longer be guaranteed and the cylinder head
h re
hole
should be renewed.
spec
es, in part or in w
t to the co
Work sequence
Calculating max. permissible reworking dimension
rrectness of i
- Insert valve and press firmly against seat.
l purpos
Note:
If the valve is to be renewed as part of a repair, use a new valve for the calculation.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- -> Measure distance -a- between end of valve stem and upper edge of cylinder head.
- Calculate max. permissible reworking dimension from measured distance -a- and minimum dimension.
Minimum dimension:
Inlet valve 33.9 mm
Exhaust valve 34.1 mm
Measured distance minus minimum dimension
= max. permissible reworking dimension.
Example:
- Measured distance -a- 34.8 mm
Minimum dimension 34.1 mm
= max. perm. rework dimension1) 0.7 mm
1)=> Page 77 .

Sharan 1996 ➤
-> Reworking inlet valve seat
a = ø38.3 mm
b = Max. permissible reworking dimension1)
c = 1.4 mm ... 2.0 mm
Z if necessary rework valve seat insert with
α 75 ° correction miller
β = Cylinder head lower edge
γ = 45 °valve seat angle
= 30 °upper correction angle
= 75 °lower correction angle
-> Reworking exhaust valve seat
a = ø33.5 mm
b = Max. permissible reworking dimension1)
c = 2.0 mm ... 2.5 mm
Z if necessary rework valve seat insert with
α 75 °correction miller
β = Cylinder head lower edge
= 45 °valve seat angle
= 30 °upper correction angle
AG. Volkswagen AG d
agen oes
olksw not
V gu
by
2.3 - Removing rised and installing camshafts ara
nte
ho eo
aut ra
ss c
ce
e

nl
pt
du
an
itte
y li

erm
ab
ility

ot p
wit
, is n
h re
Removing
hole
spec
es, in part or in w
- Set engine to TDC No. 1 Cyl. marks by turning in engine direction of rotation on the vibration damper securing
t to the co
bolt =>Page 34 , checking valve timing.

- Remove cylinder head cover =>Page 66 .
- Remove ignition transformer (N152).
rrectness of i
l purpos

nform
ercia
- Remove chain tensioner for camshaft chain.

- Remove camshaft sprocket cover.
m
at
om
- Loosen securing bolts for camshaft sprockets.

ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
77
cted agen
Prote
2.2 - Reworking valve seats
AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Sharan 1996 ➤ ut
ho eo
ra
a
ss Mechanics - Edition 06.1995 c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
-> Note:
orm
m
atio
m
Only counter-hold camshaft with 24 mm OJ spanner -arrow-. The camshaft jig 3268 must not be in place when
o
n in
c
tightening or loosening the chain sprockets.

or
thi
te
sd
a
- Remove camshaft sprockets.

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
- -> Mark camshaft chain before removing (e.g. with paint, arrow pointing in D.O.R.).
Notes:
◆ From engine number AAA-217001 camshaft drive single chains only are installed.
Therefore the chain tensioner has been changed and must not be bled.
◆ Do not mark chain with a punch mark, notch or similar!

Sharan 1996 ➤
-> Camshaft cylinder bank 1, 3 and 5
- First remove bearing caps 1 and 7.

- Slacken off bearing caps 3 and 5 alternately and diagonally.
Camshaft cylinder bank 2, 4 and 6
- First remove bearing cap 4.

- Slacken off bearing caps 2 and 6 alternately and diagonally.
Installing
- Oil running surfaces of both camshafts.
Notes:
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
◆ Observe marking (direction of rotation) of chain!
◆ -> When installing the camshafts the recess for the camshaft sprockets -arrows- must be at top.
◆ When installing bearing caps ensure that the identification mark is readable from the exhaust side of cylinder
rrectne
head and that the arrow points to vibration damper end.

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
-> Camshaft cylinder bank 1, 3 and 5
- Tighten bearing caps 3 and 5 alternately and

diagonally to
20 Nm.
- Install bearing caps 1 and 7 and also tighten to
20 Nm.
Camshaft cylinder bank 2, 4 and 6
- Tighten bearing caps 2 and 6 alternately and

diagonally to
20 Nm.
- Install bearing cap 4 and also tighten to
2.3 - Removing and installing camshafts 79

Sharan 1996 ➤
20 Nm.
- Clean sealing surfaces of camshaft sprockets cover and cylinderwahead.

gen AG
. Volkswagen AG
does
- -> Remove old sealant from 3 mm holes in cylinder head gasket
yV
olks -arrows-. not
gu b ara
ed nte
ris
Note: tho e or
au ac
ss
With the cylinder head installed the holes in the cylinder head gasket are only half visible.
ce
e
nl
pt
du
an
itte
y li
- Install camshaft sprockets with chain => Page 35 , adjusting valve timing.
erm
ab
- Fill 3 mm holes in cylinder head gasket with sealant AMV 188 001 02.
ility
ot p
- Coat sealing surfaces of cover for camshafts with AMV 188 001 02.
wit
, is n
- Oil O-ring (=> Page 60 , Pos. 12 ) and insert in cover for camshafts.
h re
- Install cover for camshafts, insert old securing bolts and tighten lightly.
hole
spec
- First tighten M8 securing bolts to
es, in part or in w
25 Nm
t to the co
then tighten M6 securing bolts to
10 Nm.
- Install chain tensioner for camshaft chain and tighten to
rrectness of i
30 Nm.
l purpos
Notes:
nf
ercia
◆ If the chain tensioner for double chain has been pulled apart, bleed chain tensioner before installing
orm
=>Page 20 , Fig. 3 .
m
atio
m
◆ When new tappets have been installed the engine must not be started for about 30 minutes. Hydraulic
o
n in
c
compensation elements must settle (otherwise valves will strike pistons).

or
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te
sd
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o
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2.4 - Checking hydraulic bucket tappets

t.
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Prote AG.
◆ Feeler gauge
◆ Wood or plastic wedge
Test sequence
Notes:
◆ Renew defective tappet complete (cannot be adjusted or repaired).
◆ Irregular valve noises when starting engine are normal.
- Start engine and run until the radiator fan has switched on once.
- Increase engine speed to about 2500 rpm for 2 minutes.
If the hydraulic tappets are still noisy, locate defective tappets as follows:
- Remove cylinder head cover =>Page 66 .

AG. Volkswagen AG d
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agen oes
not
Sharan 1996 ➤
ol
byV 6-cyl. fuel injection engine,
gu
a Mechanics - Edition 06.1995
ed ran
oris tee
- Rotate crankshaft
au
th clockwise on vibration damper securing bolt,or until cam of the tappet to be checked
ac is
pointing upwards.
ss
ce
- Determine play between cam and bucket tappet.
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
- If the play is in excess of 0.1 mm, renew bucket tappet. If the play is less than 0.1 mm or no play, proceed
m
at
with check as follows:
om
io
- -> Press tappet down with a wooden or plastic wedge. If free travel in excess of 1 mm is felt before tappet
n
c
in t
or
contacts valve, renew
his
ate
tappet.
do
priv
cum
for
Note:
en
ng
t.
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Cop py
.
After installing new tappets the engine must not be started for approx. 30 minutes. Hydraulic compensation
ht rig
rig ht
by
elements must settle (otherwise valves will strike pistons). copy Vo
by lksw
cted agen
Prote AG.
2.5 - Checking valve guides
◆ Universal dial gauge bracket VW 387

◆ 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:
Inlet valve guide = 1.0 mm
Exhaust valve guide = 1.3 mm
2.4 - Checking hydraulic bucket tappets 81

Sharan 1996 ➤
2.6 - Renewing valve guides

◆ Hand reamer 3120 and cutting fluid
◆ Drift 3121
Test sequence
- Clean and check cylinder head. Cylinder heads in which the valve seats can no longer be reworked, or
cylinder heads which have already been machined to the minimum dimension (height) =>Page 72 , item
7 , or already have service version valve guides fitted, are not suitable to have the valve guides replaced.
- -> Press out worn valve guides with 3121 from the camshaft side.
- Coat new guides with oil and press in with 3121 from the camshaft side (cylinder head cold) until shoulder
makes contact. When doing this the cylinder head must be laying flat.
n AG. Volkswagen A age G do
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Vol ot g
Note: ed
by ua
ran
oris tee
When the shoulder on guideau makes contact,
th
the pressure must not exceed o1.0 ra t otherwise shoulder may break
off. ss c
ce
le
un
pt
- Ream guides out with hand reamer 3120 using plenty of cutting fluid.
an
d
itte
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- Rework valve seats => Page 76 .

rm
ab
pe
ility
ot
wit
, is n
h re
2.7 - Renewing valve stem seals

hole
spec
es, in part or in w
t to the co
(with cylinder head fitted)

rrectness of i

l purpos
◆ Assembly tool 2036

◆ Puller 3047A
◆ Fitting tool 3129
nform
ercia
◆ Lever VW 541/1A with press piece VW 541/5

◆ Pressure hose VW 653/3
m
a
com
tion in
r
Work sequence
te o
thi
s
iva
do
- Remove camshafts => Page 77 .

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rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Sharan 1996 ➤
- Remove bucket tappets (do not interchange) and store with the contact surface downwards.
- Remove spark plugs.
- Set piston of appropriate cylinder to "bottom dead centre".
- -> Fit assembly tool 2036 and adjust mountings to height of studs.
- Screw compressed air hose VW 653/3 into spark plug thread and apply a continuous pressure of
min. 6 bar.
- Remove valve springs with lever VW 541/1A and press piece VW 541/5.
Note:
Tight cotters can be loosened by tapping lightly on the lever.
- Pull off valve stem seals with 3047A.

