Service

Workshop Manual
Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics
Engine ID AYL

Edition 06.2019

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

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.

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
AG. Volkswagen AG d
17 - Lubrication agen oes
olksw not
V gu
by
19 - Cooling d ara
ise nte
or eo
h
ut
20 - Fuel supply system ss a ra
c

ce
e

26 - Exhaust system
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.

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 © 2019 Volkswagen AG, Wolfsburg 00056608620

 agen
AG. Volkswagen AG d
oes Sharan 1996 ➤
ksw
6-cylinder
by
V injection engine (4-valve), mechanics
ol not
gu - Edition 06.2019
d ara
ise nte
r
tho
Contents
eo
s au ra
c
s

ce
le
un

pt
an
d
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

itte

y li
erm

ab
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

ility
ot p

wit
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
is n

h re
ole,

spec
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
urposes, in part or in wh

t to the co
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

rrectne
1.3 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

ss o
1.5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
cial p

f in
1.6 Additional information and assembly work for vehicles with air conditioner . . . . . . . . . . . . 11

form
mer

atio
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
om

n
c

i
or

n
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

thi
te

sd
a

1.1 Part I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
iv

o
pr

cum
1.2 Part II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
r
fo

en
ng

t.
1.3 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
yi Co
Cop py
2 Removing and installing sealing flanges and dual-mass flywheel . . . . . . . . . . . . . . . . . . . . 20
t. rig
gh ht
yri by
2.1 Renewing crankshaft oil seal, vibration damper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
op Vo
by c lksw
cted agen
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote
24
AG.

3 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.1 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.1 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.3 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.4 Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.5 Removing and installing camshaft timing chain and intermediate shaft drive chain . . . . . . 57
1.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2 Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.2 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.3 Checking variable valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.4 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.5 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.1 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.2 Assembly overview - sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.3 Dismantling and assembling oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.4 Dismantling and assembling oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.5 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.6 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.1 Parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Contents i
 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

1.2 Parts of cooling system - engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

1.3 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.4 Dismantling and assembling thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.5 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.6 Removing and installing radiator and fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.7 Checking radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.8 Checking continued coolant circulation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.9 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.1 Removing and installing fuel tank with attachments and fuel filter . . . . . . . . . . . . . . . . . . . . 119
1.2 Safety measures when working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.3 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.4 Removing and ageinstalling
n AG. Volksfuel
wagedelivery
n AG d
oes unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
ksw
1.5 Removing by V and installing fuel gauge sender
ol not
gu
ar
.................................... 125
d
1.6 Crash
rise fuel shut-off . . . . . . . . . . . . . . . . . . a.nt.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
tho eo
1.7 s auChecking fuel pump . . . . . . . . . . . . . . . . . . . . r.ac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
s
2 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ce 132
le
un

pt
2.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
an
132
d
itte

y li
2.2 Repairing parts of activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
rm

ab
pe

ility
2.3 Checking activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
ot

wit
, is n

2.4 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

h re
hole

3 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

spec
es, in part or in w

3.1 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

t to the co

3.2 Repairing parts of electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

3.3 Checking accelerator position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
rrectness of i

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

l purpos

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

1.1 Exhaust manifold, front exhaust pipe and catalytic converter with attachments . . . . . . . . 146
nform
ercia

1.2 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

m

1.3 Checking catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

com

tion in

2 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

r
te o

thi

2.1 Removing and installing parts of secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

s
iva

do
r

2.2 Checking secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

rp

cum
fo

en
g

2.3 Checking secondary air pump motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

n

t.
yi Co
op
2.4 Checking combination valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

ii Contents
 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

00 – Technical data
1 Engine number agen
AG. Volkswagen AG d
oes
olksw not
(VRL013143; Edition 06.2019) byV gu
ara
ed
ris nte
o
The engine number (“engine code” and “serialaut
h number”) -arrow- eo
ra
is located next to the vibration damper on
s the cylinder block.
s c

ce
le
un

pt
Additionally, a sticker with “engine code” and “serial number” is

an
d
itte
attached to the intake manifold.

y li
rm

ab
pe

ility
The engine code is also included on the vehicle data sticker.
ot

wit
, is n

The engine number consists of up to nine characters (alphanu‐

h re
hole

meric). The first part (maximum 3 characters) makes up the

spec
“engine code”, and the second part (6 characters), the “serial
es, in part or in w

t to the co
number”. If more than 999,999 engines were produced with the
same code letters, the first of the six digits is replaced by a letter.

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

1. Engine number 1
 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

2 Engine data
Edition 09.2011 version 4.0 AG. Volkswagen AG d
agen oes
lksw not
Engine code d byV
o gu
ara AYL
ise nte
r
Manufactured ut
ho eo
ra
06.00 ►
a
Cylinder arrangement
ss c VR1)

ce
e
nl

Cylinder angle 15.0°

pt
du

an
itte

Displacement l 2.8

y li
erm

ab
Power kW at rpm 150/6200

ility
ot p

wit
, is n

Torque Nm at rpm 265/3400

h re
hole

Bore ∅ mm 81.0

spec
es, in part or in w

Stroke mm 90.3

t to the co
Compression ratio 10.75
RON min. 98 unleaded2)

rrectness of i
System designation Motronic ME7.1
l purpos

Exhaust emissions fulfil EU4 standard

Vehicle self-diagnosis OBD

nform
ercia

Knock control 2 knock sensors

m

Lambda regulation 2 probes

at
om

ion
Catalytic converter Yes
c

in t
or

his
e

Exhaust gas recirculation No

at

do
riv

Charging No
p

cum
for

en
g

Secondary air system Yes

n

t.
yi Co
op py
Electronic power control Yes
. C rig
ht ht
rig by
Variable intake manifold Yes
copy Vo
by lksw
cted agen
Camshaft timing adjustment Prote AG.
Yes

1) VR = V-arrangement in compact in-line design

2) in exceptional circumstances at least 95 RON, but with reduced output

2 Rep. gr.00 - Technical data

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

10 – Removing and installing engine

1 Removing and installing engine

Special tools and workshop

equipment required

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
urposes, in part or in wh

t to the co
rrectne

♦ Lifting tackle - 3033-

ss o

♦ Engine support - 3269-

cial p

f inform

♦ Support clamp - VW 313-

mer

atio
m

♦ Engine support - T10102-

o

n
c

i
or

♦ Workshop hoist - V.A.G 1202 A-

thi
te

sd
iva

♦ Drip tray - V.A.G 1306-

pr

cum
r
fo

en
ng

♦ Torque wrench - V.A.G 1331-

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Removing and installing engine 3

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

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
ercia

♦ Torque wrench - V.A.G 1332-

m

a
com

tio

♦ Engine and gearbox jack - V.A.G 1383 A-

n in
r
te o

thi

♦ Assembly tool for spring-type clips - VAS 5024-

s
iva

do
r
rp

♦ Stepladder - VAS 5085-

um
fo

en
ng

t.
♦ G 000 100 grease
yi Co
Cop py
t. rig
♦ Cable tie
gh ht
pyri by
Vo
co lksw
by
1.1 Notes on removing
cted agen
Prote AG.

Procedure
– The engine is removed downwards together with the gearbox.

4 Rep. gr.10 - Removing and installing engine

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

WARNING

Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.

– All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
– Remove engine cover panel.
– First check whether a coded radio is fitted. If so, obtain anti-
theft coding.
– With ignition switched off, disconnect battery earth strap.
– Remove battery.
– During remaining disassembly, disconnect connectors
-arrows- behind battery.

AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
– Remove trim panel/air duct -1-.rised
nte
ho eo
ut
– Unbolt battery trim panel
ss -2-
a with coolant expansion tank and ra
c
lay aside; do not yet open cooling system.
ce
e
nl

pt
du

an

– Remove battery tray.

itte

y li
erm

ab

– Pull off or disconnect all other electrical cables as necessary

ility
ot p

from engine, gearbox and body and expose.

wit
, is n

h re

– Remove air filter ⇒ Rep. gr. 24 ; Dismantling and assembling

hole

spec

air filter .
es, in part or in w

t to the co

– Remove intake hose and intake manifold between air mass

meter and throttle valve module ⇒ Rep. gr. 24 ; Dismantling
and assembling intake manifold .
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

5
cted agen
Prote
1. Removing and installing engine
AG.
 AG. Volkswagen AG d
agen oes
o lksw not
V gu
d by ara
e nte
Sharan 1996 ➤ tho ris
eo
u
6-cylinder injection
ss a engine (4-valve), mechanics - Edition 06.2019 ra
c

ce
le
un

pt
– Pull fuel supply line -1- (with white marking) and fuel return line

an
d
itte
-2- (with blue marking) off fuel rail and catch fuel that escapes

y li
rm

ab
in a cloth.
pe

ility
ot

wit
, is n

h re
WARNING
hole

spec
es, in part or in w

Fuel system is under pressure! Before opening the system,

t to the co
place a cloth around the connection. Then release pressure by
carefully loosening the connection.

rrectness of i
l purpos

– Seal lines so that fuel system is not contaminated by dirt.

– Observe rules for cleanliness ⇒ page 123 .

nform
ercia

– Unclip fuel line on cylinder head cover.

m

a
com

ti
– Pull off necessary vacuum and breather hoses from engine.

on in
r
te o

thi
– Remove noise insulation tray.

s
iva

do
r

– Pull connectors off thermal switch and radiator fan.

rp

cum
fo

en
ng

– Remove front bumper ⇒ Rep. gr. 63 ; Removing and installing

t.
yi Co
op
front bumper .
C py
t. rig
gh ht
yri by
– Bring lock carrier into service position ⇒ Rep. gr. 50 ; Lock
op Vo
by c lksw
carrier service position . cted agen
Prote AG.

– Remove intake manifold ⇒ page 38 .

Note

Seal intake ports in intake manifold and in cylinder head with a

clean cloth.

– Remove poly V-belt ⇒ page 18 .

– Unbolt power-assisted steering vane pump from compact
bracket and lay to side, hoses remain connected ⇒ Rep. gr.
48 ; Vane pump, reservoir, hydraulic lines .
– Unbolt hydraulic line for power-assisted steering from right
cylinder block.
Vehicles with air conditioning system
– Observe additional information and installation work
⇒ page 11 .
Vehicles with manual gearbox
– Pull pipe/hose off slave cylinder on gearbox and expose ⇒
Rep. gr. 30 ; Assembly overview - hydraulics and clutch re‐
lease mechanism .
– Remove actuation cables from gearbox ⇒ Rep. gr. 34 ; Re‐
moving and installing actuation cables .
Vehicles with automatic gearbox
– Remove selector lever cable from gearbox ⇒ Rep. gr. 37 ;
Dismantling and assembling gear change mechanism .
Continued for all vehicles
– Remove drive shafts ⇒ Rep. gr. 40 ; Removing and installing
drive shaft .
– Remove front exhaust pipe ⇒ page 146 , removing and in‐
stalling parts of exhaust system.
– Drain coolant ⇒ page 107 .

6 Rep. gr.10 - Removing and installing engine

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Pull coolant hose quick-release couplings off radiator.

– Pull off all coolant hoses to engine using spring-type clip pliers
-VAS 5024- .
– Remove alternator and compact bracket ⇒ Rep. gr. 27 ; Re‐
moving and installing alternator .
– Unbolt bracket for secondary air pump motor -V101- from
sump and cylinder block ⇒ Item 14 (page 157) ,
⇒ Item 14 (page 157) .
– Remove pendulum support ⇒ Rep. gr. 40 ; Assembly over‐
view - subframe, anti-roll bar, wishbones .
– Fit engine support -T10102- on engine and gearbox jack -
V.A.G 1383 A- .

– Fit engine support -T10102- onto cylinder block and tighten

securing nuts -1- to 40 Nm.
– Lift engine and gearbox lightly using engine and gearbox jack
-V.A.G 1383 A- .

– Unscrew right assembly mounting securing bolts -1-.

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

– Unscrew left assembly mounting securing bolts/nuts

t to the co
-arrows-. rrectness of i

Note
l purpos

To remove securing bolts, use stepladder -VAS 5085- .

nform
ercia

– Carefully lower engine with gearbox.

m

at
om

ion
c

in t
or

Note
his
ate

do
priv

cum

Engine and gearbox must be guided carefully when lowering to

for

en
g

prevent damage to the bodywork, hoses and lines.

n

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

1. Removing and installing engine 7

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

1.2 Securing engine to assembly stand

Note

To perform the assembly measures, the engine should be se‐

cured on engine and gearbox support - VAS 6095- with either
engine bracket 3269 or universal support - VAS 6095/1- .

Procedure
– Unbolt gearbox.
Vehicles with automatic gearbox
– Secure torque converter against “falling out” after separating
engine from gearbox.
Continued for all vehicles
– Bolt engine bracket 3269 or universal support - VAS 6095/1-
on cylinder block.
– Attach lifting tackle 3033 as follows and use workshop hoist -
V.A.G 1202 A- to lift engine out of engine and gearbox jack -
V.A.G 1383 A- .
Vibration damper end: position 3.
Flywheel end: position 11
– Fit engine in support clamp -V.A.G 1202 A- using workshop
hoist -VW 313- .

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,

1.3 Notes on installing

spec
urposes, in part or in wh

t to the co

Installation is carried out in the reverse order. When installing,

note the following:
Procedure
rrectne

– Check whether dowel sleeves for centring engine and gearbox

s

are in cylinder block and install if necessary.

s o
cial p

f i

Vehicles with manual gearbox

nform
mer

– Clean input shaft splines and lightly grease with G 000 100.
atio
om

n
c

– Check and install clutch and clutch control mechanism ⇒ Rep.

i
or

n thi

gr. 30 ; Assembly overview - hydraulics and clutch release

te

sd
a

mechanism .
iv

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw

8
cted agen
Prote
Rep. gr.10 - Removing and installing engine
AG.
 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Continued for all vehicles

– Screw in all bolts on assembly mountings by hand approx. 5…
agen
AG. Volkswagen AG d
oes
6 turns. V olksw not
g by ua
ed ran
– Align assembly mountings stress-free by rocking.
ho
ris tee
t or
au ac
ss

ce
le
Note

un

pt
an
d
itte

y li
rm
Specified torques for engine and gearbox mountings

ab
pe

ility
⇒ page 10 .

ot

wit
, is n

h re
hole
– Install pendulum support ⇒ Rep. gr. 40 ; Assembly overview

spec
- subframe, anti-roll bar, wishbones .
es, in part or in w

t to the co
– Install compact bracket and alternator ⇒ Rep. gr. 27 ; Re‐
moving and installing alternator .

rrectness of i
Vehicles with air conditioning system
l purpos

– Install air conditioner compressor: ⇒ Heating, air conditioning;

Repair group 87; Removing and installing air conditioner com‐
pressor bracket .

nform
ercia

Continued for all vehicles

m

a
com

tio
– Install power steering vane pump ⇒ Rep. gr. 48 ; Vane pump,

n in
r
te o

reservoir, hydraulic lines .

thi
s
iva

do
– Bolt hydraulic line for power-assisted steering onto right cyl‐
r
rp

cum
inder block. Specified torque: 20 Nm
fo

en
ng

t.
yi Co
– Install front exhaust pipe ⇒ page 146 , removing and installing Cop py
t. rig
parts of exhaust system. opyri
gh by
Vo
ht
by c lksw
– Install drive shafts ⇒ Rep. gr. 40 ; Removing and installing Prote
cted agen
drive shaft .
AG.

Vehicles with manual gearbox

– Connect pipe/hose to slave cylinder and secure with clip ⇒
Rep. gr. 30 ; Assembly overview - hydraulics and clutch re‐
lease mechanism .
– Attach actuation cables to gearbox, adjust if necessary ⇒ Rep.
gr. 34 ; Removing and installing actuation cables .
Vehicles with automatic gearbox
– Install selector lever cable on gearbox, adjust if necessary ⇒
Rep. gr. 37 ; Dismantling and assembling gear change mech‐
anism .
Continued for all vehicles
– Install intake manifold ⇒ page 38 .
– Install intake hose and intake manifold between air mass me‐
ter and throttle valve module ⇒ Rep. gr. 24 ; Dismantling and
assembling intake manifold .
– Install air filter ⇒ Rep. gr. 24 ; Dismantling and assembling
air filter .
– Install battery and battery holder.
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Install poly V-belt ⇒ page 18 .
Filling with new coolant ⇒ page 107 .
– Install noise insulation tray.

1. Removing and installing engine 9

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Carry out a road test and read fault memory ⇒ Rep. gr. 01 ;
Reading and clearing fault memory of engine control unit .
– Adapt engine control unit to throttle valve module ⇒ Rep. gr.
24 ; Adapting engine control unit to throttle valve module .
– Perform work sequence “Procedure after open circuit in volt‐
age supply” ⇒ Rep. gr. 24 ; Procedure after open circuit in
voltage supply .
– Read readiness code ⇒ Rep. gr. 01 ; Reading readiness
code .
– If the fault memory has been cleared or the engine controln Aunit
G. Volkswagen AG d
was separated from the continuous positive supply, o lkswthe read‐
age oes
not
iness code must be regenerated ⇒ Rep. gr. d01 by ; Generating
V gu
ara
readiness code . orise nte
e th or
au
Vehicles with automatic gearbox ss
ac

ce
e
nl

– On vehicles with automatic gearbox, the gearbox control unit

pt
du

an
must also be adapted ⇒ Self-diagnosis for 5-speed automatic
itte

y li
erm

gearbox 09B; Repair group 01; Performing self-diagnosis; In‐

ab
ility
itiating basic setting .
ot p

wit
, is n

1.4 Specified torques

h re
hole

spec
es, in part or in w

Bolted connection Specified torque

t to the co
Nuts and bolts M6 10 Nm
M7 15 Nm

rrectness of i
M8 25 Nm
l purpos

M10 40 Nm
M12 60 Nm

nform
ercia

Deviations
m

at
om

i
Starter to gearbox and engine 45 Nm

on
c

in t
or

his
ate

do
riv

Note
p

cum
for

en
ng

t.
yi Co
Specified torques for engine and gearbox mountings Cop py
⇒ page 10 . ht. rig
rig ht
py by
co Vo
by lksw
cted agen
1.5 Assembly mountings
Prote AG.

Specified torques
(Bolts oiled)
Assembly mounting, right:
A - = 55 Nm
B - = 60 Nm

10 Rep. gr.10 - Removing and installing engine

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Assembly mounting, left:

A - = 60 Nm + 1/4 turn (90°) further 3)

B - = 90 Nm + 1/4 turn (90°) further 3)

C - = 50 Nm + 1/4 turn (90°) further 3)

D - = 25 Nm
3) Renew securing bolts/nuts

Note

All threaded holes into which self-locking bolts are to be screwed

must be cleaned of residual locking fluid with a thread chaser.

1.6 Additional information and assembly

work for vehicles with air conditioner

WARNING

Do not open the air conditioner refrigerant circuit. AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
Note ss c

ce
le
un

pt
♦ The opening of the refrigerant circuit can only be carried out

an
d
itte

y li
in workshops, which have trained personnel and the neces‐
rm

ab
sary range of tools and workshop equipment.
pe

ility
ot

wit
, is n

♦ To prevent damage to condenser or to refrigerant lines and

h re
hoses, ensure that lines and hoses are not stretched, kinked
hole

spec
or bent.
es, in part or in w

t to the co
♦ Ensure when installing the refrigerant lines and hoses, that the
lines and hoses are routed/installed so that they are not dam‐
aged or do not contact rotating components.

rrectness of i
l purpos

To facilitate removing and installing engine without opening re‐

frigerant circuit:
nform
ercia

– Remove retaining clamp(s) for refrigerant lines.

m

– Remove air conditioner compressor ⇒ Rep. gr. 87 ; Removing

a
com

tio

and installing compressor bracket .

n in
r
te o

thi

– Secure air conditioner compressor to body so that the refrig‐

s
iva

do

erant lines or hoses are not under tension.

r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Removing and installing engine 11

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

13 – Crankshaft group
1 Dismantling and assembling engine

Note

To perform the assembly measures, the engine should be se‐

cured on engine and gearbox support - VAS 6095- with either
engine bracket 3269 or universal support - VAS 6095/1- .

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
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Note

If when repairing an engine, metal shavings or large quantities of

small metal particles caused, for example, by partial seizure of
crankshaft and conrod bearings are found in the engine oil, one
must apart from thoroughly cleaning oil passages, renew all oil
spray jets, the oil non-return valve, the oil cooler and oil filter el‐
ement to prevent consequential damage.

12 Rep. gr.13 - Crankshaft group

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

I ⇒ page 13
II ⇒ page 16

1.1 Part I

1 - Valve timing housing

❑ Lightly lubricate contact
surfaces of oil seals be‐
fore installing.
❑ Removing and installing
⇒ page 77 Removing
and installing cam‐
shafts.
❑ Dismantling and assem‐
bling ⇒ page 75
❑ Before installing valve
timing housing, check
strainer for soiling
⇒ page 75
2 - 8 Nm n AG. Volkswagen AG do
swage es n
3 - Camshaft timing by chain
Volk ot g
ua
ed ran
❑ Before hremoving,
oris mark tee
direction
au of rotation (in‐
t or
ac
stallation position)
ss
ce
e

⇒ page 15 .
nl

pt
du

an
itte

❑ Removing and installing

y li
erm

ab

⇒ page 57
ility
ot p

4 - Exhaust camshaft adjuster

wit
, is n

h re

❑ Identification: 32A.
hole

spec

❑ Rotate engine only with

es, in part or in w

t to the co

camshaft adjuster in‐

stalled.
❑ Removing and installing
rrectness of i

⇒ page 50
l purpos

❑ Checking variable valve

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.

1. Dismantling and assembling engine 13

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

timing ⇒ page 83
5 - Intermediate shaft
6 - Thrust washer
7 - 8 Nm
❑ Apply locking fluid “D 000 600 A2” when installing
8 - Tensioning rail
❑ For camshaft drive chain, item ⇒ Item 3 (page 13) .
9 - Pivot pin, 18 Nm
❑ For tensioning rail item ⇒ Item 8 (page 14)
10 - Chain tensioner, 40 Nm
❑ For camshaft drive chain, item ⇒ Item 3 (page 13) .
❑ Only rotate engine when chain tensioner is installed.
11 - Seal
AG. Volkswagen AG d
❑ Renew if damaged or leaking agen oes
olksw not
y V gu
b ara
12 - Sprocket rise
d
nte
ho eo
❑ For roller chain item ⇒ Item 17 (page 14) s aut ra
c
s
❑ Removing and installing ⇒ page 57

ce
le
un

pt
an
d

13 - Sprocket
itte

y li
rm

ab
❑ For camshaft drive chain, item ⇒ Item 3 (page 13) .
pe

ility
ot

❑ Removing and installing ⇒ page 57

wit
, is n

h re
14 - 60 Nm + 1/4 turn (90°) further
hole

spec
es, in part or in w

❑ Renew

t to the co
❑ Use counterhold - T10069- to loosen and tighten ⇒ page 57 .
15 - Chain tensioner with tensioning rail

rrectness of i
❑ For roller chain item ⇒ Item 17 (page 14)
l purpos

❑ Before installing, release locking splines in chain tensioner using a small screwdriver and press tension‐
ing rail against chain tensioner.

nform
ercia

❑ Only rotate engine when chain tensioner is installed.

m

16 - Drive gear a
com

tion in

❑ Built into crankshaft.

r
te o

thi

❑ Ground down tooth aligned with main bearing joint = TDC No. 1 cylinder ⇒ page 57
s
iva

do
r
rp

cum

17 - Timing chain
fo

en
ng

t.
yi
❑ Before removing, mark direction of rotation (installation position) ⇒ page 15 .
Co
Cop py
t. rig
❑ Removing and installing ⇒ page 57 gh ht
pyri by
Vo
co lksw
by
18 - Slide rail Prote
cted AG.
agen

❑ For roller chain item ⇒ Item 17 (page 14)

❑ Removing and installing together with timing chain ⇒ page 57
19 - Locating pin without collar, 10 Nm
❑ For guide rail item ⇒ Item 18 (page 14)
20 - 18 Nm
❑ For guide rail item ⇒ Item 24 (page 15)
21 - 23 Nm
❑ For guide rail item ⇒ Item 24 (page 15)

14 Rep. gr.13 - Crankshaft group

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

22 - Inlet camshaft adjuster

❑ Identification: 24E
❑ Rotate engine only with camshaft adjuster installed.
❑ Removing and installing ⇒ page 50
❑ Checking variable valve timing ⇒ page 83
23 - 60 Nm + 1/4 turn (90°) further
olkswagen AG
en AG. V
❑ Renew olks
wag does
not
yV gu
❑ Contact surface of sender wheelisemust
d b
be dry around bolt head when installed.
ara
nte
or eo
❑ To remove and install, counterhold
auth using 32 mm open-end spanner on camshaft
ra ⇒ page 77 Removing
and installing camshafts. ss c

ce
le
un

pt
24 - Slide rail

an
d
itte

y li
❑ For camshaft drive chain, item ⇒ Item 3 (page 13) .
rm

ab
pe

ility
25 - Exhaust camshaft control valve 1 - N318-
ot

wit
, is n

❑ For exhaust camshaft.

h re
hole

spec
❑ Checking variable valve timing ⇒ page 83
es, in part or in w

t to the co
❑ Before removing, mark connector belonging to component.
❑ Checking activation: ⇒ Rep. gr. 01 ; Performing final control diagnosis .

rrectness of i
26 - Inlet camshaft control valve 1 - N205-
❑ For inlet camshaft.
l purpos

❑ Checking variable valve timing ⇒ page 83

❑ Before removing, mark connector belonging to component.

nform
ercia

❑ Checking activation: ⇒ Rep. gr. 01 ; Performing final control diagnosis .

m

a
com

tio
27 - Slide rail

n in
r
te o

thi
❑ For camshaft drive chain, item ⇒ Item 3 (page 13) .

s
iva

do
❑ Clipped into valve timing housing
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
. rig
Marking timing chains
t
gh ht
pyri by
Vo
co
– Mark roller chains before removing (e.g. with paint, arrow
by lksw
cted agen
Prote
pointing in direction of rotation).
AG.

Note

Do not mark chain by way of centre punch, notch or the like.

1. Dismantling and assembling engine 15

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

1.2 Part II

1 - 45 Nm
n AG. Volkswagen AG do
2 - Engine support lkswage es n
o ot g
byV ua
d
3 - 8 Nm o
ir se
ran
tee
th or
❑ Secured to intake mani‐ au ac
ss
fold.

ce
le
un

pt
4 - Dipstick

an
d
itte

y li
rm
❑ The oil level must not be

ab
pe

ility
above the max. mark!
ot

wit
, is n
❑ Markings ⇒ page 94 .

h re
hole

spec
5 - Guide tube
es, in part or in w

❑ For dipstick

t to the co
❑ Secured with bolt to in‐
take manifold.

rrectness of i
6 - Cylinder block
l purpos

❑ Removing and installing

sealing flange and dual-
mass flywheel

nform
ercia

⇒ page 20 .
m

a
com

t
❑ Removing and installing

ion in
crankshaft
r
te o

thi
⇒ page 31 .

s
iva

do
❑ Dismantling and assem‐
r
rp

cum
fo

bling pistons and con‐

en
ng

t.
rods ⇒ page 26 .
yi Co
Cop py
t. rig
7 - Knock sensor 1 - G61-
gh ht
pyri by
Vo
o
❑ 3polig
c by lksw
cted agen
Prote AG.
❑ Fitting location: be‐
tween cylinder 1 and
cylinder 3.
❑ Checking: ⇒ Rep. gr.

16 Rep. gr.13 - Crankshaft group

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

01 AG. Volkswagen AG d
agen oes
olksw not
V gu
8 - 20 Nm d by ara
ise nte
r
❑ The torque setting influences
aut the function of the knock sensor.
ho eo
ra
ss c
9 - 10 Nm

ce
e
nl

pt
du

an
10 - Oil pump drive cover

itte

y li
erm

ab
11 - O-ring

ility
ot p

wit
❑ Renew
, is n

h re
❑ Lubricate before assembling.
hole

spec
es, in part or in w

12 - Oil pump drive

t to the co
13 - Oil non-return valve, 6 Nm
❑ Observe installation position

rrectness of i
❑ Clean if badly soiled
l purpos

❑ Observe notes ⇒ page 12

14 - Intermediate shaft

nform
ercia

15 - Thrust washer
m

at
om

io
16 - 8 Nm

n
c

in t
or

❑ Apply locking fluid “D 000 600 A2” when installing

his
ate

do
priv

c
17 - Input shaft

um
for

en
g

❑ For oil pump drive.

n

t.
yi Co
Cop py
18 - Oil pump
t. rig
gh ht
pyri by
❑ Dismantling and assembling ⇒ page 96
o Vo
by c lksw
cted agen
Prote
❑ Coat oil pressure pipe with sealant - D 176 501 A1- at cylinder block and oil pump housing.
AG.

19 - 23 Nm
20 - 8 Nm
❑ Apply locking fluid “D 000 600 A2” when installing
21 - Oil drain plug, 30 Nm
❑ If seal is leaking, nip open and renew.
22 - Sump
❑ Clean sealing surface before fitting.
❑ Insert with silicon sealant “D 176 404 A2”
❑ Removing and installing ⇒ page 97
23 - Oil level and oil temperature sender - G266-
❑ Black connector, 3-pin.
❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
24 - Seal
❑ Renew
❑ Lubricate before assembling.
25 - 12 Nm
26 - Oil filter housing
❑ Dismantling and assembling ⇒ page 94
❑ Coolant hose schematic diagram ⇒ page 105 .
27 - Engine speed sender - G28-
❑ Checking: ⇒ Rep. gr. 01 ; Reading and erasing engine control unit fault memory .

1. Dismantling and assembling engine 17

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

28 - Knock sensor 2 - G66-

❑ 2polig
❑ Fitting location: between cylinder 4 and cylinder 6.
❑ Checking: ⇒ Rep. gr. 01 ; Reading and erasing engine control unit fault memory .
29 - Vibration damper
❑ Removing and installing poly V-belt ⇒ page 18
30 - 100 Nm + 1/4 turn (90°) further
❑ Renew
❑ To loosen and tighten, use counterhold - T10069- ⇒ page 18
❑ Tighten using torque wrench - V.A.G 1601- .

To loosen and tighten securing bolt, secure vibration damper us‐

ing counterhold - T10069-

Note

♦ Renew securing bolt for vibration damper.

♦ Tighten securing bolt using torque wrench - V.A.G 1601- .

1.3 Removing and installing poly-V belt

Special tools and workshop equipment required
♦ Assembly tool for spring-type clips -VAS 5024-

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

♦ Hexagon bolt M8×45

spec
es, in part or in w

Removing poly V-belt

t to the co

Note
rrectness of i
l purpos

Before removing the poly V-belt mark the direction of rotation.

When installing belt ensure it is correctly seated in pulleys.
nf
ercia

– Remove engine cover panel.

rm
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
by
18
copy Vo
by lksw
Rep. gr.13 - Crankshaft group cted agen
Prote AG.
 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Pull off return hose -1- (blue marking) and catch fuel that es‐
capes with a cloth.
– Seal lines so that fuel system is not contaminated by dirt.
– Observe rules for cleanliness ⇒ page 123 .
– Mark poly V-belt direction of rotation.

– Screw bolt M8x45 into threaded hole -A- of tensioning element

until poly V-belt is slack.

Note

Screw in bolt only far enough to remove poly V-belt because ten‐
sioning element housing may otherwise be damaged.

– Remove noise insulation tray.

– Remove poly V-belt.
Installing poly V-belt
– Install in reverse order of removal.

Note

♦ Ensure, before installing poly V-belt, that all ancillaries (alter‐

nator, air conditioner compressor, vane pump) are secured
tightly.
G. Volkswagen AG d
♦ When fitting the poly V-belt observe belt directionlkof
swarotation
gen A oes
and that the belt is seated correctly in the beltbypulleys.
not
Vo gu
d ara
e nte
ris
ho eo
aut ra
– Fit poly V-belt. ss c
ce
le
un

pt

– Unscrew M8 bolt again from tensioning element!

an
d
itte

y li

After completing repairs always:

erm

ab
ility
ot p

– Start engine and check if belt runs properly.

wit
is n

h re
ole,

– Install noise insulation tray.

spec
urposes, in part or in wh

– Install engine cover panel.

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
19
agen
Prote AG.
1. Dismantling and assembling engine
 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

2 Removing and installing sealing

flanges and dual-mass flywheel

Note

♦ Repairing clutch: ⇒ Rep. gr. 30 ; Repairing clutch .

♦ To perform the assembly measures, the engine should be se‐
cured on engine and gearbox support - VAS 6095- with either
engine bracket 3269 or universal support - VAS 6095/1- . AG. Volkswagen AG d
agen oes
ksw
♦ The sealing flange ⇒ Item 7 (page 21) can be removed by V and
ol not
gu
installed with the cylinder head fitted. rise
d ara
nte
tho eo
au ra
ss c

ce
le

1 - 100 Nm + 1/4 turn (90°) fur‐

un

pt
an
d
itte

ther

y li
erm

ab
❑ Renew

ility
ot p

wit
❑ To loosen or tighten,
is n

h re
use counterhold -
ole,

spec
T10069- ⇒ page 22 ,
urposes, in part or in wh

Renewing crankshaft oil

t to the co
seal, vibration damper
end.
❑ Tighten using torque

rrectne
wrench - V.A.G 1601- .

s
2 - Vibration damper

s o
cial p

f
❑ Removing and installing

inform
poly V-belt ⇒ page 18
mer

atio
3 - 8 Nm
om

n
c

i
or

n
4 - Seal

thi
te

sd
a

❑ PTFE oil seal:

iv

o
pr

cum
r
fo

❑ Identification: Without
en
ng

t.
inner hose spring.
yi Co
Cop py
❑ Do not additionally oil or
t. rig
gh ht
yri
grease the oil seal seal‐
p by
co Vo
by lksw
ing lip. Prote
cted AG.
agen

❑ Before installing, re‐

move oil residue from
crankshaft journal using
a clean cloth.
❑ Renewing ⇒ page 22
5 - Sealing flange
❑ Coat sealing surfaces
with sealant - D 176 501

20 Rep. gr.13 - Crankshaft group

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

A1- .
6 - Cylinder block
❑ Removing and installing
crankshaft ⇒ page 31 .
❑ Dismantling and assembling pistons and conrods ⇒ page 26 .
7 - Sealing flange
❑ Coat sealing surfaces with sealant - D 176 501 A1- .
8 - Seal
❑ PTFE oil seal:
❑ Identification: Without inner hose spring.
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Remove with extractor hook 2086
❑ Position via sleeve 2003/2A to install.
❑ Draw in to stop with installing tool 2003/1.
9 - Flywheel/drive plate
❑ Removing and installing drive plate ⇒ page 24
10 - 60 Nm + 1/4 turn (90°) further
❑ Renew
❑ Use counterhold - T10069- to loosen and tighten.
11 - 23 Nm

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

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.

2. Removing and installing sealing flanges and dual-mass flywheel 21

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

2.1 Renewing crankshaft oil seal, vibration damper end

Special tools and workshop

equipment required

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
urposes, in part or in wh

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
♦ Seal puller - 3203-
C py
ht. rig
rig ht
py by
♦ Fitting sleeves - 3266-
co Vo
by lksw
cted agen
Prote AG.
♦ Assembly tool - T10053-
♦ Counter-hold tool - T10069-
♦ Torque wrench - V.A.G 1332- (40…200 Nm)
♦ Torque wrench - V.A.G 1601- (150…800 Nm)
Removing
– Remove poly V-belt ⇒ page 18 .

22 Rep. gr.13 - Crankshaft group

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Remove vibration damper. To do this lock vibration damper

with counterhold -T10069- .
– Unscrew inner part of oil seal extractor 3203 three turns (ap‐
prox. 4 mm) out of outer part and lock with knurled screw.
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

– Lubricate threaded head of oil seal extractor 3203, place it in

wit
, is n

position and while exerting firm pressure screw it into oil seal

h re
hole

as far as possible.

spec
es, in part or in w

– Loosen knurled screw and turn inner part against crankshaft

t to the co
until the oil seal is pulled out.
Installing

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
e

Note
at

do
priv

cum
or

In place of oil seal with internal circular spring -1-, a PTFE oil seal
f

en
ng

t.
yi
is being gradually introduced (Teflon) -2-. This has a wider sealing
Co
op py
lip. PTFE oil seals are installed free of oil and grease. When a
. C rig
ht ht
rig
PTFE oil seal is installed as original equipment, then only a PTFE py by
co Vo
oil seal may be installed as a replacement.
by lksw
cted agen
Prote AG.

– Remove oil residue from crankshaft journal using clean cloth.

– Position guide sleeve -T10053/1- on front of crankshaft journal

and carefully slide oil seal as far as possible onto crankshaft
journal over guide sleeve.
– Remove guide sleeve.

2. Removing and installing sealing flanges and dual-mass flywheel 23

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Press oil seal in to stop with installing sleeve from 3266. To do

this, use old vibration damper securing bolt.

n AG. Volkswagen AG do
– Install vibration damper and lock with counterhold -T10069- . lkswage es n
ot g
o
byV ua
– Tighten new securing bolt to 100 Nm and then turn 90° (1/4 rised ran
tee
turn) further (turning further can be done in several stages).utho
or
a ac
ss

ce
e
nl

pt
du
Note

an
itte

y li
erm

ab
♦ Renew securing bolt for vibration damper.

ility
ot p

wit
, is n

♦ Tighten securing bolt with torque wrench -V.A.G 1601- .

h re
hole

spec
– Install poly V-belt ⇒ page 18 .
es, in part or in w

t to the co
2.2 Removing and installing drive plate

rrectness of i
Special tools and workshop equipment required
l purpos

♦ Counter-hold tool - T10069-

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.

♦ Torque wrench - V.A.G 1332- (40…200 Nm)

♦ Depth gauge
♦ Straight edge

24 Rep. gr.13 - Crankshaft group

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Removing
– Remove drive plate. To do this lock vibration damper with
counterhold -T10069- .
– Loosen drive plate securing bolts diagonally and remove.
AG. Volkswagen n AG do
wage es n
– Remove drive plate. y Volks ot g
ua
b
ed ran
Installing thoris tee
or
au ac
– Fit drive plate
ss on crankshaft.

ce
le
un

pt
– Insert at least 3 old securing bolts and tighten to 30 Nm.

an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

– Check dimension -a- through the three holes for securing the

spec
urposes, in part or in wh

torque converter using a straightedge and depth gauge and

t to the co
calculate average.
– Compare average with specification (measured distance +
thickness of straight edge). Specification: 15.7 to 16.5 mm

rrectne
If specification is not attained:

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
va

– Remove drive plate again and fit appropriate shim -1-.

i

o
pr

cum
r
fo

en
ng

t.
yi Co
op
Note
C py
t. rig
gh ht
pyri by
Vo
o
by c
Only one shim of the appropriate thickness may be used.
lksw
cted agen
Prote AG.

When specification is attained:

– Insert new securing bolts and tighten by hand.
– Tighten securing bolts to 60 Nm + 90° (1/4 turn) further (turning
further can be done in several stages).