AG. Volkswagen AG d
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ility
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hole
spec
es, in part or in w
t to the co
- -> To prevent damage to the new valve stem seals, place plastic sleeve -A- on valve stem.
rrectness of i
- Oil valve stem seal -B-, place it in the tool 3129 and push carefully onto the valve guide.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2.7 - Renewing valve stem seals 83

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 when repairing an engine, metal shavings or a large quantity of small metal particles caused, for example,
by partial seizure of crankshaft and conrod bearings, are found in the engine oil, to prevent consequential
damage, apart from thoroughly cleaning oil passages, it is necessary to renew all oil spray jets, the oil non-
return valve and the oil cooler.
◆ The oil level must not be above the max. mark - danger of damage atogecatalyst!
e ksw s no
Vol t gu
by
Checking oil pressure and oil pressure switch => Page 96 rise d ara
nte
tho eo
au ra
Oil system capacity1): ss c
ce
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nl
pt
du
without oil filter 5.0 ltrs.
an
itte
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with oil filter 5.5 ltrs.
erm
ab
ility
ot p
1) Up-to-date figures:
wit
, is n
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hole
=> Exhaust emissions test binder
spec
es, in part or in w
t to the co
Engine oil specifications:
Use engine oils to VW standard 500 00, 501 01 or 502 00. Only in exceptional cases: Multi-grade oils corre‐
rrectness of i
sponding to ACEA A2/A3.
l purpos
Engine oil specifications: Vehicles 06.99 ▸with long-life service
Use engine oils conforming to VW standard 503 00.
nform
mercia
Note:
at
om
ion
c
in t
r
Engines are filled at the factory with oil meeting VW standard 503 00. This engine oil is matched to long service
o
his
te
intervals.
a
do
priv
cum
or
Engine oils conforming to VW standard 500 00, 501 01 or 502 00 can be used furthermore. The oil must then
f
en
ng
t.
yi
be changed every 12 months or every 15,000 km and the service interval display must be programmed corre‐
Co
op py
spondingly. Procedure:
t. C rig
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=> Maintenance manual Prote
cted AG.
agen
84 17 - Lubrication
Sharan 1996 ➤
-> Fig.1 Oil level/oil temperature sender (G266)
Only check for vehicles 05.99▸:
=> Current flow diagrams, Electrical fault finding and Fitting locations
1- Oil level/oil temperature sender (G266)
2- 10 Nm
3- Oil seal, renew
4- 3-pin connector
AG. Volkswagen AG d
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un
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d
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ab
ility
ot p
wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
1 10 Nm
t
sd
iva
2 Oil pump drive cover

pr
cum
r
fo
3 O-ring
en
ng
t.
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◆ Renew Cop py
ht. rig
◆ Oil before installing rig ht
py by
Vo
4 Oil pump drive
co lksw
by
cted agen
Prote
AG.
6 Thrust washer
7 10 Nm
8 Oil pump
1.1 - Removing and installing parts of the lubrication system 85

Sharan 1996 ➤
◆ Coat oil pressure pipe at cylinder block and oil pump housing with AMV 188 001 02
AG. Volkswagen AG d
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un
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ab
pe
ility
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wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
9 25 Nm
10 10 Nm
◆ Renew
◆ Install with locking fluid "D6"
11 Oil drain plug, 30 Nm
12 Seal
◆ Renew
13 Oil spray jet
◆ For crankshaft bearings 2...7
◆ For piston cooling
=> Fig. 1
◆ Opening pressure: 2.0 bar
◆ See note
=> Page 84
14 15 Nm
86 17 - Lubrication
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
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hole
15 Gasket
spec
◆ Renew
es, in part or in w
t to the co
◆ Before fitting gasket coat sump flange/cylinder block flange with "D2"
16 Sump
◆ Clean sealing surface before installing
rrectness of i
17 Oil cooler
l purpos
◆ Coat contact area to flange, outside the seal, with AMV 188 100 02
◆ Ensure clearance to adjacent components
◆ See note
nf
ercia
=> Page 84
rm
m
atio
18 Oil cooler cover, 25 Nm

om
n in
c
19 Gasket
or
thi
te
◆ Renew
sd
iva

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rp
cu
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◆ Oil before fitting

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

Sharan 1996 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
20 Oil filter housing

ot p
wit
, is n
◆ Dismantling and assembling

h re
=> Page 90
hole
spec
21 Dipstick
es, in part or in w
t to the co
◆ The oil level must not be above the max. mark!

22 Guide tube
◆ Secure with bolt to inlet manifold lower part
rrectness of i
23 Oil non-return valve, 5 Nm

l purpos

◆ Clean if badly soiled
◆ See note
nf
ercia
=> Page 84
rm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
o
m
f
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
88 17 - Lubrication
Sharan 1996 ➤
-> Fig.1 Removing and installing oil spray jet
Note:
Oil spray jets are installed in main bearings 2 ... 7.
• Crankshaft removed
- Remove with 4 mm ø punch.

- Install by hand with a 6 mm øpunch -arrow-.
AG. Volkswagen AG d
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V gu
d by ara
ise nte
or eo
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aut ra
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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f
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
1.2 - Dismantling and assembling oil filter housing
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
tho eo
au ra
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nl
pt
du
an
itte
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erm
1 Gasket
ab
ility
ot p
◆ Renew
wit
, is n

h re

hole
spec
2 0.3 bar oil pressure switch (F22), 20 Nm

es, in part or in w
t to the co
◆ Brown
◆ Wiring: blue/black
rrectness of i
◆ If sealing ring is leaking nip open and replace.

3 Oil filter bracket
l purpos
4 Stop plate
◆ For oil cooler
nform
ercia
◆ Secured to oil filter bracket

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
90 17 - Lubrication
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
5 Oil filter element

rm
m
atio
◆ Observe change intervals

om
n in
◆ With by-pass valve

or c
thi
Opening pressure: 2.0 bar

te
sd
a
◆ Clip into oil filter lower part before installing

iv
o
r
rp
cu
6 O-ring
o
m
f
en
ng
t.
◆ Renew
yi Co
op py
◆ Oil before installing t. C rig
gh ht
yri
7 Oil filter lower part, 30 Nm p by
co Vo
by lksw
◆ Drain before removing
cted agen
Prote AG.
8 Oil drain screw, 10 Nm
9 25 Nm
1.2 - Dismantling and assembling oil filter housing 91

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
10 1.4 bar oil pressure switch (F1), 25 Nm

pe
ility
ot
◆ Black
wit
, is n
h re
◆ Wiring: yellow
hole

spec
◆ If sealing ring is leaking nip open and replace.

es, in part or in w
t to the co
11 Oil temperature sender (G8), 10 Nm

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
92 17 - Lubrication
Sharan 1996 ➤
1.3 - Dismantling and assembling oil pump
AG. Volkswagen AG d
agen oes
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V gu
d by ara
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or eo
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aut ra
ss c
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nl
1 Drive shaft
pt
du
an
itte
◆ For oil pump drive

y li
erm
ab
2 Oil pump housing

ility
ot p
wit
3 25 Nm
, is n
h re
4 Gears
hole
spec
◆ Checking backlash
es, in part or in w
=> Fig. 1
t to the co
◆ Checking axial clearance

=> Fig. 2
rrectness of i
5 Oil pump cover with pressure relief valve

◆ Opening pressure: 5.3...5.7 bar
l purpos
◆ Clean strainer if soiled

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
93
AG.
1.3 - Dismantling and assembling oil pump
Sharan 1996 ➤
6-cyl. fuel injection engine, Mechanics - Edition
gen AG
06.1995
. Volkswagen AG
d wa oes
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6 10 Nm
◆ Renew
◆ Install with locking fluid "D6"
7 Oil pressure pipe
◆ Coat cylinder block and oil pump housing with AMV 188 001 02
8 10 Nm
9 O-ring
94 17 - Lubrication
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
-> Fig. 1 Checking oil pump backlash
l purpos
Wear limit: 0.20 mm
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.3 - Dismantling and assembling oil pump 95

Sharan 1996 ➤
-> Fig. 2 Checking oil pump axial clearance
Wear limit: 0.10 mm
1.4 - Checking oil pressure and oil pressure switch
◆ Oil pressure tester V.A.G 1342

◆ Diode test lamp V.A.G 1527
◆ Adapter set V.A.G 1594
◆ Current flow diagram
Test sequence
Note:
Functional check and servicing the optical and acoustic

agen
oil
AG pressure
. Volkswagen Awarning:
G do
ksw es n
Vol ot g
by u
=> Current flow diagrams, Electrical faultisefinding and
d Fitting locations binder arant
r ee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
- -> Remove 0.3 bar oil pressure switch (brown insulation) and screw into the tester.
- Screw tester into the oil filter bracket in place of the oil pressure switch.
nf
ercia
- Connect brown wire -3- of tester to earth (-).

orm
m
atio
m
- Connect diode test lamp V.A.G 1527 with aux. cables from V.A.G 1594 to battery positive (+) and 0.3 bar
o
n in
c
oil pressure switch (F22) -A-. LED must light up.

or
thi
- Start engine and increase speed slowly.