2. Removing and installing sealing flanges and dual-mass flywheel 25

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

3 Dismantling and assembling pistons and conrods

1 - Piston rings
❑ Offset gaps by 120°
❑ Use piston ring pliers to
remove and install.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
⇒ page 27 .
❑ Checking ring-to-groove
clearance ⇒ page 28 .
2 - Piston
❑ Checking ⇒ page 28
❑ Mark cylinder number
and installation position
relative to conrod.
n AG. Volkswagen AG do
❑ Low point of piston lkswage es n
o ot g
crown faces to centre of byV ua
d ran
cylinder block. ir se tee
tho
u or
❑ Install with funnel 3278 ss
a ac
⇒ page 29 .

ce
e
nl

pt
du

an
3 - Retaining ring
itte

y li
erm

ab
4 - Conrod

ility
ot p

wit
❑ Renew as set only.
, is n

h re
❑ Mark cylinder number
hole

spec
-B-
es, in part or in w

t to the co
❑ Installation position:
marks -A- must be
above one another.
rrectness of i
5 - Bearing shell
l purpos

❑ Observe installation po‐

sition
nf
ercia

❑ Do not interchange
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.

26 Rep. gr.13 - Crankshaft group

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

used bearing shells.

❑ The lugs on bearing shells must fit tightly in the recesses.
❑ Axial clearance new: 0.05…0.35 mm; wear limit: 0.40wamm gen AG
. Volkswagen AG
does
olks not
❑ Measure radial clearance using Plastigage; new: d by V0.02…0.07 mm; wear limit: 0.10 gumm. Do not rotate
ara
crankshaft when checking radial clearance.oris e nte
e
h
ut or
6 - Conrod bearing cap ss
a ac

ce
le
❑ Mark cylinder number -B-

un

pt
an
d
itte
❑ Installation position: marks -A- must be above one another.

y li
rm

ab
pe

ility
7 - 30 Nm + 1/4 turn (90°) further

ot

wit
, is n
❑ Renew

h re
hole

spec
❑ Oil threads and contact surface.
es, in part or in w

❑ To measure radial clearance, tighten to 30 Nm but not further.

t to the co
8 - Cylinder block
❑ Checking cylinder bores ⇒ page 29 .

rrectness of i
❑ Removing and installing crankshaft ⇒ page 31 .
l purpos

❑ Piston and cylinder dimensions ⇒ page 30 .

9 - Piston pin

nform
ercia

❑ If difficult to remove, heat piston to 60°C.

m

a
com

tio
❑ Remove and install with drift -VW 222- a

n in
r
te o

thi
s
iva

do
r
rp

c
Checking piston ring gap

um
fo

en
ng

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

Special tools and workshop equipment required

♦ Feeler gauge
Test sequence
– Push ring at right angles to cylinder wall from above down to
approx. 15 mm from bottom end of cylinder. Push in using a
piston without rings.
Piston ring Ring gap
New Wear limit
Rectangular-section ring mm 0.20…0.40 1.0
Tapered stepped ring mm 0.20…0.40 1.0
Oil scraper ring mm 0.25…0.50 1.0

3. Dismantling and assembling pistons and conrods 27

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Checking ring-to-groove clearance

Special tools and workshop equipment required

♦ Feeler gauge
Test sequence
– Clean ring groove before checking.
Piston ring Clearance
New Wear limit
Rectangular-section ring mm 0.04…0.08 0.15
Tapered stepped ring mm 0.02…0.06 0.15
Oil scraper ring mm 0.03…0.06 0.15
Checking piston

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
Special tools and workshop equipment required
ce
e
nl

pt
du

an

♦ External micrometer 75 to 100 mm

itte

y li
erm

ab

Test sequence
ility
ot p

wit
, is n

– Measure pistons approx. 6 mm from lower edge of skirt and

h re

90° to piston pin axis.

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
yri by

28
op Vo
by c lksw
Rep. gr.13 - Crankshaft group Prote
cted AG.
agen
 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Difference between actual and nominal diameter max. 0.04 mm.

Checking cylinder bores

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
Special tools and workshop
ss
a equipment required ac

ce
e
nl

♦ Cylinder gauge 50…100 mm

pt
du

an
itte

y li
Test sequence
erm

ab
ility
ot p

– Take measurements at 3 positions in both lateral direction

wit
, is n

-A- and longitudinal direction -B-.

h re
hole

spec
Difference between actual and nominal diameter max. 0.08 mm.
es, in part or in w

Note t to the co
rrectness of i

Cylinder bores must not be measured when the cylinder block is

l purpos

secured with engine bracket - 3269- or universal support - VAS

6095/1- to engine and gearbox support - VAS 6095- as meas‐
urements may be incorrect.
nform
mercia

Installing pistons with piston fitting tool - 3278-

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

Special tools and workshop equipment required

t.
yi Co
Cop py
. rig
♦ Funnel - 3278-
t
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note

If a new piston fitting tool is used to install the pistons, first pass
piston with oiled piston rings twice through the tool and remove
any resulting metal shavings, if necessary. Only then install piston
with piston rings.

Procedure
– Push piston into oiled funnel by hand. Flat side of piston crown
must face lug on funnel -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 piston fitting tool.

3. Dismantling and assembling pistons and conrods 29

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Place piston in respective cylinder bore. Lug on piston fitting

tool -arrow- must face centre of cylinder block.
– Hold fitting tool tightly against cylinder block and push piston
in.

3.1 Piston and cylinder dimensions

Honing dimen‐ Piston ∅ Cylinder bore ∅
sion
Basic dimension mm 80.965 81.010
Stage I mm 81.465 81.510
Stage II mm 81.965 82.010

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
urposes, in part or in wh

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.

30 Rep. gr.13 - Crankshaft group

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

4 Removing and installing crankshaft

Note AG. Volkswagen AG d

agen oes
olksw not
♦ To perform the assembly measures, ed the
by engine should be se‐
V gu
ara
cured on engine and gearbox support
horis - VAS 6095- with either nte
eo
engine bracket 3269 or universal
s aut support - VAS 6095/1- . ra
c
s
♦ Before removing the crankshaft, ensure that a suitable surface

ce
e
nl

pt
du
is prepared to ensure that the sender wheel (item

an
itte

y li
⇒ Item 6 (page 32) ) is not damaged or lies against any other
erm

ab
item.

ility
ot p

wit
, is n

♦ When changing bearing shells, use only bearing shells of

h re
same colour code.
hole

spec
es, in part or in w

t to the co
1 - Bearing cap
❑ Bearing cap 1: vibration

rrectness of i
damper end
l purpos

❑ Bearing cap 5 with re‐

cesses for thrust wash‐
ers

nform
ercia

❑ Bearing shell retaining

m

at
lugs in cylinder block
om

io
and bearing caps must

n
c

in t
or

align.

his
ate

do
riv

2 - 30 Nm + 1/2 turn (180°) fur‐

p

cum
or

ther
f

en
ng

t.
yi
❑ Renew
Co
Cop py
t. rig
❑ 2 x 90° further is permit‐
gh ht
yri by
ted.
op Vo
by c lksw
cted agen
Prote AG.
3 - Bearing shells 1…7
❑ Before removing, see
notes ⇒ page 31 .
❑ 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
❑ Before removing, see
notes ⇒ page 31 .
❑ Axial clearance new:

4. Removing and installing crankshaft 31

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

0.07…0.24 mm; wear

limit: 0.30 mm
❑ Measure radial clearance using Plastigage; new: 0.02…0.06 mm; wear limit: 0.10 mm
❑ Do not rotate crankshaft when checking radial clearance
❑ Crankshaft dimensions, main bearing: 59.958…59.978 mm, conrod bearing: 53.958…53.978 mm. Re‐
working is not permitted.
6 - Sender wheel
❑ For engine speed sender - G28-
❑ Renew
❑ Fitting ⇒ page 32
7 - 10 Nm + 1/4 turn (90°) further
❑ Renew n AG. Volkswagen AG do
wage e
❑ Note correct sequence
yV
owhen tightening ⇒ page 32s n.ot g
lks
b ua
ed ran
8 - Oil spray jet ris tee
utho or
❑ For crankshaft
ss
a bearings 2 to 7 ac

ce
le

❑ For piston cooling

un

pt
an
d

❑ Opening pressure: 2.0 bar

itte

y li
rm

ab
❑ Removing and installing ⇒ page 94 , ⇒ page 94
pe

ility
ot

❑ Observe notes ⇒ page 12

wit
, is n

h re
hole

spec
es, in part or in w

Fitting sender wheel to crankshaft

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

Special tools and workshop equipment required

en
ng

t.
yi Co
op py
♦ Torque wrench - V.A.G 1331- (5…50 Nm) t. C rig
gh ht
pyri by
♦ Locking fluid D 000 600 A2
co Vo
by lksw
cted agen
Prote AG.
Ensure that contact surfaces of crankshaft and sender wheel are
free of oil and grease.
– Lightly coat contact surfaces of crankshaft and sender wheel
with locking fluid “D 000 600 A2” for additional security.
– First tighten all new securing bolts lightly by hand.
– First tighten securing bolt -1- to 10 Nm + 90° (1/4 turn) further.
– Then tighten securing bolts -2- to 10 Nm + 90° (1/4 turn) fur‐
ther.

32 Rep. gr.13 - Crankshaft group

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

15 – Cylinder head, valve gear

1 Assembly overview - cylinder head

Note

If an exchange cylinder head is installed, all the contact surfaces

between the support elements, roller rocker fingers and the run‐
ning surfaces of the camshafts must be oiled before the cylinder
head cover is installed.

Note

♦ The plastic protectors fitted to protect the open valves must be

removed only immediately before the cylinder head is fitted.
♦ When cylinder head is renewed, the complete coolant must be
renewed.

Checking compression ⇒ page 68 . agen

AG. Volkswagen AG d
oes
olksw not
♦ Removing and installing intake manifolded by ⇒ page 38 .
V gu
ara
ris nte
o
♦ Dismantling and assembling intake
aut
h manifold: ⇒ Rep. gr. 24 ; eo
ra
Repairing injection system s s 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.

1. Assembly overview - cylinder head 33

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

1 - 10 Nm
2 - Bracket
❑ For fuel lines
3 - Retaining frame
4 - 10 Nm
❑ With spacer sleeve and
seal.
❑ Renew seal if damaged
5 - O-ring
❑ Renew if damaged
❑ Lubricate before as‐
sembling.
❑ For ignition coil with out‐
put stage.
6 - Cap
AG. Volkswagen AG d
❑ Renew seal if damaged. lksw
agen oes
not
Vo gu
y
7 - Cylinder head cover rise
d b ara
nte
o eo
❑ Removing and installing auth
ra
⇒ page 38 ss c

ce
le
un

❑ Renew if damaged

pt
an
d
itte

y li
8 - Lifting eye
rm

ab
pe

ility
9 - 23 Nm
ot

wit
, is n

h re
10 - Camshaft timing chain
hole

spec
❑ Before removing, mark
es, in part or in w

direction of rotation (in‐

t to the co
stallation position)

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.

34 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

⇒ page 15 .
❑ Installing ⇒ page 57
11 - Combination valve
❑ Removing and installing
⇒ page 155 Removing and installing parts of secondary air system.
❑ Checking ⇒ page 163
12 - Inlet camshaft control valve 1 - N205-
❑ For inlet camshaft.
❑ Before removing, mark connector belonging to component.
❑ Checking variable valve timing ⇒ page 83
❑ Checking activation: ⇒ Rep. gr. 01 ; Final control diagnosis .
13 - Exhaust camshaft control valve 1 - N318-
❑ For exhaust camshaft.
❑ Before removing, mark connector belonging to component.
❑ Checking variable valve timing ⇒ page 83
❑ Checking activation: ⇒ Rep. gr. 01 ; Final control diagnosis .
14 - Bracket
❑ For wiring harness
n AG. Volkswagen AG do
15 - O-ring ksw
age es n
y Vol ot g
❑ For sealing oil channel. ed
b ua
ran
ris tee
❑ Renew ut
ho
or
ac
sa
❑ Lubricate before assembling. s

ce
le
un

pt
16 - Hall sender 2 - G163-

an
d
itte

y li
❑ For exhaust camshaft.
erm

ab
ility
ot p

❑ Before removing, mark connector belonging to component.

wit
is n

❑ Checking: ⇒ Rep. gr. 01 ; Fault memory .

h re
ole,

spec
17 - Chain tensioner, 40 Nm
urposes, in part or in wh

t to the co
❑ For camshaft drive chain, item ⇒ Item 10 (page 34) .
❑ Only rotate engine when chain tensioner is installed.
rrectne
18 - Seal
❑ Renew if damaged or leaking
ss o

19 - Bracket
cial p

f in

❑ For wiring harness and earth connection

form
mer

atio

20 - 8 Nm
om

n
c

i
or

21 - Seal
thi
te

sd
a

❑ Renew if damaged or leaking

iv

o
pr

cum
r

❑ Installing ⇒ page 37
fo

en
ng

t.
yi Co
22 - Thermostat housing t. Cop py
rig
gh
❑ Dismantling and assembling ⇒ page 105
ht
pyri by
Vo
o
by c lksw
❑ Coolant hose schematic diagram ⇒ page 105 . Prote
cted AG.
agen

23 - Seal
❑ Renew
24 - Hall sender - G40-
❑ For inlet camshaft.
❑ Before removing, mark connector belonging to component.
❑ Checking: ⇒ Rep. gr. 01 ; Fault memory .

1. Assembly overview - cylinder head 35

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

25 - Cover
❑ Can be removed and installed with cylinder head fitted.
❑ Coat sealing surfaces with sealant - D 176 501 A1- .
❑ If only cover has been removed, prepare cylinder head gasket for assembly ⇒ page 37 .
❑ With O-ring for sealing oil gallery, item ⇒ Item 15 (page 35)
26 - Securing bolt for camshaft adjuster
❑ Renew AG. Volkswagen AG d
agen oes
❑ 60 Nm + 1/4 turn (90°) further olksw not
V gu
d by ara
ise nte
❑ Contact surface of sender wheel must be dry aroundhor bolt head when installed. eo
ut ra
❑ To remove and install, counterhold using 32 smm
s a
open-end spanner on camshaft ⇒ page 77 Removing c
and installing camshafts.

ce
e
nl

pt
du

an
27 - Exhaust camshaft adjuster itte

y li
erm

ab
❑ Identification: 32A.

ility
ot p

❑ Rotate engine only with camshaft adjuster installed.

wit
, is n

h re
❑ Removing and installing ⇒ page 50
hole

spec
❑ Checking variable valve timing ⇒ page 83
es, in part or in w

t to the co
28 - Slide rail
❑ For camshaft drive chain, item ⇒ Item 10 (page 34) .

rrectness of i
❑ Clipped into valve timing housing
l purpos

29 - Inlet camshaft adjuster

❑ Identification: 24E

nf
ercia

o
❑ Rotate engine only with camshaft adjuster installed.

rm
m

atio
❑ Removing and installing ⇒ page 50
om

n in
c

❑ Checking variable valve timing ⇒ page 83

or

thi
te

sd
a

30 - Cylinder head gasket

iv

o
r
rp

cu
❑ Metal gasket.
o

m
f

en
ng

t.
yi
❑ Renew
Co
Cop py
t. rig
❑ Preparing cylinder head gasket for assembly ⇒ page 37 . opyri
gh by
Vo
ht

❑ After renewing, renew entire coolant. by c lksw

cted agen
Prote AG.
31 - Cylinder head
❑ Check for distortion ⇒ page 37 .
❑ Removing and installing ⇒ page 41
❑ After renewing, renew entire coolant.
32 - Tensioning element
❑ for poly V-belt
❑ Removing and installing poly V-belt ⇒ page 18
33 - Cylinder head bolt
❑ Renew
❑ Refer to assembly instructions and sequence when loosening and tightening ⇒ page 41 Removing and
installing cylinder head.
34 - Gasket for cylinder head cover
❑ Renew if damaged or leaking
❑ Observe installation position

36 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Checking cylinder head for distortion

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
Special tools and workshop equipment required
, is n

h re
hole

♦ Straight edge

spec
es, in part or in w

♦ Feeler gauge

t to the co
Max. permissible distortion: 0.05 mm

rrectness of i
Preparing cylinder head gasket for assembly
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
op py
Special tools and workshop equipment required
t. C rig
gh ht
pyri by
Vo
♦ Sealant - D 176 501 A1-
co lksw
by
cted agen
Prote AG.
Procedure
– Remove old sealant from 3 mm holes in cylinder head gasket
-arrows-.
– Fill 3 mm holes in cylinder head gasket with sealant - D 176
501 A1- and coat sealing surfaces on cover and sealing flange
with sealant.

Note

With the cylinder head installed, the holes in the cylinder head
gasket are only half visible.

Installing cover seals

1. Assembly overview - cylinder head 37

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Special tools and workshop equipment required

♦ Fitting sleeve - 3378-
♦ Fitting sleeve 3253/6 from assembly device 3253
Installing
– Do not lubricate seals.
– Install oil seal with fitting sleeve - 3378- in cover -1- and pull
in flush using 3252/6 from assembly tool 3253.

1.1 Removing and installing cylinder head

cover
Special tools and workshop equipment required
♦ Assembly tool for spring-type clips -VAS 5024-

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

♦ Torque wrench - V.A.G 1331- (5…50 Nm)

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

Removing
in t
or

his
ate

do
priv

WARNING
um
for

en
ng

t.
yi Co
Observe the following points during all installation work, in par‐ Cop py
t. rig
ticular in the engine compartment, due to the space limitations: opyri
gh by
Vo
ht
by c
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
lksw
cted agen
Prote
vated charcoal filter system, coolant, refrigerant, brake
AG.

fluid and vacuum) and electrical wiring in their original po‐

sitions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.

– First check whether a coded radio is fitted. If so, obtain anti-

theft coding.
– With ignition switched off, disconnect battery earth strap.

38 Rep. gr.15 - Cylinder head, valve gear

 n AG. Volkswagen AG do
wage es n
yV
olks ot g Sharan 1996 ➤
b ua
ir se
d 6-cylinder injection engine
ran
tee (4-valve), mechanics - Edition 06.2019
tho
u or
a ac
– All cable
ss ties which were opened or cut during removal must
be renewed at the same points.

ce
le
un

pt
an
d
itte

– Remove engine cover panel.

y li
erm

ab
ility
– Remove air filter: ⇒ Rep. gr. 24 ; Repairing injection system .
ot p

wit
is n

– Remove intake hose and intake manifold between air mass

h re
ole,

meter and throttle valve module: ⇒ Rep. gr. 24 ; Repairing

spec
urposes, in part or in wh

injection system .

t to the co
– Detach connecting hose of crankcase breather between cyl‐
inder head cover and intake hose from cylinder head cover.

rrectne
Note

ss o
cial p

f
Press buttons on hose couplings to do this.

inform
mer

atio
– Remove ignition coils with output stages: ⇒ Rep. gr. 28 ; Re‐
om

pairing ignition system .

n
c

i
or

n thi
e

– Pull 6-pin connector off throttle valve module -arrow-.

t

sd
iva

o
pr

cum
r

– Detach earth connection on throttle valve control module -

fo

en
ng

J338- .
t.
yi Co
Cop py
– Open and close expansion tank cap to release pressure in
t. rig
gh ht
yri
cooling system.
p by
co Vo
by lksw
cted agen
– Pull coolant hoses off throttle valve control unit and seal hose
Prote AG.

ends.

– Pull fuel supply line -1- (with white marking) and fuel return line
-2- (with blue marking) off fuel rail and catch fuel that escapes
in a cloth.

WARNING

Fuel system is under pressure! Before opening the system,

place a cloth around the connection. Then release pressure by
carefully loosening the connection.

– Seal lines so that fuel system is not contaminated by dirt.

– Unclip fuel line on cylinder head cover.

1. Assembly overview - cylinder head 39

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Now pull vacuum lines -arrows- off intake manifold.

Note

Press buttons on hose couplings to do this.

– Unclip pressure hose between combination valve and secon‐

dary air pump motor and all other lines from retainers on intake
manifold and cylinder head cover.
– Remove bracket for wiring harness from cover.
– Pull vacuum hose off intake manifold change-over vacuum
actuator.
– Remove the two bolts on the side for the intake manifold sup‐
port.
– Remove noise insulation tray.
– Pull connectors off thermal switch and radiator fan.
. Volkswagen AG
gen AG does
– Remove front bumper: ⇒ Rep. gr. 63 ; Removing and instal‐ Volkswa not
ling front bumper . ed
by gu
ara
is nte
or eo
– Bring lock carrier into service position: ⇒ Rep. gr. 50au; thLock ra
carrier service position . ss c

ce
le
un

pt
– Unscrew dipstick guide tube from intake manifold.

an
d
itte

y li
– Unscrew securing bolts of intake manifold and remove intake
erm

ab
ility
manifold together with throttle valve module.
ot p

wit
is n

– Remove intake manifold and place it on a suitable surface so

h re
ole,

that the vacuum unit will not be damaged.

spec
urposes, in part or in wh

t to the co
Note

rrectne
Seal intake ports in intake manifold and in cylinder head with a
clean cloth.

ss o
cial p

f
– Remove cylinder head cover.

inform
mer

Installing

atio
m

Installation is carried out in the reverse order. When installing,

o

n
c

i
or

n
note the following:
thi
te

sd
iva

o
pr

cum
r
fo

Note
en
ng

t.
yi Co
Cop py
♦ Renew cylinder head cover if damaged or leaking.
t. rig
gh ht
pyri by
Vo
o
♦ Bolt intake manifold first to cylinder head. Then tighten the two
c by lksw
cted agen
bolts of intake manifold support.
Prote AG.

♦ Ensure fuel hoses are seated correctly.

– If necessary fill with coolant ⇒ page 107 .

– Read fault memory: ⇒ Rep. gr. 01 ; Reading and erasing
engine control unit fault memory .
– Adapt engine control unit to throttle valve control unit: ⇒ Rep.
gr. 24 ; Adapting engine control unit to throttle valve control
unit .
– Perform work sequence “Procedure after open circuit in volt‐
age supply”: ⇒ Rep. gr. 24 ; Procedure after open circuit in
voltage supply .

40 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Read readiness code: ⇒ Rep. gr. 01 ; Reading readiness

code .
– If the fault memory has been cleared or the engine control unit
was separated from the continuous positive supply, the read‐
iness code must be regenerated: ⇒ Rep. gr. 01 ; Generating
readiness code .
Specified torques
Bolted connection Specified torque
Cylinder head cover to cylinder head 10 Nm
Intake manifold to cylinder head 13 Nm
Intake manifold to support 20 Nm
Dip stick guide tube to intake manifold 8 Nm

1.2 Removing and installing cylinder head

Special tools and workshop

equipment required

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
op py
♦ Camshaft bar - T10068 A- t. C rig
gh ht
pyri by
♦ Drip tray - V.A.G 1306-
co Vo
by lksw
cted agen
Prote AG.
♦ Torque wrench - V.A.G 1331- (5…50 Nm)

1. Assembly overview - cylinder head 41

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

♦ Torque wrench - V.A.G 1332- (40…200 Nm)

♦ Assembly tool for spring-type clips - VAS 5024-
♦ Sealant - D 176 501 A1-
Conditions
• The engine must be no more than warm to touch.
Volkswa n AG. gen AG
wage does
olks not
1.2.1 Removing
V gu
by ara
ed nte
oris eo
h
ut ra
sa c
WARNING
s

ce
e
nl

pt
du

an
itte

Observe the following points during all installation work, in par‐

y li
erm

ab
ticular in the engine compartment, due to the space limitations:

ility
ot p

♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐

wit
, is n

h re
vated charcoal filter system, coolant, refrigerant, brake
hole

fluid and vacuum) and electrical wiring in their original po‐

spec
sitions.
es, in part or in w

t to the co
♦ Ensure that there is sufficient clearance to all moving or
hot components.

rrectness of i
l purpos

– First check whether a coded radio is fitted. If so, obtain anti-

theft coding.
nf
ercia

– With ignition switched off, disconnect battery earth strap.

orm
m

atio

– All cable ties which were opened or cut during removal must
om

n in

be renewed at the same points.

or c

thi
te

– Remove intake manifold ⇒ page 38 .

sd
iva

o
r
rp

cu

– Pull 2-pin connector off coolant temperature sender - G62-

o

m
f

en
ng

-arrow-.
t.
yi Co
Cop py
.
– Drain coolant ⇒ page 107 .
t rig
gh ht
pyri by
Vo
co
– Now remove thermostat housing ⇒ page 103 Parts of cooling
by lksw
cted agen
Prote
system - engine side.
AG.

– Set crankshaft to TDC No. 1 cylinder marks -arrow- by turning

crankshaft on the vibration damper securing bolt in direction
of engine rotation:
– Remove cylinder head cover ⇒ page 38 .

42 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve),
. Volkswage
mechanics - Edition 06.2019
AG n AG d
agen oes
olksw not
– Remove chain tensioner for camshaft timing d b chain -arrow-.
yV gu
ara
rise nte
tho eo
s au ra
c
s

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
– Mark camshaft timing chain before removing (e.g. with paint,

rrectne
arrow pointing in direction of rotation).

ss o
cial p

f
Note

inform
mer

Do not mark chain by way of centre punch, notch or the like.

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.

– Disconnect connectors from the following components of cov‐

er:
♦ Hall sender - G40-
♦ Hall sender 2 - G163-
♦ Inlet camshaft control valve 1 - N205-
♦ Exhaust camshaft control valve 1 - N318-

Note

Before removing connectors, mark each connector and compo‐

nent to which it belongs.

– Move wiring harness clear.

1. Assembly overview - cylinder head 43

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Now unscrew cover securing bolts -arrows- and remove cover.

– Unbolt front exhaust pipe from exhaust manifold
⇒ page 146 , removing and installing parts of exhaust system.

– Now check valve timing. If TDC no. 1 cylinder position is cor‐

rect, a groove -arrow- can be seen on intermediate shaft
sprockets.

Note

This condition is only obtained every 2nd TDC position.

If the groove cannot be seen:

– Turn crankshaft one full turn further in direction of engine ro‐
tation.

Note

When the crankshaft is turned, the tensioner plate must be press‐

ed against the camshaft timing chain by hand instead of with chain
tensioner.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
– Camshaft bar - T10068 A- must engage in grooves in both s
ce
e

shafts.
nl

pt
du

an
itte

y li
erm

ab
ility

Note
ot p

wit
, is n

h re

If camshaft bar cannot be fitted, turn crankshaft in direction of

hole

spec

engine rotation up to approx. 5 mm past TDC setting for No. 1

es, in part or in w

cylinder (dependent on drive chain tolerances).

t to the co

Check setting marks of camshaft adjusters against marks on tim‐

rrectness of i

ing housing:
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
by
44
copy Vo
by lksw
Rep. gr.15 - Cylinder head, valve gear cted agen
Prote AG.
 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Marks -A- and -B- on camshaft adjusters must align with

notches -arrows- in valve timing housing -C-. The marks may
be slightly offset due to tolerances in the timing chain.
– First remove exhaust camshaft adjuster.Volkswa
AG. gen AG
agen does
olksw not
yV gu
db ara
rise nte
tho eo
s au ra
c
s

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
Note
es, in part or in w

t to the co
Only counterhold camshaft with 32 mm open-end spanner
-arrow-. The camshaft bar - T10068 A- must not be fitted when
camshaft adjuster is loosened or tightened.

rrectness of i
l purpos

– Remove camshaft adjuster together with camshaft timing

chain from intake camshaft.

nform
mercia

at
om

ion
c

in t
or

– Remove guide rail securing bolts -arrows- and remove guide

his
ate

do
riv

rail -1-.
p

cum
for

– Lay camshaft timing chain aside.

en
ng

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

– Loosen cylinder head bolts in sequence given and then re‐

move completely.

Note

Use tool 3452 for polydrive cylinder head bolts.

– Carefully remove cylinder head.

– Place clean cloths in cylinders so that no dirt or emery cloth
particles can get in between cylinder wall and piston.
– Also prevent dirt and emery cloth particles from getting into
coolant.

1.2.2 Installing
– Now carefully clean sealing surfaces of cylinder head and cyl‐
inder block. Ensure thereby that surfaces are not scored or
scratched (if abrasive paper is used, grade must not be less
than 100).
– Carefully remove metal particles, emery residue and cloths.

1. Assembly overview - cylinder head 45

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

If the piston for No. 1 cylinder is not at TDC:

– Set crankshaft to TDC No. 1 cylinder marks -arrow- by turning
crankshaft on the vibration damper securing bolt in direction
of engine rotation:

Note

♦ Do not remove new cylinder head gasket from its packing until
immediately before installing.
♦ Handle new gasket with extreme care. Damage will cause
leakage.

– Fit new cylinder head gasket. Inscription (Part No.) must be

readable.
AG. Volkswagen AG d
agen oes
ksw
– Ensure that dowel sleeves are inserted into bcylinder
yV
ol
block not
gu
ara
holes 12 and 20, and that cylinder head rgasket
ised is located. nte
ho eo
ut
Camshaft bar has been removed: ss a ra
c

ce
e

– Position camshafts in cylinder head to TDC No. 1 cylinder.

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
– Camshaft bar - T10068 A- must engage in grooves in both

rrectness of i
shafts.
l purpos

– Now prepare cylinder head gasket for assembly ⇒ page 37 .

– Fit cylinder head, screw in new cylinder head bolts and tighten
nf
ercia

hand tight. 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.

46 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Tighten cylinder head in sequence as follows:

Note

The longer cylinder head bolts must be inserted in the centre

holes of cylinder head.

– Pre-tighten all bolts to 30 Nm.

– Then tighten all bolts to 50 Nm.
– Then tighten all bolts 1/4 turn (90°) further using a rigid wrench.

– Then tighten all bolts again 1/4 turn (90°) further.

Further assembly is basically a reverse of the dismantling se‐

quence.

Note

Ensure that the O-ring for sealing the oil channel and the seal are
fitted in the cover.

Install camshaft adjuster ⇒ page 50 .

– Install cylinder head cover and intake manifold ⇒ page 38 .
Filling with new coolant ⇒ page 107 .

Note

It is not necessary to retighten cylinder head bolts after repairs.

– Check variable valve timing ⇒ page 83 . AG. Volkswagen AG d

agen oes
olksw not
yV gu
1.3 Checking valve timing o rised b ara
nte
h eo
ut ra
Special tools and workshop equipment
ss a required c
ce
le

♦ Camshaft bar - T10068 A-

un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f in

Test sequence
form
mer

atio

– Remove cylinder head cover and intake manifold ⇒ page 38 .

om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

1. Assembly overview - cylinder head 47

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Set crankshaft to TDC No. 1 cylinder marks -arrow- by turning

crankshaft on the vibration damper securing bolt in direction
of engine rotation:

Cams -A- of cylinder 1 must face each other.

– Insert camshaft bar - T10068 A- in both shaft grooves.

AG. VolkswIfagnec‐
en AG
agen does
essary, move the camshafts back andVoforth
lksw slightly with an not
open-end spanner. ed by gu
ara
ris nte
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

Check setting marks of camshaft adjusters against marks on tim‐

ing housing:
rrectness of i

• “Arrow” -1- on the camshaft adjuster of the inlet camshaft must

l purpos

align with the notch -2- on the control housing. Markings on

timing housing ⇒ page 49
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.

48 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019
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
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
m

• “Arrow” -1- on the camshaft adjuster of the exhaust camshaft

o

n
c

i
or

n
must align with the notch -2- on the control housing. Markings

thi
te

on timing housing ⇒ page 49

sd
iva

o
pr

cum
r

• The gap between markings of camshaft adjuster must be ex‐

fo

en
ng

actly 16 rollers of camshaft timing chain.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
Note
o
by c lksw
cted agen
Prote AG.

♦ A slight offset between marking and notch is permissible.

♦ Markings for MPI and FSI engines may be on the timing hous‐
ing, depending on version ⇒ page 49 .
♦ Position of copper-coloured chain links can be disregarded.

If the markings do not align:

– Adjust valve timing ⇒ page 57 .
If the markings align:
– Install cylinder head cover and intake manifold ⇒ page 38 .

Markings on valve timing housing on MPI engines

Note

Markings for MPI and FSI engines may be on the timing housing,
depending on version.

-A- View from flywheel end

-B- View from vibration damper end
The markings on camshaft adjusters must align with notches
-arrows-.

1. Assembly overview - cylinder head 49

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

1.4 Removing and installing camshaft ad‐

juster
Special tools and workshop equipment required
♦ Camshaft bar - T10068 A-

♦ Sealant - D 176 501 A1-

Removing camshaft adjuster
– Remove cylinder head cover ⇒ page 38 .
– Remove thermostat housing ⇒ page 105 .
– Remove hose -3- and vacuum hose -2- from combi-valve for
secondary air system.
AG. Volkswagen AG d
– Pull off coolant hose -1-. 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

– Mark and detach electrical connectors:

ole,

spec
urposes, in part or in wh

1- Hall sender - G40-

t to the co

2- Hall sender 2 - G163-

3- Inlet camshaft control valve 1 - N205-
rrectne

4- Exhaust camshaft control valve 1 - N318-

ss

– Unbolt cable guide from camshaft timing chain cover.

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.

50 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Set crankshaft to TDC No. 1 cylinder marks -arrow- by turning

crankshaft on the vibration damper securing bolt in direction
of engine rotation:

– Cams -A- of cylinder 1 must face each other.

– Insert camshaft bar - T10068 A- in both shaft grooves. If nec‐

essary, move the camshafts back and forth slightly with an
open-end spanner.

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

– Remove chain tensioner for camshaft timing chain -arrow-.

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.

1. Assembly overview - cylinder head 51

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Undo and remove bolts -1 … 3- and pull cover off cylinder head
horizontally. When doing so, ensure that cylinder head gasket
is not damaged.

– Mark chain links that are opposite the markings on the cam‐
shaft adjusters. Installation is facilitated by marking the timing
chain.
– Remove camshaft bar - T10068 A- .

Note

Make sure that the camshaft bar - T10068 A- has not been fitted
when the securing bolt for camshaft adjuster is being loosened or
tightened.

AG. Volkswagen AG d
agen oes
ksw
– Unscrew bolt for camshaft adjuster approx. 1 turn at outlet end, by Vol not
gu
ara
using an open-ended spanner to counterhold on flat side ofrise d
nte
camshaft. ut
ho eo
ra
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
– Unscrew bolt for camshaft adjuster approx. 1 turn at inlet end,

rrectness of i
using an open-ended spanner to counterhold on flat side of
camshaft.
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.

52 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injectionenengine
AG. Volk(4-valve),
swagen AG mechanics - Edition 06.2019
ag does
ksw not
y Vol gu
– Insert camshaft bar - T10068 A- in both edshaft grooves. If nec‐
b ara
nte
essary, move the camshafts back and orisforth slightly with an eo
th
open-end spanner. ss
au ra
c

ce
e
– Remove camshaft adjuster.

nl

pt
du

an
itte

y li
– Lay camshaft timing chain over the valves for camshaft ad‐

erm

ab
justment.

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
Installing camshaft adjuster
l purpos

Condition

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.

• Crankshaft -arrow- is at »TDC« position.

• Cams -A- of cylinder 1 face each other.
• The camshaft bar - T10068 A- has been placed in the two shaft
grooves.

1. Assembly overview - cylinder head 53

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Due to a fitted key, camshaft adjusters can only be bolted on in

one position -arrows- at camshaft mounting.

Note

Ensure that crankshaft is not at TDC with any piston when cam‐
shafts are turned. Danger of damage to valves and piston crowns.

– Screw on inlet camshaft adjuster -A- andsw turn

agento left as far as
AG. Volkswagen AG d
oes
stop. by
Volk not
gu
ara
ed nte
ris
tho e or
au ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
• Contact surface of sender wheel must be dry around bolt head
when installed.

rrectness of i
• Mark “24E” -item 1- and tooth behind it -2- must align with
l purpos

notch -3- in valve timing housing.

– Place camshaft timing chain in this position tight on sprocket
nform
ercia

of inlet camshaft adjuster.

m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
– From mark “24E” of inlet camshaft adjuster count exactly 16 ht. rig
rig ht
rollers on timing chain in direction of exhaust side. py by
co Vo
by lksw
cted agen
– Insert tooth at mark “32A” of exhaust camshaft adjuster into Prote AG.
chain exactly after 16th roller.
• There must now be 16 chain rollers between the teeth.
• Here, too, mark “32A” and tooth behind it must align with notch
in valve timing housing.

54 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Turn sender wheel-2- in exhaust camshaft adjuster -1- clock‐

wise as far as stop -arrow-.
– Hand-tighten exhaust camshaft adjuster to exhaust camshaft
in this position.
• Contact surface of sender wheel must be dry around bolt head
when installed.

– Press tensioning plate against camshaft timing chain.

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

Check setting marks of camshaft adjusters against marks on tim‐

erm

ab

ing housing:
ility
ot p

wit
is n

– Marks -A- and -B- on camshaft adjusters must align with

h re
ole,

notches -arrows- in valve timing housing -C-.

spec
urposes, in part or in wh

If the marks match, the further assembly process can continue.

t to the co
rrectness o
cial p

f inform
mer

– Remove camshaft bar - T10068 A- .

atio
om

– Tighten retaining bolt on inlet camshaft adjuster, counterhold‐

c

i
or

n thi

ing hexagon section of camshaft with 32 mm open-end span‐

te

sd
a

ner. Specified torque ⇒ Item 26 (page 36)

iv

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. Assembly overview - cylinder head 55

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Tighten retaining bolt on exhaust camshaft adjuster, counter‐

holding hexagon section of camshaft with 32 mm open-end
spanner.

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
Note is n

h re
ole,

spec
So that the camshaft timing chain does not jump a tooth when the
urposes, in part or in wh

crankshaft is turned, the tensioner plate must be pressed against

t to the co
the camshaft timing chain by hand instead of with chain tensioner.

rrectne
– Turn crankshaft two full turns in direction of engine rotation
and check valve timing again ⇒ page 47 .

ss
If seals in cover are to be renewed ⇒ page 37 .

o
cial p

f in
– Clean sealing surface on cover and cylinder head.

form
mer

atio
m

– Lubricate O-ring for oil channel seal -1- and insert in cover.
o

n
c

i
or

n thi
– Check that dowel sleeves -2- and -3- are inserted.
te

sd
iva

o
pr

– Insert O-ring -4- in cover.

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.

– Remove old sealant from 3 mm holes in cylinder head gasket

-arrows-.
– Fill 3 mm holes in cylinder head gasket with sealant - D 176
501 A1- . Coat sealing surface of cover with sealant - D 176
501 A1- and immediately install.

56 Rep. gr.15 - Cylinder head, valve gear

 AG. Volkswagen AG d
agen oes
olksw not
y V gu
rise
d b
Sharan
ara
nte 1996 ➤
6-cylinderautinjection engine (4-valve), mechanics - Edition
ho e o06.2019
ra
ss c

ce
le
– First insert all securing bolts -arrows- and tighten lightly.

un

pt
an
d
itte
– Then tighten M8 securing bolts to 23 Nm and then tighten M6

y li
rm

ab
securing bolts to 8 Nm.

pe

ility
ot

wit
– Install chain tensioner for camshaft timing chain and tighten to

, is n

h re
40 Nm.

hole

spec
– Install cylinder head cover and intake manifold ⇒ page 38 .

es, in part or in w

t to the co
rrectness of i
l purpos

1.5 Removing and installing camshaft timing chain and intermediate shaft drive

nform
ercia

chain
m

a
com

tion in
r
te o

thi
Special tools and workshop

s
iva

do
equipment required
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.