te
sd
a
At
iv
o
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rp
cu
0.15...0.45 bar
o
m
f
en
ng
the LED must go out, otherwise renew 0.3 bar oil pressure switch.
t.
yi Co
- Connect diode test lamp to 1.4 bar oil pressure switch (black insulation) -B-. Cop py
t. rig
At yri
gh by
ht
1.2...1.6 bar cop Vo
by lksw
The LED must light up, otherwise renew 1.4 bar oil pressure switch (F1). cted agen
Prote AG.
- Increase engine speed further.
At 2000 rpm and an oil temperature of 80 °C the oil pressure should be at least 2.0 bar.
At higher engine speed the oil pressure must not exceed 7.0 bar. If necessary renew oil pump.
96 17 - Lubrication
Sharan 1996 ➤
19 - Cooling system
1 - Removing and installing parts of cooling system

1.1 - Removing and installing parts of cooling system
Notes:
◆ When the engine is warm the cooling system is under pressure. If necessary release pressure before com‐
mencing repair work.
◆ Hoses are secured with spring-type clips. In cases of repair only use spring-type clips.
◆ Assembly tool VAS 5024 or hose clip pliers V.A.G 1921 are recommended for fitting spring-type clips.
◆ The refractometer T10007 is recommended for determining the current anti-freeze density.
◆ 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).
swage es n
Draining and filling with coolant=>
byV
olk Page 109 ot g
ua
d ran
ir se tee
Coolant mixture ratios
uth => Page 109 , draining and filling with coolant
o
or
a ac
ss
ce
Carry out cooling system leakage check with V.A.G 1274 and adapter 1274/7.
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.1 - Removing and installing parts of cooling system 97

AG. Volkswagen AG d
agen oes
ksw
Sharan 1996 ➤ by V ol not
gu
d ara
orise engine, Mechanics - Edition nt06.1995
ee
h
aut or
ac
1.2 - Parts of cooling
ss system body side
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1 Rubber mounting
2 Upper coolant hose
◆ From thermostat housing
=>Page 104 , Pos. 17
3 Radiator
=>Page 110
◆ After replacing renew entire coolant
4 Air intake ducting
5 10 Nm
6 Rubber washer
7 Reinforcing strip
98 19 - Cooling system
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
8 2 pin connector
ion
c
in t
r
◆ Black
o
his
e
◆ For right radiator fan (V35)

at
do
riv
9 Retaining clip
p
cum
for
en
g
◆ Check seated securely

n
t.
yi Co
◆ For 2 pin connector Cop py
t. rig
10 Right radiator fan (V35)
gh ht
pyri by
Vo
o
by c lksw
cted agen
=>Page 110
Prote AG.
11 Fan ring
12 Intake hose
◆ Ensure seated tightly
13 Pressure hose
1.2 - Parts of cooling system body side 99

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
14 Secondary air pump motor (V101)

◆ Removing and installing =>Page 158 , Removing and installing parts of the secondary air system
◆ Checking:
=> Repair Group 01; Self diagnosis; Final control diagnosis Self diagnosis Final control diagnosis
15 25 Nm
16 Retaining clip
◆ For intake hose
17 2 pin connector
◆ Black
◆ For left radiator fan (V7)
18 Left radiator fan (V7)
=>Page 110

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
19 Lower coolant hose

t to the co
◆ To thermostat housing
=>Page 105 , Item 19
rrectness of i
20 Connector
◆ Black, 3 pin
l purpos
◆ For radiator fan thermo switch

21 Radiator fan thermo switch (F18),
nf
ercia
35 Nm
orm
◆ Switching temperatures:
m
atio
m
Stage 1
o
n in
c
on: 92...97 °C
or
thi
e
off: 84...91 °C
t
sd
iva
Stage 2
o
r
rp
cu
on: 99...105 °C
o
m
f
en
ng
off: 91...98 °C
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.2 - Parts of cooling system body side 101

Sharan 1996 ➤
1.3 - Parts of cooling system engine side
AG. Volkswagen AG d
agen oes
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byV gu
ara
ed
ris nte
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aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1 25 Nm
◆ To loosen and tighten use V.A.G 1590
◆ Modify water pump spanner V.A.G 1590 => Fig. 1
2 Belt pulley
◆ For coolant pump
3 20 Nm
4 Coolant pump
◆ Check for ease of movement
=> Page 111
5 O-ring
◆ Renew
6 From cylinder head

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
7 Rubber bush
AG.
◆ For continued coolant circulation pump

◆ Secured with bracket to the camshaft sprocket cover
=>Page 61 , Pos. 19
8 Connector
◆ Black, 2 pin
◆ For continued coolant circulation pump
9 Continued coolant circulation pump (V51)
◆ Checking =>Page 114
10 Throttle valve control part (J338)
◆ Heated by coolant
11 To heat exchanger
12 10 Nm
1.3 - Parts of cooling system engine side 103

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
13 Cap
rrectne
◆ Check with cooling system tester V.A.G 1274 and adapter V.A.G 1274/1A
◆ Test pressure 1.4...1.6 bar
ss
14 Expansion tank
o
cial p
f in
◆ Check with cooling system tester V.A.G 1274 and adapter V.A.G 1274/7
form
mer
◆ Test pressure 1.4...1.6 bar

atio
m
15 Connector
o
n
c
◆ Black, 2 pin
i
or
n thi
te
16 From heat exchanger

sd
iva
o
pr
17 Upper coolant hose

um
r
fo
en
ng
◆ To top of radiator
t.
yi Co
op
=>Page 98 , Pos. 2 C py
ht. rig
18 ATF cooler
rig ht
py by
co Vo
◆ Only on vehicles with automatic gearbox
by lksw
cted agen
Prote
◆ Removing and installing:
AG.
=> Automatic gearbox 096; Repair group 37; Dismantling and assembling gearbox; Removing and installing
ATF cooler and ATF filler tube Dismantling and assembling gearbox Removing and installing ATF cooler and
ATF filler tube

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
19 Lower coolant hose

hole
spec
◆ From bottom of radiator

es, in part or in w
t to the co
=>Page 101 , Item 19

20 Oil cooler
rrectness of i
=> Page 87 , Pos. 17

l purpos
nform
ercia
22 To cylinder block
23 Drain plug, 10 Nm
m
at
om
◆ Draining and filling with coolant

on
c
in t
=> Page 109

or
his
te
24 Coolant pipe
a
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.3 - Parts of cooling system engine side 105

Sharan 1996 ➤
lkswage es n
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byV ua
d ran
ir se
-> Fig.1 Modifying water pump spanner uth V.A.G 1590
o tee
or
a ac
- Due to the modified bolts for securing the coolant pump pulley, file out the three corners
ss which have already
ce
e
been rounded off by a further

nl
pt
du
a = 1 mm.
an
itte
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erm
ab
ility
ot p
wit
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1.4 - Dismantling and assembling coolant thermostat housing
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
Note:
Connecting the coolant hoses to thermostat housing
=>Page 102 , parts of cooling system engine side.
2 10 Nm
3 Coolant thermostat
◆ Installation position: Breather slot/valve uppermost
◆ Checking: heat-up thermostat in water
◆ Opening commences approx. 80 °C
◆ Ends approx. 105 °C
◆ Opening lift min. 7 mm
4 Connection
AG. Volkswagen AG d
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
5 10 Nm
um
fo
en
g
6 O-ring
n
t.
yi Co
op
◆ Renew
C py
t. rig
gh ht
yri
7 Connection p by
co Vo
by lksw
8 Air conditioner cut-off thermo switch (F163) and radiator fan 3rd speed thermo switch (F165) cted agen
Prote AG.
◆ Brown, 4 pin
1.4 - Dismantling and assembling coolant thermostat housing 107

lkswage es n
o ot g
byV ua
ed ran
Sharan 1996 ➤hor is tee
t or
au engine, Mechanics - Edition 06.1995 ac
ss
ce
le
◆ On vehicles with air conditioning
un
pt
an
d
itte
y li
rm
=> Heating, air conditioning; Repair group 87
ab
pe
ility
ot
wit
◆ A plug is fitted on vehicles without air conditioner
, is n
h re
hole
spec
9 Coolant temperature sender (G62)
es, in part or in w
t to the co
◆ Blue, 2-pin
◆ For Motronic
◆ Checking:
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
10 Radiator fan run-on thermo switch (F87) with coolant temperature gauge sender (G2)
◆ Yellow, 4-pin
◆ Checking =>Page 114 , checking pump for continued coolant circulation and radiator fan run-on
◆ Switching temperatures:
on: 101...107°C
off: 94...100 °C
11 Retaining clip
◆ Check seated securely

Sharan 1996 ➤
1.5 - Draining and filling cooling system
Draining
- Remove cap from 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.
- Remove drain plug from coolant pipe => Page 105 , Pos. 23
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!
◆ If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.
◆ To fill coolant circuit the cooling system charging unit VAS 6096 is recommended.
Recommended mixture ratios:

AG. Volkswagen AG d
agen oes
lksw not
Vehicle Anti- Anti-freeze Gby112)
Vo Water2) gu
ara
equipment freeze to amount1) orise d
nte
th eo
One -25 °C 40 % s au 3.6 ltr. 5.4 ltr. ra
c
heat ex‐ -35 °C 50 %s 4.5 ltr. 4.5 ltr. ce
e
changer
nl
pt
du
an
itte
Two -25 °C 40 % 4.3 ltr. 6.5 ltr.