♦ Camshaft bar - T10068 A-

♦ Counter-hold tool - T10069-
♦ Torque wrench - V.A.G 1331-
♦ Torque wrench - V.A.G 1332-

1. Assembly overview - cylinder head 57

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

♦ Sealant - D 176 501 A1-

Removing timing chains:
– Remove gearbox ⇒ Rep. gr. 34 .
– Remove flywheel or drive plate ⇒ page 24 .
– Remove sump ⇒ page 97 .
– Remove cylinder head cover ⇒ page 38 .
– Remove thermostat housing ⇒ page 105 .
– Remove hose -3- and vacuum hose -2- from combi-valve for
secondary air system.
– Pull off coolant hose -1-.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
ho
– Mark and separate electrical connectors.
aut or
ac
ss
1- Hall sender - G40-

ce
e
nl

pt
du

an
itte

2- Hall sender 2 - G163-

y li
erm

ab
ility
3- Inlet camshaft control valve 1 - N205-
ot p

wit
, is n

4- Exhaust camshaft control valve 1 - N318-

h re
hole

spec
– Unscrew cable routing from camshaft timing chain cover.
es, in part or in w

t to the co
rrectness of i
l purpos

– Turn crankshaft at vibration damper in engine direction of ro‐

tation to TDC No. 1 cylinder -arrow-.
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.

58 Rep. gr.15 - Cylinder head, valve gear

 AG. Volkswagen AG d
ksw
agen oes
not
Sharan 1996 ➤
ol
d byV 6-cylinder injection
gu engine
ara (4-valve), mechanics - Edition 06.2019
ise nte
or eo
th
– Camss au-A- of cylinder 1 must face each other. ra
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

– Insert camshaft bar - T10068 A- in both shaft grooves. If nec‐

essary, move the camshafts back and forth slightly with an
open-end spanner.

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.
– Unscrew chain tensioner for camshaft timing chain -arrow-.

– Undo and remove bolts -1 … 3- and pull cover off cylinder head
horizontally. When doing so, ensure that cylinder head gasket
is not damaged.

1. Assembly overview - cylinder head 59

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Unscrew bolts and remove timing chain cover at bottom

-arrow- horizontally from cylinder block. When doing so, en‐
sure that cylinder head gasket is not damaged.
– Press crankshaft seal - on timing chain side - out of cover.
– Remove camshaft bar - T10068 A- .

n AG. Volkswagen AG do
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
urposes, in part or in wh

t to the co
– Loosen and unscrew bolt -arrow-.

rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
op py
– To do this, counterhold vibration damper using counterhold - t. C rig
gh ht
yri
T10069- . p by
co Vo
by lksw
cted agen
– Remove small sprocket with camshaft timing chain. Prote AG.

– Carefully withdraw camshaft timing chain behind web of cyl‐

inder head gasket.

Removing drive chain for intermediate shaft:

– Unscrew chain tensioner for intermediate shaft drive chain
-arrow-.
– Remove large sprocket with intermediate shaft drive chain.

Note

If the camshaft adjusters and guide rails are also to be renewed,

carry out this work before refitting the timing chains.

60 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Installing drive chain and chain tensioner for intermediate shaft:

– Set crankshaft to TDC for No. 1 cylinder. Ground tooth of drive
sprocket -arrow- must align with bearing joint.
– Turn intermediate shaft with oflattened
en AG. V
lkswagen Aside
G
upwards.
ag does
ksw n
Vol into guide rail and place onocrankshaft.
– Insert drive chain t gu
by a
ed ran
ris tee
tho or
au ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

– Insert large sprocket into drive chain so that lug on sprocket

h re
aligns with lug behind -B- on cylinder block.
hole

spec
es, in part or in w

– Fit large sprocket with drive chain attached onto intermediate

t to the co
shaft.
When installing, ensure that drive chain runs completely straight

rrectness of i
in guide rail from crankshaft to intermediate shaft.
• Ground tooth of drive sprocket -arrow A- must align with bear‐
l purpos

ing joint.

nform
ercia

• Lug on sprocket of intermediate shaft must align with lug be‐

hind -arrow B-.
m

a
com

tio
– If large sprocket cannot be fitted, turn intermediate shaft slight‐
n in
r

ly.
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
– Fit small sprocket of intermediate shaft. Installation is only
Prote AG.

possible in one position.

– Tighten bolt -arrow- hand-tight only as small sprocket has to
be taken off again.

– Install chain tensioner for drive chain. To do this, release lock‐

ing teeth of chain tensioner with a small screwdriver and press
tensioning plate against chain tensioner.

Note

If a transport lock is fitted, do not remove until installation is com‐

plete .

1. Assembly overview - cylinder head 61

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Install chain tensioner in this position and tighten to 8 Nm

-arrows-.

Installing camshaft timing chain:

Condition
• The camshaft adjusters are installed
• Cams -A- of cylinder 1 face each other.

– Insert camshaft bar - T10068 A- in both shaft grooves.

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
urposes, in part or in wh

t to the co

– Remove small sprocket on intermediate shaft. The large

sprocket must not be pulled off.
– Guide camshaft timing chain from above between tensioning
rrectne

plate and guide rail towards intermediate shaft.

ss o
cial p

Note
inform
mer

♦ The 3 copper-coloured chain links next to each other must be

atio
m

placed on the intermediate shaft sprocket.

o

n
c

i
or

n thi

♦ The new camshaft timing chain may contain an additional

te

sd
va

copper-coloured link. Please ignore this link.

i

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.

62 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Turn both camshaft adjusters to left as far as stop. Illustration

shows inlet camshaft adjuster -A-.

– Place camshaft timing chain onto guide rail and camshaft ad‐
juster. 2 individual copper-coloured links -C- must align with
markings on camshaft adjuster.
– Fit small sprocket of intermediate shaft into camshaft timing
chain. Marking -B- must align with middle copper coloured
chain link -A-.

AG. Volkswagen AG d
agen oes
olksw not
yV g
– Fit small sprocket withsecamshaft
db timing chain attached ontouaran
intermediate shaft. tInstallation
ho
ri
is only possible in one position. tee o
Hand-tighten securing
au bolt -arrow-. 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

– Press tensioning plate against timing chain -arrow-.

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. Assembly overview - cylinder head 63

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Check position of crankshaft to intermediate shaft.

• Ground tooth of drive sprocket -arrow A- must align with bear‐
ing joint.
• Lug on sprocket of intermediate shaft -arrow B- must align with
lug behind.

Checking position of copper-coloured chain links relative to ad‐

justment markings:
• Copper-coloured chain links -A- and -C- must align with ad‐
justment markings. en AG. V
olkswagen AG
wag does
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
l purpos

Check position of camshaft adjuster to valve timing housing:

• “Arrow” -1- on the camshaft adjuster of the inlet camshaft must
nform
ercia

align with the left notch -2- on the control housing.

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

64 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

• The marking -1- on the camshaft adjuster of the exhaust cam‐

shaft must align with the left notch -2- on the valve timing
housing.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
Note
l purpos

When turning the crankshaft, the tensioning plate must be press‐

ed against the camshaft timing chain by hand -arrow- to prevent

nform
ercia

the chain from jumping.

m

a
com

tion in
– Press tensioning plate against camshaft timing chain by hand
r
te o

and rotate crankshaft two revolutions in direction of engine ro‐

thi
s
iva

tation.
do
r
rp

cum
fo

en
ng

t.
yi Co
Note t. Cop py
rig
gh ht
yri by
The copper coloured chain links no longer align with the adjust‐
cop Vo
by lksw
cted
ment markings once the crankshaft has been turned.
agen
Prote AG.

If all the adjustment marks match, the further assembly process

can continue.

– Lock vibration damper using counterhold - T10069- .

1. Assembly overview - cylinder head 65

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Tighten securing bolt for intermediate shaft sprockets

-arrow- to 60 Nm + 90° (1/4 turn) further. Turning further can
be done in several stages.
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

– Remove old sealant from 3 mm holes in cylinder head gasket

spec
-arrows-.
es, in part or in w

t to the co
Note

rrectness of i
With the cylinder head installed, the holes in the cylinder head
l purpos

gasket are only half visible.

nf
ercia

– Clean sealing surfaces on engine and both covers; they must

orm
be free of oil and grease.
m

atio
om

n in
or c

thi
te

sd
iva

– Check if dowel pins for bottom cover for timing chains are in‐
o
r
rp

cu

serted in cylinder block.

o

m
f

en
ng

t.
yi Co
– Coat -hatched- clean sealing surfaces of cover thinly with Cop py
sealant - D 176 501 A1- .
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note

The bottom cover for the timing chains must be fitted within 5 mi‐
nutes of applying the sealant.

66 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Locate bottom cover -arrow- and tighten securing bolts alter‐

nately in several stages.

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
urposes, in part or in wh

t to the co
rrectne
– Fill 3 mm holes in cylinder head gasket -arrows- with sealant

s
- D 176 501 A1- .

s o
cial p

f i
– In event of leaks, fit new seals in top cover for timing chains

nform
⇒ page 37 .
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.
– Check whether dowel sleeves -2- and -3- are inserted in top
cover for timing chains.
– Fit new seal -1- and new gasket -4-.
– Coat sealing surface of cover with sealant - D 176 501 A1- and
immediately install.

1. Assembly overview - cylinder head 67

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Locate top cover for timing chains and tighten all securing bolts
slightly. Then tighten bolts as follows:
♦ Tighten bolts -1- and -2- to 5 Nm.
♦ Tighten bolts -3- to 23 Nm.
♦ Tighten bolts -1- and -2- to 10 Nm.
– Install chain tensioner for camshaft timing
agenchain and tighten
AG. Volkswagen AG dto
oes
40 Nm. olksw not
yV gu b ara
ed nte
– Install thermostat housingth⇒oripage
s
105 . e or
au ac
– Install cylinder head cover
ss and intake manifold ⇒ page 38 .

ce
le
un

pt
Specified torques

an
d
itte

y li
erm

ab
Component Nm

ility
ot p

Bolts for guide rail to cylinder block 10

wit
is n

h re
ole,

Chain tensioner to cylinder block 8

spec
urposes, in part or in wh

Sprockets to intermediate shaft 60 + 90°

t to the co
Camshaft adjuster to camshafts 60 + 90°
Bottom cover for timing chains to cylinder block 10

rrectne
Top cover for camshaft timing chain M6 10
M8 23

ss o
Chain tensioner for camshaft timing chain to cyl‐ 40
cial p

f in
inder head

form
mer

atio
m

1.6 Checking compression

o

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

68 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Special tools and workshop

equipment required

n AG. Volkswagen AG do
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
♦ Spark plug socket - 3122 B- t. Cop py
rig
gh ht
yri
♦ Torque wrench - V.A.G 1331- (5…50 Nm)p by
co Vo
by lksw
cted agen
♦ Compression tester - V.A.G 1763- Prote AG.

♦ Puller - T10095 A-
Prerequisites for check
• Engine oil temperature at least 30°C
• Battery voltage must be at least 11.5 V.
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
• If the vehicle is equipped with an air conditioner, it must be
switched off.

1. Assembly overview - cylinder head 69

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Test sequence
– Remove fuse no. 14 out of fuse holder.

Note

Removing fuse no. 14 interrupts the voltage supply to the injec‐

tors.

– Remove engine cover panel.

– Remove intake hose and intake manifold between air mass
meter and throttle valve module: ⇒ Rep. gr. 24 ; Repairing
injection system .
– Remove ignition coils with output stages: ⇒ Rep. gr. 28 ; Re‐
pairing ignition system .
n AG. Volkswagen A
– Unscrew spark plugsousing
ksw spark plug socket and
age G do
es n extension -
3122 B- . y V l ot g
ua
db r e an
ris te
– Have a second
ut
ho mechanic fully depress the accelerator pedal.
eo
r a ac
ss
– Check compression using compression tester - V.A.G 1763- .
ce
le
un

pt
an
d
itte

y li
erm

Note ab
ility
ot p

wit
is n

Using compression tester ⇒ Operating instructions.

h re
ole,

spec
urposes, in part or in wh

– Operate starter until tester shows no further pressure in‐

t to the co

crease.
Compression pressures:
rrectne

New: 10…13 bar; wear limit: 7.5 bar

Maximum permissible difference between all cylinders: 3 bar
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.

70 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

2 Repairing valve gear agen

AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
rise nte
Note utho eo
ra
s a c
s
Cylinder heads which have cracks between the valve seats or

ce
e
nl

pt
du
between valve seat inserts and the spark plug thread can be used

an
itte

y li
further without reducing service life, providing the cracks do not

erm

ab
exceed a maximum of 0.5 mm in width.

ility
ot p

wit
, is n

h re
hole

spec
1 - 5 Nm + 1/8 turn (45°) further es, in part or in w

t to the co
2 - Exhaust camshaft bearing
cap
❑ Fitting position

rrectness of i
⇒ page 74
l purpos

❑ Installation sequence
⇒ page 77 Removing
and installing camshaft.

nform
ercia

3 - Seal
m

at
om

io
❑ Renew if leaking.

n
c

in t
or

his
❑ When installing valve
ate

do
riv

timing housing, lightly

p

cum
lubricate contact surfa‐
for

en
g

ces of seal.
n

t.
yi Co
op py
❑ When replacing seals, t. C rig
gh ht
do not spread too wide‐ yri
p by
o Vo
ly.
c by lksw
cted agen
Prote AG.
4 - Exhaust camshaft
❑ Check radial clearance
with Plastigage; wear
limit: 0.1 mm
❑ Runout: max. 0.01 mm
❑ Checking axial clear‐
ance ⇒ page 73 .
❑ Identification and valve
timing ⇒ page 75
❑ Removing and installing
⇒ page 77
5 - Valve timing housing
❑ Lightly lubricate contact
surfaces of oil seals be‐

2. Repairing valve gear 71

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

fore installing.
❑ Dismantling and assem‐
bling ⇒ page 75
❑ Before installing valve timing housing, check strainer for soiling ⇒ page 75
❑ Removing and installing ⇒ page 77 Removing and installing camshafts.
6 - Camshaft timing chain
❑ Before removing, mark direction of rotation (installation position) ⇒ page 15 .
❑ Installing ⇒ page 57
7 - Exhaust camshaft adjuster
❑ Identification: 32A.
❑ Rotate engine only with camshaft adjuster installed.
❑ Removing and installing ⇒ page 50 . Volkswage
AG n AG d
❑ Checking variable valve timing agen
ksw⇒ page 83
oes
not
Vol y gu
db ara
8 - 60 Nm + 1/4 turn (90°) further
or
ise nte
eo
h
ut ra
❑ Renew ss
a c

ce
e

❑ Contact surface of sender wheel must be dry around bolt head when installed.
nl

pt
du

an
❑ To remove and install, counterhold using 32 mm open-end spanner on camshaft ⇒ page 77 Removing
itte

y li
erm

and installing camshafts.

ab
ility
ot p

9 - Inlet camshaft adjuster

wit
, is n

h re
❑ Identification: 24E
hole

spec
❑ Rotate engine only with camshaft adjuster installed.
es, in part or in w

t to the co
❑ Removing and installing ⇒ page 50
❑ Checking variable valve timing ⇒ page 83
10 - Cylinder head height rrectness of i
l purpos

❑ Minimum height: a = 139.9 mm.

11 - Valves
nform
ercia

❑ Do not rework; only lapping-in is permitted.

m

at

❑ Valve dimensions ⇒ page 74

om

ion
c

in t

12 - Cylinder head
or

his
ate

❑ Check for distortion ⇒ page 37 .

do
priv

cum

❑ Observe notes ⇒ page 71

for

en
ng

t.
❑ Removing and installing ⇒ page 41
yi Co
Cop py
❑ Reworking valve seats ⇒ page 75 .
ht. rig
rig ht
py by
❑ After renewing, renew entire coolant.
co Vo
by lksw
cted agen
Prote AG.
13 - Support element
❑ Before installing, check camshaft axial clearance ⇒ page 73 .
❑ Do not interchange
❑ With hydraulic valve clearance compensation.
14 - Valve stem seal
❑ Renewing ⇒ page 88
15 - Securing clip
❑ Check for firm seating
16 - Roller rocker fingers
❑ Before installing, check camshaft axial clearance ⇒ page 73 .
❑ Do not interchange
❑ Check roller bearing for ease of movement.
❑ Oil contact surface
❑ When installing, secure to supporting element using securing clip.

72 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

17 - Valve springs
❑ Observe installation position
❑ Removing and installing ⇒ page 88 , Renewing valve stem seals.
18 - Valve spring plate
19 - Valve cotters
20 - Inlet camshaft bearing cap
❑ Fitting position ⇒ page 74
❑ Installation sequence ⇒ page 77 Removing and installing camshaft.
wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
21 - Inlet camshaft ed
by ara
ris nte
❑ Check radial clearance with Plastigage; wear limit:
th 0.1 mm
o eo
au ra
❑ Runout: max. 0.01 mm ss c

ce
e
nl
❑ Checking axial clearance ⇒ page 73 .

pt
du

an
itte

y li
❑ Identification and valve timing ⇒ page 75 erm

ab
❑ Removing and installing ⇒ page 77

ility
ot p

wit
, is n

h re
hole

spec
Camshafts, checking axial clearance
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
Special tools and workshop equipment required
o

m
f

en
ng

t.
yi
♦ Universal dial gauge bracket - VW 387-
Co
Cop py
ht. rig
♦ Dial gauge rig ht
py by
co Vo
by lksw
Test sequence cted agen
Prote AG.

Perform measurements with support elements and roller rocker

fingers removed.
Middle bearing cap of respective camshaft installed.

2. Repairing valve gear 73

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Wear limit: max. 0.10 mm

Fitting position of camshaft bearingagcaps
en AG. V
olkswagen AG
do w es n
olks o
Point of bearing cap -arrow d bA- of inlet and outlet camshafts face
yV t gu
ara
outwards. rise nte
ho e t or
au ac
Identification on bearing
ss caps is right side up when viewed from
inlet side.

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f i
Valve dimensions

nform
mer

atio
om

n
Note
c

i
or

n thi
te

sd
a

Do not rework valves. Only lapping-in is permitted.

iv

o
pr

cum
r
fo

en
ng

t.
Dimensions of inlet valves
yi Co
Cop py
t. rig
gh
Dimension Short inlet valve Long inlet valve
ht
pyri by
Vo
o
by c lksw
∅a mm cted
31.00 31.00
agen
Prote AG.

∅b mm 5.96 5.96
c mm 102.20 136.10
α ∠° 45 45
Dimensions of exhaust valves
Dimension Short exhaust valve Long exhaust
valve
∅a mm 27.00 27.00
∅b mm 5.94 5.94
c mm 102.50 136.40
α ∠° 45 45

74 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Camshaft identification
Identification between cam pair for cylinders 4 and 5 of respective
camshaft.
Camshaft Identification
A - Exhaust camshaft 022 101 Index
B - Inlet camshaft 022 102 Index
Valve timing at 1 mm valve lift
Inlet valve Exhaust valve
Opens BTDC --- 211.5°
Closes BTDC --- 6.5°
Opens ATDC 18.5° ---
Closes ATDC 223.5° ---

Dismantling and assembling valve timing housing

n AG. Volkswagen AG do
1 - Guide rail: clipped into timing housing lkswage es n
o ot g
yV ua
2 - Valve timing housing ir se
d b ran
tee
tho
or
3 - Valve -1- for inlet camshaft control -N205- au ac
ss

ce
e

4 - Valve -1- for exhaust camshaft control -N318-

nl

pt
du

an
itte

5 - 8 Nm

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
Checking valve timing housing strainer for soiling
– Unclip strainer -2- from back of valve timing housing -1- and
remove any dirt.

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

2.1 Reworking valve seats

t.
yi Co
Cop py
t. rig
gh
Special tools and workshop equipment required
ht
pyri by
Vo
co lksw
by
♦ Depth gauge
cted agen
Prote AG.

♦ Valve seat refacing tool

2. Repairing valve gear 75

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Procedure

Note

♦ When repairing engines with leaking valves, it is not sufficient

to rework or renew valve seats and valves. Particularly on high
mileage engines, it is necessary also to check valve guides for
wear ⇒ page 88 .
♦ Valve seats are only to be reworked to the extent required
en AG. V
oto
lkswagen AG
yield a proper surface appearance. Before beginning ksw to rework
ag does
not
Vol
valve seats, calculate the maximum permissible
ed
by reworking di‐ gu
ara
mensions. If the reworking dimensionhoisrisexceeded, the hy‐ nte
eo
draulic valve clearance compensation aut can no longer be ra
guaranteed and the cylinder headsmust be renewed.
s c

ce
le
un

pt
an
d
itte

– Remove camshafts ⇒ page 77 .

y li
erm

ab
ility
The max. permissible reworking dimension is calculated as fol‐
ot p

lows:

wit
is n

h re
ole,

– Insert valve and press firmly against seat.

spec
urposes, in part or in wh

t to the co
Note

rrectne
If the valve is to be renewed as part of a repair, use a new valve
for the calculation.

ss o
– Measure distance -a- between end of valve stem and upper
cial p

f in
edge of cylinder head.

form
mer

atio
– Calculate maximum permissible reworking dimension from
om

measured distance -a- and minimum dimension

n
c

i
or

n thi
e

Minimum dimension:
t

sd
iva

o
pr

cum
r

Short inlet valve mm 31.8

fo

en
ng

t.
yi
Long inlet valve mm 10.2
Co
Cop py
t. rig
Short exhaust valve mm 31.8
gh ht
pyri by
Vo
co
Long exhaust valve mm 10.2
by lksw
cted agen
Prote AG.

Measured distance minus minimum dimension = max. permissi‐

ble reworking dimension.
Example:
Measured distance 10.6 mm
— Minimum dimension 10.2 mm
= Max. permissible reworking dimension 0.4 mm

76 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Reworking inlet valve seat

a - = 30.6 mm diameter
b - = max. permissible reworking dimension
c - = 0.9…1.5 mm
d - = max. ∅ 35.0 mm
r2 - = radius 2.0 mm
Z - = bottom surface of cylinder head
α - 45° valve seat angle
β - 30° upper correction angle
γ - 60° lower correction angle

Reworking exhaust valve seat

a - = 26.7 mm diameter
b - = max. permissible reworking dimension
c - = 1.2…1.7 mm
d - = max. ∅ 29.0 mm
r2 - = radius 2.0 mm
Z - = bottom surface of cylinder head
α - 45° valve seat angle
β - 30° upper correction angle
γ - 60° lower correction angle

2.2 Removing and installing Vcamshafts

olkswa AG. gen AG
agen does
olksw not
yV gu
db ara
rise nte
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
urposes, in part or in wh

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.

2. Repairing valve gear 77

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Special tools and workshop

equipment required

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

or

♦ Camshaft bar -T10068 A-

m
m

atio
om

♦ Torque wrench (5…50 Nm) -V.A.G 1331-

n in
or c

thi
e

♦ Torque wrench (40…200 Nm) -V.A.G 1332-

t

sd
iva

o
r
rp

cu

♦ Sealant - D 176 501 A1-

o

m
f

en
ng

t.
yi
(With cylinder head installed)
Co
Cop py
t. rig
gh
Removing
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
WARNING

Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.

78 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– First check whether a coded radio is fitted. If so, obtain anti-

theft coding.
– With ignition switched off, disconnect battery earth strap.
– All cable ties which were opened or cut during removal must
be renewed at the same points.
– Remove intake manifold ⇒ page 38 .
– Pull 2-pin connector off coolant temperature sender -G62-
-arrow-.
– Drain coolant ⇒ page 107 .
– Now remove thermostat housing ⇒ page 103 Parts of cooling
system - engine side.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
– Set crankshaft to TDC No. 1 cylinder marks -arrow- by turning

ce
e
nl

crankshaft on the vibration damper securing bolt in direction

pt
du

an
of engine rotation:
itte

y li
erm

ab
– Remove cylinder head cover ⇒ page 38 .

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 chain tensioner for camshaft timing chain -arrow-.

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.

2. Repairing valve gear 79

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Mark camshaft timing chain before removing (e.g. with paint,

arrow pointing in direction of rotation).

Note

Do not mark chain by way of centre punch, notch or the like.

– Disconnect connectors from the following components of cov‐

er:
♦ Valve -1- for inlet camshaft control -N205-
♦ Valve -1- for exhaust camshaft control -N318-
♦ Hall sender -G40-
♦ Hall sender 2 -G163-

Note

Before removing connectors, mark each connector and compo‐

nent to which it belongs.

– Move wiring harness clear.

– Now unscrew camshaft cover.
– First remove exhaust camshaft adjuster.
gen AG
. Volkswagen AG
d a oes
lksw not
– Remove camshaft adjuster db
ytogether
Vo with camshaft timing gu
ara
chain from intake camshaft.
or
ise nte
eo
th
au ra
c
ss
ce
le
un

pt

Note
an
d
itte

y li
erm

ab

Only counterhold camshaft with 32 mm open-end spanner

ility
ot p

-arrow-. The camshaft bar -T10068 A- must not be in place when

wit
is n

tightening or loosening the camshaft adjusters.

h re
ole,

spec
urposes, in part or in wh

– Lay camshaft timing chain aside.

t to the co
rrectness

– Unbolt control housing from cylinder head -arrows-.

o
cial p

f inform

– Pull valve timing housing carefully off camshaft seals.

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.

80 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

A - Inlet camshaft
– First remove bearing caps 1 and 13.
– Remove bearing caps 3 and 11.
– Remove bearing cap 7.
– Loosen bearing caps 5 and 9 alternately and diagonally.

B - Exhaust camshaft
– First remove bearing caps 2 and 14. AG. Volkswagen AG d
agen oes
lksw not
– Remove bearing caps 4 and 12. by Vo gu
ara
d
ise nte
– Remove bearing cap 8. uthor eo
ra
s a c
– Loosen bearing caps 6 and 10 alternately and diagonally. s

ce
le
un

pt
– Carefully remove camshafts and lay aside on clean surface.

an
d
itte

y li
erm

ab
– Remove roller rocker fingers together with support elements

ility
ot p

and lay aside on a clean surface.

wit
is n

h re
– Ensure that roller rocker fingers and support elements are not
ole,

spec
interchanged.
urposes, in part or in wh

t to the co
Installing:
Conditions

rrectne
• When camshafts are installed, cams for No. 1 cylinder must
point upwards.

ss
• The pistons cannot be positioned at TDC.

o
cial p

f inform
– Install supporting elements in cylinder head and fit respective
mer

roller rocker finger onto respective valve stem end or support‐

atio
m

ing element.
o

n
c

i
or

n thi
e

– Ensure that all roller rocker fingers -1- seat properly on valve
t

sd
iva

o
stem ends and are clipped into their respective support ele‐
pr

cum
r
fo

ments -2-. en
ng

t.
yi Co
op
– Oil running surfaces of camshafts. C py
t. rig
gh ht
yri by
– Carefully place each camshaft in its respective bearing in the cop Vo
by lksw
cylinder head. When doing this, observe camshaft identifica‐ cted agen
Prote AG.
tion ⇒ page 75 .

2. Repairing valve gear 81

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

AG. Volkswagen AG d
Note
lksw
agen oes
not
Vo gu
d by ara
e
♦ Observe fittingthposition
oris of bearing caps: nte
eo
au ra
♦ Point of bearing
ss cap -arrow A- of inlet and outlet camshafts c
face outwards.

ce
le
un

pt
an
d
itte

♦ Identification on bearing caps is right side up when viewed

y li
rm

ab
from inlet side.
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

A - Inlet camshaft
m

a
com

t
– Tighten bearing caps 5 and 9 alternately and diagonally to

ion in
5 Nm + 1/8 turn (45°).
r
te o

thi
s
iva

– Install bearing caps 1 and 13 and tighten to 5 Nm + 1/8 turn do

r
rp

(45°).
um
fo

en
ng

t.
yi
– Install bearing cap 7 and tighten to 5 Nm and turn 1/8 (45°)
Co
op py
further. t. C rig
gh ht
pyri by
– Install bearing caps 3 and 11 and also tighten to 5 Nm + 1/8
o Vo
by c lksw
cted
turn (45°).
agen
Prote AG.

B - Exhaust camshaft
– Tighten bearing caps 6 and 10 alternately and diagonally to 5
Nm and 1/8 turn (45°) further.
– Install bearing caps 2 and 14 and tighten to 5 Nm and 1/8 turn
(45°).
– Install bearing cap 8 and tighten to 5 Nm and turn 1/8 (45°)
further.
– Install bearing caps 4 and 12 and also tighten to 5 Nm + 1/8
turn (45°).
– Position camshafts in cylinder head to TDC No. 1 cylinder.

– Camshaft bar -T10068 A- must engage in grooves in both

shafts.
– Before installing, check valve timing housing strainer for soil‐
ing ⇒ page 75 , ⇒ page 75 .
– Before installing valve timing housing, lightly lubricate valve
timing housing surfaces contacting camshaft seals.
– Lightly lubricate contact surfaces of camshaft seals and slowly
push valve timing housing over camshaft seals.

82 Rep. gr.15 - Cylinder head, valve gear

 AG. Volkswagen AG d
lksw
agen oes
not Sharan 1996 ➤
o
6-cylinder
d by
V
injection engine (4-valve), gu mechanics
ara - Edition 06.2019
ise nte
or eo
h
– Install control housing aut
-arrows- and tighten to 8 Nm. ra
ss c

ce
le
– Install camshaft adjuster ⇒ page 50 .

un

pt
an
d
itte
– Install cylinder head cover and intake manifold ⇒ page 38 .

y li
rm

ab
pe

ility
– Check variable valve timing ⇒ page 83 .
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

2.3 Checking variable valve timing

Function

nform
ercia

The timing of the camshafts is controlled according to the engine

m

a
com

ti
load and engine speed. The electric camshaft control valves

on in
switches oil pressure to the camshaft adjusters (mechanical ad‐
r
te o

thi
justers), which then adjusts the camshafts.

s
iva

do
r
rp

c
Special tools and workshop equipment required

um
fo

en
ng

t.
yi
♦ -V.A.G 1551- Fault reader
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

♦ -V.A.G 1551/3- Cable

Note

Vehicle system tester -V.A.G 1551- can be used instead of fault

reader -V.A.G 1552- , however a print-out is not possible.

2. Repairing valve gear 83

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Test conditions
• Fuses must be OK.
• Battery voltage must be at least 11.5 V.
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
• Engine oil level OK, checking ⇒ page 94 .
• No fault may be stored in fault memory: ⇒ Rep. Gr. 01; Fault
memory; Reading and erasing engine control unit fault mem‐
ory
• Coolant temperature must be 80…95°C, ⇒ display group 01,
display zone 2 AG. Volkswagen
n AG do
wage es n
Checking activation Volks ot g
by ua
ed ran
– First check activation of inlet camshaft control
thoris valve 1 -1- - tee
or
N205- and exhaust camshaft control svalve
au 1 -1- -N318- via ac
final control diagnosis: ⇒ Rep. Gr. 01; Final control diagnosis;
s

ce
e
nl

Performing final control diagnosis

pt
du

an
itte

y li
If activation is OK:
erm

ab
ility
ot p

– Check position of camshafts to crankshaft ⇒ page 84 .

wit
, is n

h re
Test sequence
hole

spec
– Connect fault reader -V.A.G 1551- (V.A.G 1552). Start engine
es, in part or in w

t to the co
and select “Address word” 01 of engine control unit. Connect
fault reader and select engine control unit: ⇒ Rep. Gr. 01;
General notes for self-diagnosis: Connecting fault reader

rrectness of i
V.A.G 1551 and selecting engine electronics control unit .
l purpos

Indicated on display:
Rapid data transfer HELP

nform
ercia

Select function XX
m

at
– Press keys 0 and 4 for function “Initiate basic settings” and
om

io
confirm entry with Q key. n
c

in t
or

his
te

Indicated on display:
a

do
priv

cum
for

Basic setting
en
ng

t.
Enter display group number XXX yi Co
Cop py
t. rig
– Press buttons 0 , 0 and 1 for “Display group number 1” and gh ht
yri by
confirm entry with Q button.
cop Vo
by lksw
cted agen
Prote AG.
Indicated on display: (1…4 = display zones)
System in basic setting 1 ->
1 2 3 4

Only continue with the test when:

• Coolant temperature is 80…95°C, -display zone 2-
Checking position of camshafts to crankshaft
– Change to display group 208 as follows:
– Press the C button.
Indicated on display:
Basic setting
Enter display group number XXX

– Press buttons 2 , 0 and 8 for “Display group number 208” and

confirm entry with Q button.

84 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Indicated on display: (1…4 = display zones)

System in basic setting 208 ->
1 2 3 4

– Depress brake pedal and hold.

– Depress accelerator to full throttle position. Engine revolutions
are raised by engine control unit to approx. 2300 rpm.

Display zones
1 2 3 4
Display group 208: Position of inlet camshaft to crankshaft
Display xxxx rpm xxx (° CA) xxx (° CA) xxxxxxxx
Display Speed Detected 1st phase Adapted offset State
shows flank
Speci‐ approx. 2300 rpm 106…146 (° CA) -20…20 (° CA) xxxxx100
fied val‐
ue

If specifications are not met:

– Press → button.
– Read fault memory: ⇒ Rep. Gr. 01; Fault memory; Reading
nAG. Volkswagen AG d
and erasing engine control unit fault memory
lkswage oes
not
Vo y gu
db ara
– Read readiness code: ⇒ Rep. Gr. 01;risReadiness code; Read‐
e nte
ing readiness code utho eo
ra
a c
ss
– If the fault memory has been cleared or the engine control unit

ce
le
un

pt
was separated from the continuous positive supply, the read‐

an
d
itte

iness code must be regenerated: ⇒ Rep. Gr. 01; Readiness

y li
rm

ab
code; Generating readiness code
pe

ility
ot

If no fault is stored in the fault memory:

wit
, is n

h re
hole

– Press buttons 0 and 6 for function “End output” and confirm

entry with Q button. spec
es, in part or in w

t to the co

– Switch off ignition.

– Check valve timing ⇒ page 47
rrectness of i

If the specifications are obtained:

l purpos

– Change to display group 209 as follows: -V.A.G 1551- : Press

key 3 -V.A.G 1552- : Press key ↑
nform
ercia

Indicated on display: (1…4 = display zones)

m

System in basic setting 209 ->

com

tio

1 2 3 4
n in
r
te o

thi

– Depress brake pedal and hold.

s
iva

do
r

– Depress accelerator to full throttle position. Engine revolutions

rp

cum
fo

are raised by engine control unit to approx. 2300 rpm.

en
ng

t.
yi Co
op py
Display zones
t. C rig
gh ht
yri by
1 2 3 4
cop Vo
by lksw
cted agen
Display group 209: Position of exhaust camshaft to crankshaft
Prote AG.

Display xxxx rpm xxx (° CA) xxx (° CA) xxxxxxxx

Display Speed Detected 1st phase Adapted offset State
shows flank
Speci‐ approx. 2300 rpm 106…146 (° CA) -20…20 (° CA) xxxxx100
fied val‐
ue

2. Repairing valve gear 85

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

If specifications are not met:

– Press → button.
– Read fault memory: ⇒ Rep. Gr. 01; Fault memory; Reading
and erasing engine control unit fault memory
– Read readiness code: ⇒ Rep. Gr. 01; Readiness code; Read‐
ing readiness code
. Volkswage
– If the fault memory has been cleared or thekengine
swa
gen Acontrol
G
unit n AG does n
was separated from the continuous positive
yV
ol
supply, the read‐ ot g
ua
db
iness code must be regenerated: ⇒ris Rep. Gr. 01; Readiness
e ran
tee
code; Generating readiness code au
tho
or
a
ss c
If no fault is stored in the fault memory:

ce
e
nl

pt
du

an
– Press buttons 0 and 6 for function “End output” and confirm
itte

y li
entry with Q button.
erm

ab
ility
ot p

– Switch off ignition.

wit
, is n

h re
– Check valve timing ⇒ page 47
hole

spec
es, in part or in w

If the specifications are obtained:

t to the co
– Check camshaft adjustment.
Checking variable valve timing

rrectness of i
– Change to display group 210 as follows: -V.A.G 1551- : Press
l purpos

key 3 -V.A.G 1552- : Press key ↑

nf
Indicated on display: (1…4 = display zones)
ercia

o
System in basic setting 210 ->

rm
1 2 3 4
m

atio
m

– Depress brake pedal and hold.

o

n in
or c

thi
e

– Depress accelerator to full throttle position. Engine revolutions

t

sd
iva

are raised by engine control unit to approx. 2300 rpm.

o
r
rp

cu
o

m
f

en
ng

Display zones
t.
yi Co
op py
1 2 3 4
t. C rig
gh ht
yri by
Display group 210: Adjustment of inlet camshaft
op Vo
by c lksw
cted agen
Prote
Display xxx.x° CA xxx.x° CA x xxxxxxxx
AG.

Display Specified angle Actual angle Fine adaptation State

shows
Speci‐ 0.0° CA -4.0…4.0° CA 0 xxxxx100
fied val‐
ue

Note

♦ The display values increase to approx. 52.0° CA and then drop

back to the specified value.
♦ Specified value “xxxxx100” in display zone 4 is only displayed
after approx. 40 seconds.

If specifications are not met:

– Press → button.
– Read fault memory: ⇒ Rep. Gr. 01; Fault memory; Reading
and erasing engine control unit fault memory

86 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Read readiness code: ⇒ Rep. Gr. 01; Readiness code; Read‐

ing readiness code
– If the fault memory has been cleared or the engine control unit
was separated from the continuous positive supply, the read‐
iness code must be regenerated: ⇒ Rep. Gr. 01; Readiness
code; Generating readiness code
If no fault is stored in the fault memory:
– Press buttons 0 and 6 for function “End output” and confirm
entry with Q button.
– Switch off ignition.
– Check Hall sender ( -G40- and G163) (connectors may be in‐
terchanged): ⇒ Rep. Gr. 28; Repairing ignition system; Check‐
ing Hall sender
– Check oil pressure ⇒ page 98 , checking oil pressure and oil
pressure switch.
If no fault is detected:
– Renew inlet camshaft adjuster ⇒ page 50 .
If the specifications are obtained:
– Change to display group 211 as follows:
n AG.-V.A.G
Volkswag1551-
en AG : Press
key 3 -V.A.G 1552- : Press key
lkswage
↑ does
not
o
yV gu
db ara
Indicated on display: (1…4
or = display zones)
ise nte System in basic setting 211 ->
eo1 2 3 4
th
au ra
c
ss
– Depress brake pedal and hold.
ce
le
un

pt
an
d
itte

– Depress accelerator to full throttle position. Engine revolutions

y li
rm

ab
are raised by engine control unit to approx. 2300 rpm.
pe

ility
ot

wit

Display zones
, is n

h re
hole

1 2 3 4
spec
es, in part or in w

Display group 211: Adjustment of exhaust camshaft

t to the co

Display xxx.x° CA xxx.x° CA x xxxxxxxx

Display Specified angle Actual angle Fine adaptation State
rrectness of i

shows
Speci‐
l purpos

0.0° CA -5.0…5.0° CA 0 xxxxx100

fied val‐
ue
nform
mercia

a
com

tion in
r
te o

thi

Note
s
iva

do
r
rp

cum
fo

♦ The display values increase to approx. 22.0° CA and then drop

en
ng

t.
yi
back to the specified value.
Co
Cop py
t. rig
gh
♦ Specified value “xxxxx100” in display zone 4 is only displayed
ht
pyri by
after approx. 40 seconds.
co Vo
by lksw
cted agen
Prote AG.