y li
erm
ab
heat ex‐ -35 °C 50 % 5.4 ltr. 5.4 ltr.

ility
ot p
changers
wit
, is n
Two -25 °C 40 % 4.6 ltr. 6.8 ltr.

h re
hole
heat ex‐ -35 °C 50 % 5.7 ltr. 5.7 ltr.

spec
changers
es, in part or in w
t to the co
and addi‐
tional wa‐
ter heater
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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.
1.5 - Draining and filling cooling system 109

Sharan 1996 ➤
2) The quantity of coolant can vary depending upon the vehicle equipment.
- -> Screw drain plug on coolant pipe again -arrow-.
With cooling system charging unit

swa
VAS
gen AG6096
. Volkswagen AG
does
k not
Vol gu
by ara
- Screw adapter V.A.G ris 1274/7 onto expansion tank again.
ed
nte
- Fill coolant circuitutusing
ho
cooling system charging unit VAS 6096.e or
a ac
ss
=> Operating instructions for cooling system charging unit VAS 6096
ce
le
un
pt
an
d
itte
y li
Not using cooling system charging unit VAS 6096
erm
ab
ility
ot p
- Press top radiator hose down.
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
- -> Fill with coolant up to MAX. mark on expansion tank.

iv
o
pr
- Start engine and run at approx. 2500 rpm and at the same time fill with coolant up to overflow hole on
um
r
fo
en
ng
expansion tank.
t.
yi Co
- Fit expansion tank cap. . Cop py
- Run engine until radiator fan cuts-in.
ht rig
rig ht
by
- Then run for about a further 10 minutes at approx. 2500 rpm. copy Vo
by lksw
- Check coolant level and top-up if necessary. When the engine is at normal operating temperature, the
cted agen
Prote AG.
coolant level must be on the MAX. mark, when the engine is cold, between the MIN. and MAX. marks.
1.6 - Removing and installing radiator and radiator fan
Removing

- Remove power assisted steering vane pump and lay to side; hoses remain connected.
=> Running gear; Repair group 48; Assembly overview: vane pump, hydraulic pipes, reservoir; Removing and
installing P.A.S. vane pump Assembly overview: vane pump, hydraulic pipes, reservoir Removing and installing
P.A.S. vane pump
Warning!
- Observe additional information and removal work => Page 111 .

Sharan 1996 ➤
- Pull connectors off thermo switch, secondary air pump and radiator fan.
- Pull intake and pressure hoses off the secondary air pump.
- Unscrew fan ring securing bolts and remove fan ring with fan and secondary air pump.
AG. Volkswagen AG d
- Drain coolant => Page 109 . kswagen oes
not
- Pull coolant hoses off radiator. y Vol gu
b ara
- Remove radiator securing bolts. orise
d
nte
- Remove radiator downwards. auth eo
ra
ss c
ce
le
Installing
un
pt
an
d
itte
y li
Installation is carried out in the reverse order, when doing this note the following:
rm
ab
pe
ility
ot
wit
, is n
h re
- Electrical connections and routing:
hole
spec
es, in part or in w
=> Electrical system; Repair group 97
t to the co
- Check headlight adjustment and adjust if necessary:
rrectness of i
=> Maintenance booklet
l purpos
Additional information and removal work on vehicles with air conditioner
nform
mercia
a
com
t
Warning!
ion in
r
te o
thi
s
iva
do
r
rp
cum
fo
Note:
en
ng
t.
yi Co
Cop py
t. rig
To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are
yri
gh by
ht
not stretched, kinked or bent. cop Vo
by lksw
cted agen
Prote AG.
- Remove condenser from radiator and pull forward as far as is possible.
- Remove radiator downwards.
- Secure condenser to body so that refrigerant pipes/hoses are not stressed.
1.7 - Removing and installing coolant pump

◆ Support bracket 10-222A with adapters 10-222 A/3 and legs 10-222 A/5
◆ Water pump wrench V.A.G 1590
Removing
- With ignition switched off disconnect battery earth strap.
Note:
If necessary the anti-theft coding for the radio must be obtained first.
1.6 - Removing and installing radiator and radiator fan 111

Sharan 1996 ➤
- Disconnect exhaust pipe from catalyst flange => Page 142 , exhaust manifold, front exhaust pipe and
catalyst with attachments.
- Drain coolant => Page 109

- Remove spark plug connectors with H.T. cables:
- -> Remove ignition cable ducts -2- and -4-.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
- -> Pull vacuum hose from intake manifold upper
ut
ho
part off fuel pressure regulator -arrow-. e or
- Pull vacuum hose to brake servo off intake
ss manifold upper part.
a ac
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f i
- -> Pull 2 pin connector off intake manifold intake temperature sender -arrow-.
nform
- Remove intake manifold temperature sender from intake manifold upper part.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
en AG.Mechanics
Volkswagen AG - Edition 06.1995
ag does
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y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
- -> Fit engine support bracket 10-222 A with adapters 10-222 A/3 and legs 10-222 A/5.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
- Secure legs 10-222 A/5 with body bolts -arrows-.
agen
Prote AG.
- Locate support bracket in lifting eyes on left and right of cylinder head and take-up weight of engine.
- -> Remove securing bolts -1- from right assembly mounting.

- Carefully lower right end of engine.
- Remove coolant pump pulley (use V.A.G 1590 to loosen and tighten the securing bolt).
Note:
If necessary modify water pump spanner V.A.G 1590
=>Page 106 , Fig. 1 .
- Remove coolant pump.
Installing
Installation is carried out in the reverse order, when doing this note the following:
- Screw in all bolts on assembly mountings by hand approx. 5...6 turns.
- Align engine mountings stress-free by rocking.
1.7 - Removing and installing coolant pump 113

Sharan 1996 ➤
Tightening torques
Bolted connection Tightening torque

Coolant pump to cylinder block 20 Nm
Pulley to coolant pump 25 Nm
Assembly mounting to right engine 60 Nm
bracket
Intake manifold temperature sender 10 Nm
to intake manifold upper part
Drain plug in coolant pipe 10 Nm
Front exhaust pipe to catalyst 25 Nm
1.8 - Checking coolant continued circulation pump and radiator fan run-on
Special tools, testers and auxiliary items agen

AG. Volkswagen AG d
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◆ Test system V.A.G 1466 ised b ara
nte
◆ Adapter set V.A.G 1594 ut
hor eo
◆ Current flow diagram ss a ra
c
ce
le
un
pt
Test sequence
an
d
itte
y li
rm
ab
- Switch on ignition and then switch off again.
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
- -> Pull 4-pin connector off radiator fan run-on thermo switch (F87) with coolant temperature gauge sender
r
te o
thi
(G2) -yellow-.
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
- -> Bridge contacts -1- and -3- of connector (brown/red and brown/green wires) with aux. cables from V.A.G
1594.
Radiator fan (V7) and continued coolant circulation

Sharan 1996 ➤
pump (V51) must run.
Note:
Check radiator fan run-on with test system V.A.G 1466:
=> Current flow diagrams, Electrical fault finding and Fitting locations binder
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.8 - Checking coolant continued circulation pump and radiator fan run-on 115
Sharan 1996 ➤
20 - Fuel supply system

AG. Volkswagen AG d
agen oes
olksw not
yV gu
1 - Removing and installing parts of fuel supply system d b ara
ise nte
or eo
h
aut ra
c
1.1 - Removing and installing parts of fuel supply system ss
ce
e
nl
pt
du
an
itte
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erm
ab
Notes:
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ot p
wit
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◆ Hose connections are secured with either screw, spring or clamp-type clips.
h re
◆ Always replace clamp-type clips with screw or spring-type clips.
hole
spec
◆ Fuel hoses in engine compartment must only be secured with spring-type clips. The use of clamp or screw-
es, in part or in w
type clips is not permissible.
t to the co
◆ For fitting the spring-type clips commercially available pliers e.g. Hazet 798-5 are recommended.
Observe safety precautions=> Page 130 .
rrectness of i
l purpos
Observe rules for cleanliness => Page 131 .
Adjusting throttle cable => Page 131
nform
mercia
at
Servicing parts of the activated charcoal filter system => Page 139 .
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
116 20 - Fuel supply system

Sharan 1996 ➤
1.2 - Removing and installing fuel tank with its attachments and fuel filter, front wheel drive
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ho eo
aut ra
ss c
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e
nl
pt
du
Note:
an
itte
y li
erm
ab
After all repairs to the fuel supply unit or the fuel gauge sender unit have been carried out, ensure the the supply
ility
ot p
or return flow hoses do not make contact with the fuel tank (pump noises may be transferred).
wit
, is n
h re
hole
1 Cap
spec
es, in part or in w
2 Seal
t to the co
◆ If damaged only replace together with cap

3 Retaining ring
rrectness of i
4 Rubber cup
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
1.2 - Removing and installing fuel tank with its attachments and fuel filter, front wheel
py by
co Vo
117
by lksw
cted agen
Prote drive
AG.
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g
5 Gravity valve
n
t.
yi Co
op
◆ To remove valve unclip upwards out of filler neck C py
t. rig
gh
◆ Check valve for through-flow
ht
pyri by
valve vertical: open,
co Vo
by lksw
cted agen
valve tilted 45 °: closed Prote AG.
6 O-ring
7 Vent valve
◆ Cannot be removed, replace together with filler neck => item 17
◆ Checking =>Page 129 , Fig. 2
8 Pressure retaining valve
◆ For fuel tank venting
◆ Checking => Page 129 , Fig. 3