If specifications are not met:

– Press → button.
– Read fault memory: ⇒ Rep. Gr. 01; Fault memory; Reading
and erasing engine control unit fault memory
– Read readiness code: ⇒ Rep. Gr. 01; Readiness code; Read‐
ing readiness code
– If the fault memory has been cleared or the engine control unit
was separated from the continuous positive supply, the read‐

2. Repairing valve gear 87

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

iness code must be regenerated: ⇒ Rep. Gr. 01; Readiness

code; Generating readiness code
If no fault is stored in the fault memory:
– Press buttons 0 and 6 for function “End output” and confirm
entry with Q button.
– Switch off ignition.
– Check Hall sender ( -G40- and G163) (connectors may be in‐
terchanged): ⇒ Rep. Gr. 28; Repairing ignition system; Check‐
ing Hall sender
– Check oil pressure ⇒ page 98 , checking oil pressure and oil
pressure switch.
If no fault is detected:
– Renew exhaust camshaft adjuster ⇒ page 50 .
If the specifications are obtained:
– Press buttons 0 and 6 for function “End output” and confirm
entry with Q button.
AG. Volkswagen AG d
agen oes
– Switch off ignition. Volksw not
gu
d by ara
2.4 Checking valve guides ise nte
or eo
h
aut ra
s c
Special tools and workshop equipment required s

ce
e
nl

pt
du

♦ Universal dial gauge bracket - VW 387-

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

♦ Dial gauge
rm
m

atio
m

Test sequence
o

n in
or c

thi

– Insert new valve into guide. The end of the valve stem must
te

sd
a

be flush with the guide. Due to slight differences in stem di‐

iv

o
r
rp

cu

ameters, use only an inlet valve in inlet guide and an exhaust

o

m
f

en
ng

valve in exhaust guide.

t.
yi Co
op py
– Determine rock. Wear limit: 0.8 mm
t. C rig
gh ht
pyri by
Vo
If the amount of sideways play is exceeded:
o
by c lksw
cted agen
Prote AG.
– Renew cylinder head.

2.5 Renewing valve stem seals

(With cylinder head installed)

88 Rep. gr.15 - Cylinder head, valve gear

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Special tools and workshop

equipment required

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
urposes, in part or in wh

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.

♦ Assembly tool 2036 with adapter plates 2036/1

♦ Spark plug spanner 3122B
♦ Puller 3364
♦ Fitting tool 3365
♦ Assembly lever -VW 541/1A- with thrust piece -VW 541/6-
♦ Pressure hose -VW 653/3-
♦ Torque wrench (5…50 Nm) -V.A.G 1331-

2. Repairing valve gear 89

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Removing
– Remove camshafts ⇒ page 77 .
– Remove roller rocker fingers together with support elements
and lay aside on a clean surface.
– Remove spark plugs with spark plug spanner 3122B.
– Set piston of respective cylinder to “bottom dead centre”.
– Insert valve assembly device 2036 with adapter plates 2036/1
and adjust mountings.
– Screw compressed air hose -VW 653/3- into spark plug thread
and apply a continuous pressure. At least 6 bar pressure.
– Remove valve springs with assembly lever -VW 541/1A- and
thrust piece -VW 541/6- .

Note

Tight valve cotters can be loosened by tapping lightly on assem‐

bly lever.

– Pull off valve stem oil seals with puller 3364.

Installing

– To prevent damage to new valve stem seals, place plastic

sleeve -A- on valve stem.
– Oil sealing lip of valve stem seal -B-, place it in valve stem seal
fitting tool 3365 and push carefully onto valve guide.
– Install camshafts ⇒ page 77 .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by

90
op Vo
by c lksw
Rep. gr.15 - Cylinder head, valve gear Prote
cted AG.
agen
 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

17 – Lubrication
1 Removing and installing parts of lu‐
brication system

Note

♦ If when repairing an engine, metal shavings or large quantities

of small metal particles caused, for example, by partial seizure
of crankshaft and conrod bearings are found in the engine oil,
one must apart from thoroughly cleaning oil passages, renew
all oil spray jets, the oil non-return valve, the oil cooler and oil
filter element to prevent consequential damage.
♦ The oil level must remain below the max. mark - danger of
damage to catalytic converter! Markings ⇒ page 94 .

Dismantling and assembling oil filter bracket ⇒ page 94 .

Dismantling and assembling oil pump ⇒ page 96 .
Checking oil pressure and oil pressure switch ⇒ page 98

1.1 Engine oil:

Oil capacities
With oil filter 5.5 l
4) Up-to-date figures: ⇒ Data sheets for exhaust emissions test n AG. Volkswagen AG do
lkswage es n
o ot g
Engine oil specifications with long-life service d byV ua
ran
ir se tee
o
New VW standard (specially developed, ageing resistant)
auth initial or
ac
filling: VW standard 503 00 (VW TL 52 173). ss

ce
le
un

pt
an
d
itte

y li
Note
rm

ab
pe

ility
ot

♦ The engine is filled at the factory with engine oil conforming to

wit
, is n

VW standard 503 00. This engine oil is designed for long

h re
hole

maintenance intervals. However, the engine oils listed below

spec
can also be used.
es, in part or in w

t to the co
♦ Engine oils conforming to VW standard 500 00, 501 01 or
502 00 can be used furthermore. The oil must then be changed
every 12 months or every 15,000 km and the service interval
rrectness of i

display must be programmed accordingly. Procedure: ⇒ Main‐

l purpos

tenance ; Booklet 10.1 .

1.2 Assembly overview - sump

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

1. Removing and installing parts of lubrication system 91

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

1 - 8 Nm
❑ Secured to intake mani‐
fold.
2 - Dipstick AG. Volkswagen AG d
agen oes
ksw
❑ The oil level must by Vnot be
ol not
gu
ara
above the max.
ris mark!
ed
nte
o
th page 94 . eo
❑ Markingsau⇒ ra
c
ss
3 - Guide tube

ce
le
un

pt
an
d

❑ For dipstick
itte

y li
erm

ab
❑ Secured with bolt to in‐

ility
ot p

take manifold.

wit
is n

h re
4 - Cylinder block
ole,

spec
❑ Removing and installing
urposes, in part or in wh

sealing flange and dual-

t to the co
mass flywheel
⇒ page 20 .

rrectne
❑ Removing and installing
crankshaft ⇒ page 31 .

s
❑ Dismantling and assem‐

s o
bling pistons and con‐
cial p

f in
rods ⇒ page 26 .

form
mer

5 - Oil non-return valve, 6 Nm

atio
om

n
❑ Observe installation po‐
c

i
or

sition
thi
te

sd
va

❑ Clean if badly soiled

i

o
pr

cum
r
fo

❑ Observe notes
en
ng

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

92 Rep. gr.17 - Lubrication

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

⇒ page 91
6 - 10 Nm
7 - Oil pump drive cover
8 - O-ring
❑ Renew
❑ Lubricate before assembling.
9 - Oil pump drive
10 - Intermediate shaft
11 - Thrust washer
12 - 8 Nm
❑ Apply locking fluid “D 000 600AA2” when installing
G. Volkswagen n AG do
wage es n
13 - Input shaft olks ot g
yV ua
db ran
❑ For oil pump drive.
or
ise
tee
h
ut or
14 - Oil spray jetss a ac

ce
le

❑ For crankshaft bearings 2 to 7

un

pt
an
d
itte

❑ For piston cooling

y li
rm

ab
❑ Opening pressure: 2.0 bar
pe

ility
ot

wit
❑ Removing and installing ⇒ page 94
, is n

h re
❑ Observe notes ⇒ page 91
hole

spec
es, in part or in w

15 - Oil pump

t to the co
❑ Dismantling and assembling ⇒ page 96
❑ Coat oil pressure pipe with sealant - D 176 501 A1- at cylinder block and oil pump housing.
rrectness of i
16 - 23 Nm
l purpos

17 - 8 Nm
❑ Apply locking fluid “D 000 600 A2” when installing
nform
ercia

18 - Oil drain plug, 30 Nm

m

a
com

ti

❑ Renew plug with attached seal.

on in
r
te o

thi

19 - Sump
s
iva

do

❑ Clean sealing surface before fitting.

r
rp

cum
fo

❑ Insert with silicon sealant “D 176 404 A2”

en
ng

t.
yi Co
op
❑ Removing and installing ⇒ page 97 C py
ht. rig
rig ht
by
20 - Oil level and oil temperature sender - G266- copy Vo
by lksw
cted agen
❑ Black connector, 3-pin. Prote AG.

❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
21 - Seal
❑ Renew
❑ Lubricate before assembling.
22 - 12 Nm
23 - Oil filter housing
❑ Dismantling and assembling ⇒ page 94
❑ Coolant hose schematic diagram ⇒ page 105 .

1. Removing and installing parts of lubrication system 93

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Removing and installing oil spray jet

Special tools and workshop equipment required

♦ Drift ∅ 4 mm
♦ Drift ∅ 6 mm

Note

Oil spray jets are installed in main bearings 2 to 7.

Condition
• Crankshaft removed
Removing
– Press oil spray jet out towards bearing using a 4 mm ∅ drift.
Installing
– To install, press oil spray jet in by hand using a 6 mm ∅ drift
-arrow-.
G. Volkswagen AG d
Markings on oil dipstick lkswagen A oes
not
o
yV gu
1 - Max. mark isedb ara
nte
r
tho eo
2 - Min. mark s au ra
c
s
ce

a - Area above hatched field up to max. mark: Do not top up with

e
nl

pt
du

engine oil!
an
itte

y li
erm

ab

b - Oil level within hatched field: Can be topped up with engine

ility
ot p

oil.
wit
, is n

h re

c - Area from min. mark up to hatched field: top up, max. 0.5 l of
hole

spec

engine oil!
es, in part or in w

t to the co

1.3 Dismantling and assembling oil filter housing

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.

94 Rep. gr.17 - Lubrication

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

1 - Plug, 15 Nm
❑ If seal is leaking, nip
open and renew.
2 - 1.4 bar oil pressure switch -
F1- , 20 Nm
❑ Identification: black
❑ If seal is leaking, nip
open and renew.
❑ Checking ⇒ page 98
3 - Oil filter housing
❑ With non-return valve
opening pressure: 0.05
bar.
4 - O-ring
❑ Renew
n AG. Volkswagen AG do
❑ Lubricate before as‐ lkswage es n
o ot g
sembling. byV ua
d ran
ir se tee
o
5 - Oil cooler auth or
ac
ss
❑ Ensure clearance to ad‐

ce
le

jacent components
un

pt
an
d
itte

❑ Coat contact surfaces

y li
rm

ab
outside the seal with
pe

ility
sealant - D 176 501 A1- .
ot

wit
, is n

❑ Observe notes

h re
hole

⇒ page 91

spec
es, in part or in w

❑ Coolant hose schematic

t to the co
diagram ⇒ page 105 .
6 - Seal

rrectness of i
❑ Renew
l purpos

❑ Lubricate before as‐

sembling. nform
ercia

7 - Oil cooler cover, 25 Nm

m

8 - O-ring
com

tion in

❑ Insert in oil cooler before installing

r
te o

thi

❑ Renew
s
iva

do
r
rp

❑ Lubricate before assembling.

um
fo

en
ng

t.
yi
9 - 23 Nm
Co
Cop py
t. rig
10 - Oil filter element
gh ht
pyri by
Vo
co
❑ Observe change intervals.
by lksw
cted agen
Prote AG.
❑ Observe notes ⇒ page 91
11 - Oil filter lower part, 25 Nm
❑ Drain before removing.
❑ With by-pass valve, opening pressure: 2.50 bar
12 - Oil drain plug, 10 Nm

1. Removing and installing parts of lubrication system 95

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

1.4 Dismantling and assembling oil pump

1 - Input shaft
❑ For oil pump drive.
2 - Oil pump housing
3 - 23 Nm
4 - Gear wheels
❑ Checking backlash
⇒ page 96 .
❑ Checking axial clear‐
ance ⇒ page 97 .
5 - Oil pump cover with pres‐
sure relief valve
❑ Opening pressure: 5.3
to 5.7 bar
❑ Clean strainer if soiled
6 - 8 Nm
❑ Apply locking fluid “D
000 600 A2” when in‐
stalling
7 - Oil pressure pipe
❑ Coat with sealant - D
176 501 A1- at cylinder
block and oil pump
housing.
8 - 8 Nm
9 - Seal
❑ Renew if damaged
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

Checking oil pump backlash

ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio

Special tools and workshop equipment required

om

n
c

i
or

♦ Feeler gauge
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
96
AG.
Rep. gr.17 - Lubrication
 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Wear limit: 0.20 mm

Checking oil pump axial clearance

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
Special tools and workshop equipment required
hole

spec
♦ Straight edge
es, in part or in w

t to the co
♦ Feeler gauge
Wear limit: 0.10 mm

rrectness of i
1.5 Removing and installing sump
l purpos

Special tools and workshop equipment required

nf
ercia

♦ Torque wrench (5…50 Nm) -V.A.G 1331-

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.

♦ Silicone sealant D 176 404 A2

♦ Hand drill with plastic brush attachment
♦ Safety glasses
♦ Scraper
Removing
– Remove noise insulation tray.
– Pull 3-pin connector off oil level and temperature sender -
G266- and unclip wire from sump.
– Unscrew bracket for secondary air pump motor - V101- on
sump and cylinder block ⇒ Item 14 (page 157) .
– Drain engine oil.

Note

Please observe disposal instructions!

– Remove sump.
– Loosen sump with light blows of a rubber headed hammer if
necessary.

1. Removing and installing parts of lubrication system 97

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Remove sealant residue from cylinder block with a flat scraper.

– Remove sealant residue on sump using a rotating brush, e.g.
an electric drill with a plastic brush attachment (wear safety
goggles).
– Clean sealing surfaces. They must be free of oil and grease.
Installing

Note

♦ Check the expiry date of the sealant.

♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.

– Cut off tube nozzle at forward marking (approx. 3 mm ∅ of

nozzle).
– Apply silicone sealing compound, as shown, to clean sealing
surface on sump. Sealant bead must be:
♦ 2…3 mm thick.
♦ Run bead along inner side of bolt holes -arrows-.

Note

The sealant bead must not be thicker, otherwise excess sealing

compound will enter the oil sump and may block the oil suction
line strainer.

– Apply silicon sealant -arrows-, as shown in illustration, to clean AG. Volkswagen AG d

agen
sealing surface of sump. Volksw
oes
not
y gu
db ara
– Install sump immediately and tighten all sump bolts lightly.
or
ise nte
eo
th
– Tighten oil sump bolts to 12 Nm. s au ra
c
s
ce
e
nl

– Tighten bolts securing sump to gearbox to 45 Nm. pt

du

an
itte

y li
– Tighten bracket for secondary air pump motor. Securing bolts
erm

ab
to sump: 10 Nm, securing bolt to cylinder block: 20 Nm
ility
ot p

wit
, is n

h re
hole

Note
spec
es, in part or in w

t to the co

Let sealing compound dry for approx. 30 minutes after installing

oil sump. Only then fill with engine oil.
rrectness of i

Further assembly is basically a reverse of the dismantling se‐

l purpos

quence.
nform
ercia

1.6 Checking oil pressure and oil pressure switch

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

98 Rep. gr.17 - Lubrication

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Special tools and workshop

equipment required

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
♦ Oil pressure tester - V.A.G 1342-
♦ Adapter - V.A.G 1342/14-
♦ Voltage tester - V.A.G 1527B- rrectness of i
l purpos

♦ Auxiliary measuring set - V.A.G 1594 A-

nform
ercia

Test conditions
m

• Engine oil level OK, checking ⇒ page 94 .

com

tion in

• Engine oil temperature at least 80°C (radiator fan must have

r
te o

thi

run at least once).

s
iva

do
r
rp

cum
fo

en
ng

t.
Note
yi Co
Cop py
t. rig
gh ht
yri
Functional check and repair of the optical and acoustic oil pres‐ p by
co Vo
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
by lksw
cted agen
Prote
Fitting locations
AG.

Checking oil pressure switch

– Remove noise insulation tray.
– Pull connectors off thermal switch and radiator fan.
– Remove front bumper: ⇒ Rep. gr. 63 ; Front bumper .

1. Removing and installing parts of lubrication system 99

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Bring lock carrier into service position: ⇒ Rep. gr. 50 ; Body,

front .
– Remove oil pressure switch -F1- and screw into tester.
– Screw tester -V.A.G 1342- into oil filter housing instead of oil
pressure switch using adapter -V.A.G 1342/14- .

Note

Observe installation position of adapter: the conical connecting

piece of the adapter must be screwed into the pressure hose of
the tester.

– Connect brown wire of tester to earth (-).

– Connect diode test lamp -V.A.G 1527 B- using auxiliary cables
from -V.A.G 1594 A- to battery positive (+) and oil pressure
switch. LED must not light up.
If the LED lights up:
– Renew oil pressure switch -F1- ⇒ Item 2 (page 95) .
If LED does not light up:
– Start engine and run at idling speed. At 1.2…1.6 bar the LED
must light up, otherwise renew oil pressure switch -F1-
⇒ Item 2 (page 95) .
Checking oil pressure AG. Volkswagen AG d
agen oes
lksw not
– Check oil pressurebyat V different revolutions:
o gu
ara
ed
is nte
At 1500 rpm: 1.7ut
hobar
r eo
a ra
s c
At 2000 rpm:s3.0…5.5 bar
ce
le
un

pt

If specifications are not met:

an
d
itte

y li
rm

ab

– Rectify mechanical damage, e.g. bearing damage.

pe

ility
ot

wit

At higher engine speeds, the oil pressure must remain at or below

, is n

h re

7.0 bar.
hole

spec

If the specification is exceeded:

es, in part or in w

t to the co

– Check the oil passages.

– Renew oil pump if necessary ⇒ page 96 , dismantling and as‐
rrectness of i

sembling oil pump.

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.

100 Rep. gr.17 - Lubrication

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

19 – Cooling
1 Removing and installing parts of cool‐
ing system

WARNING

Observe the following points during all installation work, in par‐

olkswagen AG
ticular in the engine compartment, due to the space wa en AG. V
glimitations: does
lks n o ot g
yV ua
♦ Route all the various lines (e.g. for rfuel,
ise hydraulics, acti‐
db ran
vated charcoal filter system, coolant, refrigerant, brake
o tee
th or
fluid and vacuum) and electrical au
ss wiring in their original po‐
ac
sitions.

ce
le
un

pt
an
d

♦ Ensure that there is sufficient clearance to all moving or

itte

y li
hot components.
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

Note

t to the co
♦ Cooling system is pressurised when engine is warm. If nec‐
essary, release pressure before carrying out repairs.

rrectne
♦ Hose connections are secured with spring-type clips. In case
of repair, only use spring-type clips.

ss o
♦ Hose clip pliers - VAS 5024- or hose clip pliers - V.A.G 1921-
cial p

f in
are recommended for installation of spring-type clips.

form
mer

♦ When installing coolant hoses, route stress-free so that they

atio
m

do not come into contact with other components (observe

o

n
c

i
or

n
markings on coolant connection and hose).

thi
te

sd
iva

o
pr

c
Test for leaks in cooling system using cooling system tester -
um
r
fo

en

V.A.G 1274 B- and adapters - V.A.G 1274/1 A- and -

ng

t.
yi Co
V.A.G 1274/7- . ht. Cop py
rig
rig ht
Parts of cooling system - body side ⇒ page 101 . py by
co Vo
by lksw
cted agen
Parts of cooling system - engine side ⇒ page 103 . Prote AG.

Coolant hose schematic diagram ⇒ page 105 .