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
9 Return pipe
n in
or c
thi
◆ Secure with spring-type clips

te
sd
a
◆ Check securely seated

iv
o
r
rp
cu
◆ Blue
o
m
f
en
◆ From fuel manifold

ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
nition system Servicing injection part cop Vo
by lksw
cted agen
Prote AG.
10 Union nut
◆ Remove and install with 3217
11 Connector
◆ Black, 4 pin
◆ For fuel gauge sender (G) and fuel pump (G6)
12 Flange
◆ Note fitting position on fuel tank => Page 129 , Fig. 1
◆ Underside marked with "V" and "R" for supply and return hoses
drive 119
Sharan 1996 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
13 Supply hose
14 Sealing ring
ss
◆ Coat with fuel when installing
o
cial p
f i
nform
mer
15 Return hose
atio
m
16 10 Nm
o
n
c
17 Filler neck
or
n thi
te
sd
◆ With expansion tank and vent valve

iva
o
pr
18 Vent pipe
um
r
fo
en
ng
◆ To junction piece between activated charcoal filter and solenoid valve 1

t.
yi Co
op
=>Page 139 , item 1 C py
t. rig
gh ht
19 Sealing ring yri
p by
co Vo
by lksw
◆ Renew if damaged Prote
cted AG.
agen

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
20 Retaining ring
an
d
itte
y li
21 Non-return valve
erm
ab
ility
ot p
◆ Check for freedom of movement

wit
is n
22 Vent pipe
h re
ole,
23 25 Nm
spec
24 Fuel tank
t to the co
◆ Support with engine and gearbox jack V.A.G 1383 A when removing
25 Securing strap
rrectne
◆ Note differing length

26 20 Nm
s
27 Bracket
s o
cial p
◆ For fuel filter

inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
drive 121
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
28 Supply pipe
ce
le
un
pt

an
d
itte

y li
erm
ab
◆ Black
ility
ot p
◆ To fuel manifold
wit
is n
h re
ole,
spec

t to the co
29 Fuel filter
◆ Installation position: Arrow points in through-flow direction
rrectne
30 Fuel gauge sender (G)

31 Fuel delivery unit
ss

o
cial p
=> Page 133

inform
◆ Checking fuel pump

mer
=> Page 134

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

Sharan 1996 ➤
1.3 - Removing and installing fuel tank with its attachments and fuel filter, four wheel drive
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
Note:
o
r
rp
cu
o
m
f
en
ng
After all work on the fuel delivery unit or the fuel gauge sender ensure that the supply/return hoses (partly
t.
yi Co
op
corrugated pipes) item 13 and item 15 do not touch the fuel tank (transmission of pump noises). C py
ht. rig
rig ht
py by
o Vo
1 Cap by c lksw
cted agen
Prote AG.
2 Seal
◆ If damaged only replace together with cap
3 Retaining ring
4 Rubber cup
1.3 - Removing and installing fuel tank with its attachments and fuel filter, four wheel
drive 123
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
5 Gravity valve
um
for
en
g
◆ To remove valve unclip upwards out of filler neck

n
t.
yi Co
op
◆ Check valve for through-flow C py
t. rig
valve vertical: open, gh ht
yri by
valve tilted 45 °: closed cop Vo
by lksw
cted agen
6 O-ring Prote AG.
7 Vent valve
◆ Cannot be removed, replace together with filler neck => item 17
◆ Checking =>Page 129 , Fig. 2
8 Pressure retaining valve
◆ For fuel tank venting
◆ Checking => Page 129 , Fig. 3

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
9 Return pipe
l purpos
◆ Blue
◆ From fuel manifold
nf
ercia

rm
m
atio
om
n in
or c

thi
te
sd
iva
o
r
rp
cu
10 Union nut
o
m
f
en
ng
◆ Remove and install with 3217

t.
yi Co
op
11 Connector
C py
t. rig
gh ht
yri
◆ Black, 4 pin p by
co Vo
◆ For fuel gauge sender (G) and fuel pump (G6)
by lksw
cted agen
Prote AG.
12 Flange
◆ Note fitting position on fuel tank => Page 129 , Fig. 1
◆ Underside marked with "V" and "R" for supply and return hoses
drive 125
Sharan 1996 ➤
en AG. V- Edition
olkswagen AG06.1995
ag does
ksw not
y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
13 Supply hose
14 Sealing ring
◆ Coat with fuel when installing
15 Return hose
16 10 Nm
17 Filler neck
◆ With expansion tank and vent valve
◆ To remove remove brake pipe retaining clip
=> Page 130 , Fig. 4
◆ Loosen right axle beam
=> Page 130 , Fig. 5
=> Repair group 42; Running gear assembly overview, Syncro rear axle beam Running gear assembly over‐
view, Syncro rear axle beam
18 Vent pipe
◆ To junction piece between activated charcoal filter and solenoid valve 1
=>Page 139 , item 1

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
19 Boot
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
◆ To remove pull filler neck out of tank
◆ Remove brake pipe retaining clip
=> Page 130 , Fig. 4
◆ Loosen right axle beam
=> Page 130 , Fig. 5
=> Repair group 42; Running gear assembly overview, Syncro rear axle beam Running gear assembly over‐
view, Syncro rear axle beam
25 Securing strap
◆ Note differing length
drive 127
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
26 20 Nm
27 Bracket
◆ For fuel filter
28 Supply pipe
◆ Black
◆ To fuel manifold
29 Fuel filter
◆ Installation position: Arrow points in through-flow direction
30 Fuel gauge sender (G)
31 Fuel delivery unit
=> Page 133
◆ Checking fuel pump
=> Page 134
32 Strainer

Sharan 1996 ➤
-> Fig. 1 Installation position of fuel delivery unit flange
Marking on the flange must align with marking

gen AG
. Von
olksthe
wagfuel
en AGtank.
d wa oes
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
-> Fig. 2 Checking vent valve
l purpos
Valve in rest position: Closed

nform
mercia
at
Valve pushed in direction of arrow: Open

om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
-> Fig. 3 Checking pressure retaining valve
From the gravity valve direction the pressure retaining valve is open in both directions of flow -arrow -1-.
drive 129
Sharan 1996 ➤
From the direction junction piece activated charcoal filter/solenoid valve 1 it is only open in one direction of flow
-arrow -2-.
-> Fig. 4 Remove right brake pipe retaining clamp
Unhook brake pipe, do not open.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
-> Fig. 5 Loosen axle beam

wit
, is n
h re
hole
spec
es, in part or in w
Remove bolts -arrow-

t to the co
rrectness of i
1.4 - Safety precautions when working on the fuel supply system

l purpos
Warning!
nf
ercia
Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connec‐
rm
m
tion. Then release pressure by carefully pulling hose off connection.

atio
om
n in
or c
thi
e
When removing and installing the fuel gauge sender or fuel pump (fuel delivery unit) from a full or partly full fuel
t
sd
iva
tank the following must be observed:

o
r
rp
cu
o
m
f
en
ng
t.
◆ Before commencing work, switch on exhaust extraction system and place an extraction hose close to the
yi Co
op
sender opening in the fuel tank to extract escaping fuel fumes.
C py
ht. rig
If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displace‐
rig ht
py by
o Vo
ment greater than 15 m3/h can be used. by c lksw
cted agen
◆ Prevent skin contact with fuel! Wear fuel-resistant gloves! Prote AG.

Sharan 1996 ➤
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 - Adjusting throttle cable

Additionally for vehicles with automatic gearbox:

◆ Hand multimeter V.A.G 1526
◆ Distance piece 13 mm
Work sequence
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
- Remove spark plug connectors with ignition cables for cylinder bank 1, 3 and 5: t to the co
rrectne
- -> Remove H.T. cable guides -1- and -2-.

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.5 - Rules for cleanliness 131

Sharan 1996 ➤
- -> Adjust throttle cable by moving the retainer -arrow- at the support bracket, so that the full throttle position
is attained at the throttle valve lever.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
- -> Clamp distance piece -1-,
h re
hole
a = 13 mm,
spec
between accelerator pedal -2- and stop -3- and hold accelerator pedal in this position.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi
- -> Fully open throttle valve by pulling on the outer cable and locate in this position with the retainer -arrow-.
Co
op py
- Release accelerator pedal.
t. C rig
gh ht
yri
- Pull 2-pin connector off kick-down switch (F8) in engine compartment (on the bulkhead). p by
co Vo
by lksw
cted agen
Prote AG.
- -> Connect hand multimeter V.A.G 1526 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.

Sharan 1996 ➤
1.7 - Removing and installing fuel delivery unit

◆ Union nut spanner 3217
Removing
- Observe safety precautions => Page 130
Note:
If necessary the anti-theft coding for the radio must be obtained before disconnecting the battery.
- Remove luggage compartment floor cover
- -> Pull 4-pin connector and supply and return pipes off flange.
- Remove union nut with 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.
AG. Volkswagen A n G do
wage es n
olks ot g
Note: ed
by
V ua
ran
oris tee
If the delivery unit is still full of fuel, empty itaubefore
th replacing. or
ac
ss
.
ce
e
nl
pt
du
an
itte
Installing
y li
erm
ab
ility
Installing the fuel delivery unit is carried out in the reverse order.
ot p
wit
, is n
Notes:
h re
hole
spec
◆ When inserting the fuel delivery unit ensure that the fuel gauge sender is not bent.
es, in part or in w
t to the co
◆ Coat flange seal with fuel when fitting.

◆ Installation position of fuel delivery unit flange => Page 129 , Fig. 1 .
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.7 - Removing and installing fuel delivery unit 133

Sharan 1996 ➤
◆ -> When the fuel delivery unit is correctly installed the fuel gauge sender float points in direction of travel A:
1.8 - Checking fuel pump
◆ Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2

◆ Diode test lamp V.A.G 1527
◆ Union nut spanner 3217
◆ Pressure tester V.A.G 1318
◆ Hose V.A.G 1318/1
◆ Adapter V.A.G 1318/10
◆ Adapter 1318/11
◆ Measuring container
Check conditions
• Battery voltage at least 11.5 V

• Fuse No. 18 OK.
Test sequence
Attention!
The fuel system is pressurized! Before loosening hose connections or opening the test connection, wrap a cloth
around the connection. Then release pressure by carefully pulling off the hose/unscrewing sealing plug.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
- -> Remove fuel manifold sealing plug -1- and connect pressure gauge V.A.G 1318 with adapter V.A.G
rrectne
1318/10 and hose V.A.G 1318/1 to fuel manifold.

The cut-off tap on the pressure gauge must be closed (lever -arrow- at right angles to direction of flow).
- Start engine and run at idling speed.
ss
- Check fuel pressure.

o
cial p
f i
Specification: Approx. 2.5 bar

nform
mer
atio
If the fuel pressure does not build-up:

om
n
c
i
or
- Switch off ignition.

thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o

c by lksw
cted agen
Prote AG.
Sharan 1996 ➤
- Pull off cover in front of relay plate.
- -> Pull the fuel pump relay (J17) out of relay plate (relay position 12).
G. Volkswage
A n AG d
agen oes
lksw not
Notes: d by Vo gu
ara
rise nte
◆ If tools are necessary tout pull relays or control units out of the relay plate,
ho e o first disconnect
ra battery earth strap.
◆ Before disconnecting ss a
battery earth strap obtain code for radios with anti-theft
c coding.
ce
e
nl
pt
du
- Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to contact 4 and battery positive
an
itte
y li
(+).
erm
ab
- Operate remote control.
ility
ot p
wit
, is n
If fuel pressure builds-up:
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
- Check activation of fuel pump relay:

p
cum
for
en
ng
t.
=> Fault finding with test system V.A.G 1466
yi Co
Cop py
t. rig
If fuel pressure is not built-up:
gh ht
pyri by
Vo
co lksw
by
- Remove cover in luggage boot floor. cted agen
Prote AG.
- -> Pull 4-pin connector off fuel tank flange.
1.8 - Checking fuel pump 135

Sharan 1996 ➤
- -> Connect diode test lamp V.A.G 1527 with aux. cables from V.A.G 1594 to the outer contacts of the
connector.
- Operate remote control.
LED must light up
AG. Volkswagen AG d
LED does not light up: agen oes
olksw not
byV gu
ara
ed
- Locate and eliminate open circuit
horis
using current flow diagram: nte
eo
aut ra
s c
=> Current flow diagrams, Electrical fault finding and Fitting locations binder
s
ce
le
un
pt
an
d
itte
LED lights up (voltage supply OK.):
y li
rm
ab
pe
ility
- Unscrew union nut with 3217.
ot
wit
, is n
- Check that the electrical wires between flange and fuel pump are connected.
h re
hole
spec
If no open circuit can be found:
es, in part or in w
t to the co
- Fuel pump defective, renew fuel delivery unit =>Page 133 , Removing and installing fuel delivery unit.
rrectness of i
Checking delivery rate
l purpos
• Voltage supply OK.

• Remote control V.A.G 1348/3A connected.
nform
ercia
Test sequence
m
a
com
tion in
- Remove filler cap from fuel tank filler neck.
r
te o
thi
s
iva
do
r
Attention!
rp
cum
fo
The fuel system is pressurized! Before loosening hose connections or opening the test connection, wrap a cloth
en
ng
t.
yi
around the connection. Then release pressure by carefully pulling off the hose/unscrewing sealing plug.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
- Pull fuel supply pipe -1- off fuel manifold.

- -> Connect pressure gauge V.A.G 1318 with adapter 1318/10 to the fuel supply pipe -1- .
- Push the hose V.A.G 1318/1 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.
- Connect multimeter to vehicle battery to measure voltage using auxiliary cables from V.A.G 1594.
- Operate remote control for
30 seconds.

Sharan 1996 ➤
- -> 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.
AG. Volkswagen AG d
agen oes
If the minimum delivery rate is not attained: Volksw not
gu
d by ara
ise nte
- Check the fuel pipes for possible restrictions
ut
hor
(kinks) or blockages. eo
a ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
- -> Pull the supply hose -1- off inlet to fuel filter.
- Connect the pressure gauge V.A.G 1318 to hose with adapter 1318/10.
nform
ercia
- Repeat delivery rate check.

m
a
com
If the minimum delivery rate is now attained:

ion in
r
te o
thi
- Replace the fuel filter.

s
iva
do
r
rp
cum
If the minimum delivery rate is again not attained:

fo
en
ng
t.
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op py
- Remove fuel delivery unit (=> Page 133 ) and check the strainer for soiling. t. C rig
gh ht
pyri by
Vo
o
by c
Only when up to now no fault has been detected:
lksw
cted agen
Prote AG.
- Replace the fuel delivery unit.
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:

Sharan 1996 ➤
- Reconnect all disconnected fuel pipes.
AG. Volkswagen AG d
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- -> Connect the multimeter V.A.G 1715 using the current clamp to the red/white wire from wiring loom.
- Start the engine and run at idling speed.
- Measure the current draw of the fuel pump.
rrectness of i
Specification: max. 8 amps.
l purpos
Note:
nform
ercia
If the fuel system malfunction is intermittent, you can perform the check during a test drive with the help of a
2nd person.
m
a
com
tion in
If the current draw is exceeded:
r
te o
thi
s
iva
- Replace the fuel delivery unit.
do
r
rp
cum
fo
Checking fuel pump non-return valve
en
ng
t.
yi Co
Cop py
• Remote control V.A.G 1348/3A connected
t. rig
gh ht
yri
• Pressure gauge V.A.G 1318 connected to the fuel supply pipe at fuel manifold p by
co Vo
by lksw
cted agen
Prote AG.
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.
- -> Close pressure gauge shut-off tap (lever at right angles to throughflow direction - position -B-).
- Operate 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 cut-off tap.
Warning!
Danger of spray when opening the shut-offtap, hold container over the free connection of the pressure gauge.
- Observe pressure drop. After 10 minutes the pressure must not drop
below 2.2 bar

Sharan 1996 ➤
If necessary check line connections for leaks and/or renew fuel delivery unit
=>Page 133 , Removing and installing fuel delivery unit
1.9 - Servicing parts of the activated charcoal filter system
AG. Volkswagen AG d
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nl
pt
du
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itte
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erm
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ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
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f
en
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t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.
1 Vent pipe
◆ From pressure retaining valve on fuel tank
=> Page 118 , item 8
2 Retaining ring
◆ For solenoid valve 1
3 Throttle valve control part
4 Breather hose
◆ Breather hose must not come into contact with other components
5 Vacuum hose
◆ From crankcase breather valve:

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
6 Solenoid valve 1 (N80)

◆ With ignition switched off valve open in direction of arrow
◆ When the engine is warm the valve will be activated from the Motronic control unit (J220) (pulsed)
◆ Checking:
7 Connector
◆ Green, 2-pin
◆ For solenoid valve 1
8 Air cleaner lower part
9 Activated charcoal filter
◆ Location: in front right wheel housing
◆ Remove wheel housing liner to remove

Sharan 1996 ➤
lkswage es n
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nl
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du
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ab
ility
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wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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om
n in
or c
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te
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t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.
10 10 Nm
11 Vent pipe
◆ To atmosphere
◆ Secured to body
12 Connection
13 O-ring
14 Bracket
◆ For activated charcoal filter
15 Junction piece
1.9 - Servicing parts of the activated charcoal filter system 141

Sharan 1996 ➤
26 - Exhaust system
1 - Removing and installing parts of exhaust system, front wheel drive

1.1 - Removing and installing parts of exhaust system, front wheel drive
Notes:
◆ After working on the exhaust system ensure that the system is not under stress, and that it has sufficient
clearance from the bodywork. If necessary, loosen double and single clamps and align silencer and exhaust
pipe so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.
◆ Renew self-locking nuts.
1.2 - Exhaust manifold, front exhaust pipe and catalyst with attachments
lkswage es n
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rm
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pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
1 Heat shield
thi
s
iva
do
2 Exhaust manifold
r
rp
cum
◆ 2 part
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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by
cted agen
142 26 - Exhaust system

Prote AG.
Sharan 1996 ➤
3 Lifting eye
4 M8 - 25 Nm
M10 - 40 Nm
◆ Renew
5 Heat shield
6 Sheet metal nut
◆ Must be screwed-on/off
7 Front exhaust pipe
8 Gasket
◆ Renew
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
9 4-pin connector
C py
t. rig
gh ht
yri
◆ Black p by
co Vo
◆ For Lambda probe and Lambda probe heating:
by lksw
cted agen
Prote AG.
10 Catalyst
11 To front silencer
◆ => Page 146 , item 7
12 Securing clip
1.2 - Exhaust manifold, front exhaust pipe and catalyst with attachments 143
Sharan 1996 ➤
13 10 Nm swage
es n
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ir se tee
tho
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ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
14 Lambda probe (G39), 50 Nm

◆ Grease only the threads with "G5"; "G5" must not get into the slots on the probe body
◆ Checking:
=> Repair Group 01; Self diagnosis; Interrogating fault memory Self diagnosis Interrogating fault memory
◆ Checking Lambda probe and Lambda control:
◆ Checking Lambda probe heating:
15 35 Nm
◆ Connection for exhaust gas recirculation valve
=>Page 152 , exhaust gas recirculation system

Sharan 1996 ➤
1.3 - Silencer with mountings

swa
gen AG
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does
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pe
ility
ot
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Note:
Align the exhaust system longitudinally so that the dimensions -a- and -b- are maintained.
1 From catalyst
◆ => Page 143 , item 10
2 Clamp
3 40 Nm
◆ Renew
4 Retaining ring
5 Sheet metal nut
◆ Must be screwed-on/off
6 Heat shield
1.3 - Silencer with mountings 145

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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ara
ed
ris nte
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aut ra
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le
un
pt
7 Front silencer
an
d
itte
y li
8 Rear silencer
rm
ab
pe
ility
9 Dimension -b- = approx. 50 mm

ot
wit
, is n
h re
10 Dimension-a- = ca. 5 mm
hole
spec
es, in part or in w
t to the co
1.4 - Removing and installing parts of exhaust system, four wheel drive
rrectness of i
l purpos
Exhaust manifold, front exhaust pipe and catalyst with attachments =>Page 147 .
Removing and and installing front exhaust pipe and catalyst with attachments => Page 151
nform
mercia
Silencer with mountings =>Page 145 .

a
com
tion in
r
Notes:
te o
thi
s
iva
do
r
rp
◆ After working on the exhaust system ensure that the system is not under stress, and that it has sufficient
um
fo
clearance from the bodywork. If necessary, loosen double and single clamps and align silencer and exhaust
en
ng
t.
yi
pipe so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
ksw
agen oes
not
Sharan 1996 ➤
ol
d byV 6-cyl. fuel injection
gu
ara engine, Mechanics - Edition 06.1995
ise nte
or eo
◆ Renew self-locking
aut
h nuts. ra
ss c
ce
le
un
pt
an
d
itte
1.5 - Exhaust manifold, front exhaust pipe and catalyst with attachments
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1 Heat shield
2 Exhaust manifold
◆ 2 part
3 Lifting eye
4 M8 - 25 Nm
M10 - 40 Nm
5 Gasket
◆ Renew
6 Front exhaust pipe
1.4 - Removing and installing parts of exhaust system, four wheel drive 147
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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ara
ed
ris nte
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aut ra
ss c
ce
e
nl
pt
du
an
itte
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ab
ility
ot p
wit
, is n
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spec
es, in part or in w
t to the co
7 4-pin connector
◆ Black
◆ For Lambda probe and Lambda probe heating:
rrectness of i
l purpos
nf
ercia
8 Catalyst
rm
m
atio
m
9 To front silencer
o
n in
c
◆ => Page 151 , item 5

or
thi
te
10 Securing clip
sd
iva
o
r
rp
cu
11 10 Nm
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
12 Lambda probe (G39), 50 Nm
cial p
f inform
◆ Grease only the threads with "G5"; "G5" must not get into the slots on the probe body
mer
◆ Checking: atio
om
n
c
or
n thi
te
sd
iva
o
r
◆ Checking Lambda probe and Lambda control:

p
cum
r
fo
◆ Checking Lambda probe heating:

en
ng
t.
yi Co
op py
t. C rig
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yri
nition system Servicing injection part p by
o Vo
by c lksw
cted agen
Prote AG.
13 35 Nm
◆ Connection for exhaust gas recirculation valve
=>Page 152 , exhaust gas recirculation system
1.5 - Exhaust manifold, front exhaust pipe and catalyst with attachments 149
Sharan 1996 ➤
1.6 - Silencer with mountings
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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ss
ce
e
nl
pt
du
an
itte
Note: y li
erm
ab
ility
ot p
Align the exhaust system longitudinally so that the dimensions -a- and -b- are maintained.
wit
, is n
h re
hole
1 From catalyst
spec
es, in part or in w
◆ => Page 148 , item 8

t to the co
2 Clamp
3 40 Nm
rrectness of i
◆ Renew
4 Retaining ring
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
5 Front silencer C py
t. rig
gh ht
yri
6 Rear silencer
p by
co Vo
by lksw
7 Dimension -b- = approx. 50 mm
cted agen
Prote AG.
8 Pre-tension
◆ approx. 5 mm
◆ With exhaust system cold
1.7 - Removing and installing front exhaust pipe and catalyst with attachments
Work sequence
- Separate 4 pin connector to Lambda probe.

- Remove catalyst.
- Remove front propshaft section.
=> Automatic gearbox 099 four wheel drive; Repair group 39; Removing and installing propshaft Removing and
installing propshaft
- Remove exhaust pipe from exhaust manifold.
1.6 - Silencer with mountings 151

AG. Volkswagen AG d
agen oes
ksw
Sharan 1996 ➤ by
Vol not
gu
d ara
6-cyl. fuel injection engine, orMechanics
ise - Edition 06.1995 nte
h eo
aut ra
- Take out exhaust pipe downwards.
ss c
ce
le
un
pt
Installation is carried out in the reverse sequence.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
2 - Exhaust gas recirculation system
h re
ole,
spec
2.1 - Exhaust gas recirculation system
t to the co
Notes:
◆ The function/control of the exhaust gas recirculation system is checked by the self-diagnosis of the Motronic
rrectne
control unit (J220).
◆ Components marked with an * are checked via the self-diagnosis.
ss o
cial p
f
=> Repair group 01; Self-diagnosis; Interrogating fault memory Self-diagnosis Interrogating fault memory
inform
◆ Components marked with ** are checked via the final control diagnosis.
mer
atio
m
=> Repair group 01; Self-diagnosis; Final control diagnosis Self-diagnosis Final control diagnosis
o
n
c
i
or
n
◆ Always renew sealing rings and gaskets when assembling.
thi
te
◆ Vacuum pipes and hose connections must be free of leaks.
sd
iva
o
r
◆ Vacuum pipes must not be blocked/kinked.

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

Sharan 1996 ➤
1 35 Nm
◆ To intake manifold upper part
2 30 Nm
3 Pipe
AG. Volkswagen AG d
◆ For exhaust gas outlet lksw
agen oes
not
o
4 Air cleaner d by V gu
ara
ise nte
◆ If soiled it can cause engine running faultsthor eo
u ra
5 Connector ss a c
ce
e
◆ Brown, 2-pin
nl
pt
du
◆ For exhaust gas recirculation valve (N18)
an
itte
y li
6 Exhaust gas recirculation valve (N18)*/**
erm
ab
ility
ot p
◆ Two-way valve
wit
, is n
◆ Checking:
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7 10 Nm
8 Connecting hose
9 Vacuum hose
◆ To vacuum pipe collective connection brake servo
10 Pipe
◆ For exhaust gas inlet
2.1 - Exhaust gas recirculation system 153

Sharan 1996 ➤
◆ From exhaust manifold
11 Exhaust gas recirculation temperature sensor (G98)*, 20 Nm
12 Exhaust gas recirculation valve (mechanical)
13 Gasket
◆ Renew
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pt
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itte
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ility
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wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
14 Bracket
◆ For electric wiring and exhaust gas recirculation valve
◆ Secured to cylinder head cover
15 2 pin connector
◆ Black
◆ For exhaust gas recirculation temperature sensor (G98)
2.2 - Checking exhaust gas recirculation valve with temperature sensor

◆ Hand vacuum pump V.A.G 1390
◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3

Sharan 1996 ➤
◆ Test box V.A.G 1598/18
◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715
Check conditions
• Vacuum pipes and hose connections free of leaks.

• Vacuum pipes not blocked/kinked.
• Engine oil temperature at least 50 °C
Test sequence
- Connect fault reader V.A.G 1551 (V.A.G 1552) and select engine electronics control unit (address word 01);
carry out selection at idling:
=> Repair group 01; Self-diagnosis; Connecting fault reader V.A.G 1551 and selecting engine electronics con‐
trol unit Self-diagnosis Connecting fault reader V.A.G 1551 and selecting engine electronics control unit
-> Indicated on display:

Rapid data transfer HELP
Select function XX
- Input 08 for "Read measured value block" function and confirm with Q.

Read measured value block HELP
Input display group number XX
- Input 01 for "Display group number" and confirm with Q.

(1...4 = Display zones)
Read measured value block 1
1 2 3 4
Only continue with the test when AG. Volkswagen AG d

agen oes
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• The coolant temperature is above 50 °C d by V gu
ara
-Display zone 2- rise nte
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s c
- Press C key. s
ce
le
- Input 02 for "Display group number" and confirm with Q.

un
pt
an
d
itte
y li
erm
ab

ility
ot p
(1...4 = Display zones)

wit
is n
Read measuring value block 2

h re
ole,
1 2 3 4
spec
t to the co
- Read off figure displayed in display zone 4.

Specification: EGRn. active
(exhaust gas recirculation system not active)
- Increase engine speed.
rrectne
- Read off figure displayed in display zone 4.

Specification: EGR active
ss
(exhaust gas recirculation system active)

o
cial p
- Pull vacuum hose off (mechanical) exhaust gas recirculation valve.

inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by
155
cted agen
Prote
2.2 - Checking exhaust gas recirculation valve with temperature sensor
AG.
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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- -> Connect hand vacuum pump V.A.G 1390 to valve with aux. hose.
rm
ab
pe
- Operate pump.
ility
ot
The idling characteristics must noticeably
wit
, is n
deteriorate.
h re
hole
spec
If the idling characteristics do not deteriorate:
es, in part or in w
t to the co
- Press ⇒ button.
- Input 06 for "End output" and confirm with Q.
- Switch off ignition
rrectness of i
- Check pipes and connections for blocking, clean, if necessary replace exhaust gas recirculation valve.
l purpos
- Check activation of exhaust gas recirculation valve (N18):
=> Repair group 01; Self-diagnosis; Final control diagnosis Self-diagnosis Final control diagnosis
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Exhaust gas recirculation valve clicks during the final control diagnosis:
- Check wiring to exhaust gas recirculation valve temperature sensor (G98):
- Remove dash panel insert:
=> Electrical system; Repair group 90

- -> Connect test box V.A.G 1598/18 to control unit wiring loom.

Sharan 1996 ➤
- -> Separate 2 pin connector to exhaust gas recirculation system temperature sensor -arrow-.
- Check wiring between test box and 2 pin connector for open circuit according to current flow diagram.
Contact 1+socket 15
Contact 2+socket 33
Wire resistance: Max. 1.5 ω
- -> Check wiring at 2 pin connector for short to one another.
Contact 1+socket 33
Contact 2+socket 15
Specification: ∞ω
If the specifications are attained:
- Replace exhaust gas recirculation temperature sensor (G98).

- Interrogate fault memory:
=> Repair group 01; Self-diagnosis; Interrogating fault memory Self-diagnosis Interrogating fault memory
3 - Secondary air system lksw

agen
AG. Volkswagen AG d
oes
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3.1 - Secondary air systemtho rise nte
eo
au ra
ss c
ce
e
nl
pt
du
an
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3.2 - Function
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The secondary air system blows air in behind the exhaust valve for 65 seconds during the cold start (+15 °C ...
hole
spec
+35 °C coolant temperature). This produces an oxygen rich exhaust gas, causes afterburning and reduces the
es, in part or in w
heating-up phase of the catalyst. Activation occurs from the Motronic control unit (J220) via the secondary air
t to the co
pump relay (J229) to secondary air inlet valve (N112, change-over valve) and combi-valve. Additionally after
each subsequent engine start (up to max. 85 °C engine temperature) the secondary air system will after a 20
second delay switch in for 5 seconds during idling and will be checked by the self-diagnosis.
rrectness of i
l purpos
nf
ercia
orm
m
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om
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2.2 - Checking exhaust gas recirculation valve with temperature sensor 157
Sharan 1996 ➤
3.3 - Removing and installing parts of the secondary air system
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Notes: Cop py
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◆ Components marked with an * are checked by the self-diagnosis:
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◆ Components marked with ** are checked by the final control diagnosis:
◆ Secondary air pump relay (J299)** =>Page 162 , Fig. 1
1 Air channel
◆ In cylinder head
2 Vacuum hose

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gen AG 1996 ➤
wage does
VolksMechanics - Edition 06.1995
not
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db ran
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nl
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du
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erm
ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
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ercia
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3 25 Nm
4 Lifting eye
◆ On left of cylinder head
5 Retainer
◆ For secondary air inlet valve
6 Secondary air inlet valve (N112)*/**
7 Connector
◆ Black, 2-pin
◆ For secondary air inlet valve
8 Vacuum hose
◆ To junction piece between intake manifold upper part and fuel manifold
=> Repair group 24; injection and ignition system injection and ignition system
3.3 - Removing and installing parts of the secondary air system 159
AG. Volkswagen AG d
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Sharan 1996 ➤ d by ara
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6-cyl. fuel injection engine, Mechanics - Edition
ut
ho 06.1995 eo
ra
s a c
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un
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itte
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rm
ab
pe
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
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tion in
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te o
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s
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9 Intake hose
◆ From air cleaner upper part
=> Repair group 24; injection and ignition system injection and ignition system
10 Secondary air pump motor (V101)**

11 Connector
◆ Black, 2-pin
◆ For secondary air pump motor
12 Bracket
◆ For secondary air pump motor
◆ Secured to fan ring of radiator fan
13 10 Nm

Sharan 1996 ➤
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14 Retaining clip s
ce
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un
◆ For intake hose

pt
an
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15 Pressure hose
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ab

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16 Bracket
is n
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◆ For combi-valve
ole,
spec
◆ Secured to dipstick guide tube

17 Combi-valve
t to the co
◆ Checking =>Page 162

rrectne
=> Page 163

18 15 Nm
s
19 O-ring
s o
cial p
◆ Renew
inform
mer
atio
om
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c
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3.3 - Removing and installing parts of the secondary air system 161
Sharan 1996 ➤
-> Fig.1 Secondary air pump relay (J299) -arrow 1-
◆ With fuse S 130 arrow -2-
3.4 - Checking combi-valve

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Special tools, testers and auxiliary items horis nte
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◆ Hand vacuum pump V.A.G 1390 s
ce
le
un
pt
an
d
Check conditions
itte
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erm
ab
ility
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• Vacuum pipes and hose connections free of leaks.
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
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c
i
or
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• Vacuum pipes not blocked/kinked.

t
sd
iva
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Test sequence
en
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- Pull vacuum hose from combi-valve off secondary air inlet valve (N112).
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- -> Connect hand vacuum pump V.A.G 1390 to vacuum hose -1- to combi-valve. p by
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Note:
Do not use compressed air during the following check!
- Detach hose from combi valve at air cleaner upper part and pressurize slightly by blowing into hose.
Combi-valve must be closed.
- Operate hand vacuum pump.
Combi valve must open.
If the combi-valve does not open:

Sharan 1996 ➤
- Replace combi-valve.
3.5 - Removing and installing combi-valve
Removing
Note:
If necessary the anti-theft coding for the radio must be obtained first.

- Remove power assisted steering vane pump and lay to side; hoses remain connected.
=> Running gear; Repair group 48; Assembly overview: vane pump, hydraulic pipes, reservoir; Removing and
installing P.A.S. vane pump Assembly overview: vane pump, hydraulic pipes, reservoir Removing and installing
P.A.S. vane pump
Warning!
Notes:
◆ The opening of the refrigerant circuit canagonly

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AG din workshops, which have trained personnel
and the necessary range of tools and lksw e
workshop equipment.
oes
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◆ To prevent damage to condenser se
d byand the refrigerant pipes/hoses, ensure ara
nte
that the pipes and hoses are not
stretched, kinked or bent. thori eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
- Remove pressure hose between combi-valve and secondary air pump.

y li
erm
ab
- Pull vacuum hose off combi-valve.

ility
ot p
- Remove dipstick guide tube from intake manifold lower part and combi-valve bracket.
wit
, is n
- Unbolt combi-valve from cylinder head and pull out.

h re
hole
spec
Installing
es, in part or in w
t to the co
Install in reverse order.

rrectness of i
l purpos
nform
mercia
at
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en
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Cop py
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Vo
co
163
by lksw
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Prote AG. 3.4 - Checking combi-valve

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Service

Service Department. Technical Information

Repair Group agen

20 - Fuel supply system

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Copyright © 2010 Volkswagen AG, Wolfsburg 00056605820

1.6 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2 Removing and installing sealing flanges and flywheel/drive plate . . . . . . . . . . . . . . . . . . . .41

2.3 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

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

1.1 - Technical data 1

1.3 - Engine data

Engine code AAA / AMY

Engine code AAA / AMY

RON min. 95 unleaded

Injection system Motronic

Exhaust gas recirculation system x

Secondary air system x

10 - Removing and installing engine

1 - Removing and installing engine

Special tools, testers and auxiliary items

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

must be disconnected. Obtain radio code first if necessary.

- Remove battery trim -2-.

1.1 - Removing and installing engine 3

nition system Servicing injection part

- -> Remove H.T. cable guides -1-, -2- and -4-.

- Separate 42-pin connector (near ignition transformer).

4 10 - Removing and installing engine

Vehicles with manual gearbox

- Remove drive shafts:

shafts Removing and installing drive shafts.

shafts Removing and installing drive shafts.

Vehicles with air conditioner

- Observe additional information and removal instructions => Page 11 .

1.2 - Notes on removing 5

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

- -> Unbolt assembly mounting, left securing bolts -A-.

- Lower assembly carefully.

1.3 - Securing engine to engine stand

Special tools, testers and auxiliary items

◆ Workshop crane V.A.G 1202 A

◆ Lifting tackle 2024 A

◆ Extension 2024 A/1

(for vehicles with automatic gearbox)

◆ Engine bracket 3269

6 10 - Removing and installing engine

Vehicles with manual gearbox

Vehicles with automatic gearbox

1.3 - Securing engine to engine stand 7

Vibration damper end:

Continuation for all vehicles

- Remove engine bracket 3395 from cylinder block.

1.4 - Notes on installing

Assembly mounting tightening torques

- Install pendulum support:

8 10 - Removing and installing engine

Vehicles with manual gearbox

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