Dismantling and assembling thermostat housing ⇒ page 105 .
Draining and filling with coolant ⇒ page 107 .
Coolant mixture ratios ⇒ page 107 , draining and filling with cool‐
ant.

1.1 Parts of cooling system, body side

1. Removing and installing parts of cooling system 101

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

1 - Rubber grommet
2 - Radiator
❑ Removing and installing
⇒ page 110
❑ After renewing, renew
entire coolant.
3 - 8 Nm
4 - Radiator fan thermal switch
- F18- , 35 Nm
❑ Switching tempera‐
tures: stage 1 on: 92…
97°C off: 84…91°C,
stage 2 on: 99…105°C
off: 91…98°C
5 - Connector
❑ Black, 3-pin
❑ For thermal switch for AG. Volkswagen AG d
radiator fan. agen oes
olksw not
byV gu
ara
d
6 - Rubber bush orise nte
h eo
ut ra
7 - Cowling ss a c

ce
le

8 - 9 Nm
un

pt
an
d
itte

y li
9 - Right radiator fan - V35-
erm

ab
ility
❑ With fan ring.
ot p

wit
is n

❑ Vehicles with optional

h re
ole,

equipment only

spec
urposes, in part or in wh

❑ Removing and installing

t to the co
⇒ page 110
10 - Bracket
rrectne

❑ For lower coolant hose.

11 - Radiator fan - V7-
ss o

❑ With fan ring.

cial p

f in

❑ Removing and installing ⇒ page 110

form
mer

atio

12 - Connector
om

n
c

❑ Black, 2-pin
i
or

n thi
te

❑ For radiator fan.

sd
iva

o
pr

cum
r

13 - Lower coolant hose

fo

en
ng

t.
yi
❑ Check for firm seating
Co
Cop py
. rig
❑ Coolant hose schematic diagram ⇒ page 105 .
ht ht
rig by
copy Vo
lksw
14 - Quick-release coupling
by
cted agen
Prote AG.
❑ With retaining clip.
❑ Check for firm seating
15 - O-ring
❑ Renew if damaged
16 - Upper coolant hose
❑ Ensure firm seating
❑ Coolant hose schematic diagram ⇒ page 105 .

102 Rep. gr.19 - Cooling

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

1.2 Parts of cooling system - engine side

1 - Connection
❑ On cylinder head.
2 - 8 Nm
3 - Earth cable
4 - Throttle valve control mod‐
ule
❑ Heated with coolant
5 - To heat exchanger
❑ Coolant hose schematic
diagram ⇒ page 105 .
6 - 10 Nm
7 - Expansion tank
n AG. Volkswagen AG do
❑ Test for leaks in cooling lkswage es n
system using cooling byV
o ot g
ua
ed
system testero-risV.A.G ran
tee
1274 B- and au adapter -
th or
ac
V.A.G 1274/7-
ss .

ce
le

❑ Observe markings
un

pt
an
d

⇒ page 107 Draining

itte

y li
and filling coolant
rm

ab
pe

ility
ot

8 - Cap
wit
, is n

❑ Note oil seal installation h re

hole

spec
position in sealing cap.
es, in part or in w

❑ Renew seal if damaged

t to the co

❑ Check using cooling

system tester - V.A.G
rrectness of i

1274 B- and adapters -

V.A.G 1274/1 A- and -
l purpos

V.A.G 1274/7- .
❑ Pressure relief valve
nform
ercia

must open at pressure

m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

1. Removing and installing parts of cooling system 103

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

of 1.4…1.6 bar
9 - Connector
❑ Black, 2-pin
❑ For low coolant indicator sender.
10 - From heat exchanger
❑ Coolant hose schematic diagram ⇒ page 105 .
11 - Bracket
❑ For continued coolant circulation pump
12 - Continued coolant circulation pump - V51-
AG. Volkswagen AG d
❑ Black 2-pin connector agen oes
olksw not
y V gu
❑ Checking ⇒ page 113 d b ara
rise nte
ho eo
13 - Upper coolant hose aut ra
c
ss
❑ To top of radiator

ce
e
nl

pt
❑ Check for firm seating du

an
itte

y li
❑ Coolant hose schematic diagram ⇒ page 105 .
erm

ab
ility
ot p

14 - Lower coolant hose

wit
, is n

h re
❑ From bottom of radiator.
hole

spec
❑ Check for firm seating
es, in part or in w

t to the co
❑ Coolant hose schematic diagram ⇒ page 105 .
15 - Thermostat housing

rrectness of i
❑ Dismantling and assembling ⇒ page 105
l purpos

16 - Seal
❑ Renew

nf
ercia

o
17 - Oil cooler

rm
m

atio
❑ Dismantling and assembling ⇒ page 94 , Dismantling and assembling oil filter housing.
om

n in
or c

18 - To cylinder block.

thi
te

sd
a

❑ Coolant hose schematic diagram ⇒ page 105 .

iv

o
r
rp

cu
o

m
19 - O-ring
f

en
ng

t.
yi Co
❑ Renew t. Cop py
rig
gh ht
yri
20 - Coolant pipe p by
co Vo
by lksw
cted agen
21 - Plug, 2 Nm Prote AG.

22 - Coolant pump
❑ Observe installation position
❑ Check for ease of movement.
❑ If damaged or leaking, renew complete.
❑ Removing and installing ⇒ page 114
23 - 20 Nm
24 - Pulley
❑ For coolant pump
❑ Removing and installing poly V-belt ⇒ page 18
25 - 20 Nm
❑ Use water pump spanner - V.A.G 1590- to loosen and tighten ⇒ page 114 , removing and installing
coolant pump

104 Rep. gr.19 - Cooling

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

1.3 Coolant hose schematic diagram

1 - Expansion tank agen

AG. Volkswagen AG d
oes
olksw not
V
2 - Gear oil cooler ed by gu
ara
ris nte
❑ Only on vehicles with ut
ho eo
ra
automatic gearbox. ss a c

ce
e
nl
3 - Upper coolant hose

pt
du

an
itte

y li
4 - Lower coolant hose erm

ab
ility
ot p

5 - Radiator

wit
, is n

h re
6 - Thermostat housing
hole

spec
7 - Oil cooler
es, in part or in w

t to the co
8 - Coolant pipe
9 - Coolant pump

rrectness of i
10 - Cylinder block
l purpos

11 - Cylinder head

nform
ercia

12 - Throttle valve control mod‐

ule
m

at
om

io
13 - Heat exchanger for heater

n
c

in t
or

his
e

14 - Additional heat exchanger

at

do
riv

❑ Vehicles with optional

p

cum
or

equipment only
f

en
ng

t.
yi Co
op
15 - Continued coolant circula‐
C py
t. rig
gh
tion pump - V51-
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1.4 Dismantling and assembling thermostat

housing

Note

Routing of coolant hoses on thermostat housing ⇒ page 103 ,

parts of cooling system - engine side.

1. Removing and installing parts of cooling system 105

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

1 - O-ring
❑ Renew if damaged
2 - Retaining clip
❑ Check for firm seating
3 - Thermostat housing
4 - 8 Nm
5 - Thermostat
❑ Observe installation po‐
sition
AG. Volkswagen AG d
❑ Checking: heat thermo‐ agen oes
olksw not
stat in water. byV gu
ara
ed
ris nte
❑ Begins to open at ap‐ uth o eo
ra
prox. 80°C ss a c

ce
le

❑ Ends at approx. 95°C

un

pt
an
d

❑ Opening travel at least 8

itte

y li
erm

mm

ab
ility
ot p

6 - Connection

wit
is n

h re
ole,

7 - Seal

spec
urposes, in part or in wh

❑ Renew

t to the co
8 - Radiator outlet coolant -
G62-

rrectne
❑ Black, 2-pin
❑ For engine control unit

ss
❑ Before removing, re‐

o
cial p

f
lease pressure in cool‐
ing system if necessary. inform
mer

atio

❑ Checking: ⇒ Rep. gr.

om

01 ; Reading and eras‐

n
c

i
or

ing engine control unit

thi
te

sd
a

fault memory .
iv

o
pr

cum
r
fo

9 - Plug
en
ng

t.
yi Co
❑ Before removing, release pressure in cooling system if necessary. . Cop py
rig
ht
❑ On vehicles with air conditioner: thermal switch for fan run-on - F87- . rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

106 Rep. gr.19 - Cooling

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

1.5 Draining and adding coolant

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
urposes, in part or in wh

t to the co

Special tools and workshop equipment required

rrectne

♦ Refractometer - T10007-
ss

♦ Drip tray - V.A.G 1306-

o
cial p

f inform

♦ Assembly tool for spring-type clips - VAS 5024-

mer

atio
m

Not illustrated:
o

n
c

i
or

♦ Cooling system charge unit - VAS 6096-

thi
te

sd
iva

Draining
pr

cum
r
fo

en
ng

– Remove engine cover panel.

t.
yi Co
Cop py
– Open cap on coolant expansion tank.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
WARNING
Prote AG.

Hot steam may escape when expansion tank is opened. Place

cloth over cap and open with caution.

1. Removing and installing parts of cooling system 107

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Remove noise insulation tray.

– Pull out retaining clip -arrow- for coolant hose and remove
coolant hose from quick-release coupling of radiator.

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.

108 Rep. gr.19 - Cooling

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– To drain coolant from engine, also remove coolant hose from

oil cooler -arrow-.

Note

Please observe disposal instructions!

Replenishing

Note

♦ In vehicles as of model year 2008, only G 12 plus-plus ac‐

cording to TL VW 774 G may be used as coolant additive.
♦ For vehicles up to and including model year 2007 coolant ad‐
ditive G 12 plus according to TL VW 774 F and G 12 plus-plus
according to TL VW 774 G can be used.
♦ The coolant additive G 12 plus-plus can be mixed with the
previous coolant additive G 12 plus. Identification: both are
coloured purple.
♦ Coolant additives marked “according to TL VW 774 G” or “ac‐
cording to TL VW 774 F” prevent frost and corrosion damage,
scaling and also raise boiling point of coolant. Therefore, the
cooling system must be filled all year round with coolant ad‐
ditive.
AG. Volkswagen AG d
agen oes
♦ Because of its high boiling point, the coolant improves
yV
olksengine
w not
gu
reliability under heavy loads, particularly in countries
ed
b with trop‐ ara
nte
ical climates. oris eo
th u ra
sa c
♦ The frost protection must be guaranteeds to approx. -25°C. In

ce
e

countries with an artic climate, to approx. -35 °C.

nl

pt
du

an
itte

♦ Do not reduce the coolant concentration by adding water even

y li
erm

ab
in warmer seasons and in warmer countries. The coolant ad‐

ility
ot p

ditive concentration must be at least 40%.

wit
, is n

h re
♦ If for climatic reasons greater frost protection is required, the
hole

spec
amount of coolant additive can be increased, but only up to
es, in part or in w

60% (frost protection to about -40°C). Otherwise frost protec‐

t to the co
tion and cooling effectiveness are reduced again.
♦ The refractometer - T10007- is recommended for determining rrectness of i
the current anti-freeze density.
l purpos

♦ If radiator, heat exchanger, cylinder head or cylinder head

gasket is renewed, do not reuse old coolant.
nform
ercia

Recommended mixture ratios:

m

at
om

io

Vehicle equipment Frost pro‐ Anti- G 126) Water6)

n
c

in t
r

tection to freeze
o

his
te

quantity5)
a

do
priv

cum

One heat exchanger -25°C 40% 3.6 l 5.4 l

for

en
g

-35°C 50% 4.5 l 4.5 l

n

t.
yi Co
op py
Two heat exchang‐ -25°C 40% 4.3 l 6.5 l
. C rig
ht ht
rig
ers -35°C 50% 5.4 l 5.4 l
py by
co Vo
by lksw
Two heat exchang‐ -25°C 40% 4.6 l 6.8 l
cted agen
Prote AG.
ers and additional -35°C 50% 5.7 l 5.7 l
water heater
5) The amount of anti-freeze must not exceed 60%; frost protection and cooling
effectiveness will decrease if amount of anti-freeze is too high.
6) The quantity of coolant can vary depending upon vehicle equipment.

1. Removing and installing parts of cooling system 109

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Install lower coolant hose and secure with retaining clip

-arrow-.

n AG. Volkswagen AG
– Push coolant hose onto oil swa
ge connection anddsecure
olkcooler
oes
not with
a spring-type clip. d by V gu
ara
e nte
ris
With cooling system
au
thocharge unit - VAS 6096- eo
ra
ss c
– Screw adapter - V.A.G 1274/7- onto expansion tank.

ce
le
un

pt
an
d

– Fill coolant circuit using cooling system charge unit - VAS

itte

y li
6096- ⇒ Operating instructions for cooling system charge unit
rm

ab
pe

VAS 6096.

ility
ot

wit
, is n

Without cooling system charge unit - VAS 6096-

h re
hole

spec
– Turn off heater controls.
es, in part or in w

t to the co
– Press upper radiator hose down.

– Slowly fill coolant to max. marking on expansion tank. Filling rrectness of i

takes approx. 5 minutes.
l purpos

– Start engine and run at increased engine speed (approx. 2500

rpm). Fill with coolant up to max. mark on expansion tank.
nform
ercia

– Close expansion tank cap.

m

a
com

– Run engine until radiator fan cuts in.

ion in
r
te o

– Then run for about a further 10 minutes at increased speed

thi
s
iva

(approx. 2500 rpm).

do
r
rp

cum
fo

– Check coolant level and top-up if necessary. When the engine

en
ng

t.
is at normal operating temperature, the coolant level must be
yi Co
op
on the max. mark and between the min. and max. marks when
C py
ht. rig
the engine is cold.
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
WARNING

Hot steam may escape when expansion tank is opened. Place

cloth over cap and open with caution.

– Install noise insulation tray.

1.6 Removing and installing radiator and fan

110 Rep. gr.19 - Cooling

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
Special tools and workshop equipment required
ce
le
un

pt
an
d

♦ Refractometer - T10007-
itte

y li
erm

ab

♦ Drip tray - V.A.G 1306-

ility
ot p

wit
is n

♦ Assembly tool for spring-type clips - VAS 5024-

h re
ole,

♦ Torque wrench - V.A.G 1331-

spec
urposes, in part or in wh

t to the co

Removing
– Drain coolant ⇒ page 107 .
rrectne

– Pull out retaining clips for upper coolant hose and remove
coolant hose from plug-in connector of radiator.
ss

– Detach lower coolant hose from bracket on the air ducting.

o
cial p

f in

– Remove bracket for lower coolant hose.

form
mer

atio

– Pull connectors off thermal switch and radiator fan.

om

n
c

– Unscrew lateral radiator securing bolts and remove radiator

or

n thi
e

with fans downwards.

t

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. Removing and installing parts of cooling system 111

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Additional information and assembly instructions for vehicles with

air conditioner:
AG. Volkswagen AG d
agen oes
WARNING olksw not
V gu
d by ara
ise nte
r
Do not open the air conditioner refrigerant circuit.
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
Note

ility
ot p

wit
, is n

To prevent damage to condenser, refrigerant lines or hoses, en‐

h re
sure that lines and hoses are not stretched, kinked or bent.
hole

spec
es, in part or in w

t to the co
– Remove retaining clamp(s) for refrigerant lines.
– Unscrew fan ring securing bolts and remove fan ring with fan.

rrectness of i
– Remove lateral radiator securing bolts.
l purpos

– Remove condenser from radiator.

– Secure condenser to body so that the refrigerant lines/hoses

nform
ercia

are not under tension.

m

at
– Remove radiator downwards.
om

ion
c

in t
r

Installing
o

his
ate

do
riv

Installation is carried out in the reverse order. When installing,

p

cum
or

note the following:

f

en
ng

t.
yi Co
– Electrical connections and routing ⇒ Current flow diagrams, Cop py
t. rig
Electrical fault finding and Fitting locations. opyri
gh by
Vo
ht
by c lksw
Filling with new coolant ⇒ page 107 . Prote
cted AG.
agen

1.7 Checking radiator fan

Special tools and workshop equipment required
♦ Auxiliary measuring set - V.A.G 1594 A-

♦ Current flow diagram

112 Rep. gr.19 - Cooling

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Test conditions
• The main fuses must be OK.
• Radiator fan thermal switch -F18- OK.
Test sequence
– Remove noise insulation tray.
– Pull 3-pin connector off radiator fan thermal switch - F18- .

– Bridge contact -1- and contact -2- of connector with auxiliary

cables from -V.A.G 1594 A- . Stage 1 of radiator
wage
n AGfan
. Volk-sV7-
wageand
n AG d
oes
radiator fan on right of radiator - V35-
y Vomust start up.
lks not
g b ua
ed ran
– Bridge contact -2- and contactho-3-
ris of connector with auxiliary tee
cables from -V.A.G 1594 A-s a. Stage 2 of radiator fan - V7- and
ut or
ac
radiator fan, right - V35- must
s run.

ce
le
un

pt
If fan speeds 1 or 2 do not run:

an
d
itte

y li
rm

ab
– Locate and eliminate open circuit referring to current flow di‐
pe

ility
agram ⇒ Current flow diagrams, Electrical fault finding and
ot

wit
, is n

Fitting locations.

h re
hole

If no fault in the wires is detected:

spec
es, in part or in w

t to the co
– Renew radiator fan - V7- or right radiator fan - V35- .

1.8 Checking continued coolant circulation

rrectness of i
pump
l purpos

Special tools and workshop equipment required

nform
ercia

♦ Voltage tester - V.A.G 1527B-

m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

♦ Auxiliary measuring set - V.A.G 1594 A-

1. Removing and installing parts of cooling system 113

 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Sharan oris 1996 ➤
e nte
h eo
6-cylinder
aut injection engine (4-valve), mechanics - Edition ra
c
06.2019
ss

ce
le
♦ Current flow diagram
un

pt
an
d
itte

y li
Prerequisites for check
erm

ab
ility
ot p

• All fuses must be OK.

wit
is n

h re
Test sequence
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
– Pull 2-pin connector off continued coolant circulation pump -
c

i
or

n
V51- -arrow-.

thi
te

sd
iva

o
r

Checking function
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.

– Connect contacts of continued coolant circulation pump - V51-

to battery using auxiliary cables from -V.A.G 1594 A- . Con‐
tinued coolant circulation pump must start up.
If the continued coolant circulation pump does not run:
– Renew continued coolant circulation pump - V51- .
If the continued coolant circulation pump - V51- runs:
Checking activation
– Switch ignition on and off again.

– Connect voltage tester - V.A.G 1527B- with auxiliary cables

from -V.A.G 1594 A- to removed connector of continued cool‐
ant circulation pump - V51- . LED must light up.

Note

This check must be performed within 3 minutes of switching igni‐

tion off.

If LED does not light up:

– Locate and eliminate open circuit referring to current flow di‐
agram ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.

1.9 Removing and installing coolant pump

114 Rep. gr.19 - Cooling

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

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.

(with engine installed)

Special tools and workshop equipment required
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /14- and adapter - 10 - 222 A /15-
♦ Adapter - 10 - 222 A /16-
♦ Refractometer - T10007-
♦ Drip tray - V.A.G 1306-
♦ Torque wrench - V.A.G 1331- (5…50 Nm)
♦ Torque wrench - V.A.G 1332- (40…200 Nm)
♦ Water pump wrench - V.A.G 1590-

1. Removing and installing parts of cooling system 115

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Sharan 1996au ➤
th or
ac
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019
ss

ce
e
nl

pt
du

an
♦ Assembly tool for spring-type clips - VAS 5024-
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

♦ Stepladder - VAS 5085-

m

at
om

io
♦ 2 bolts M8×35

n
c

in t
or

his
e

Removing
at

do
priv

c
– First check whether a coded radio is fitted. If so, obtain anti-

um
for

en
g

theft coding.
n

t.
yi Co
op py
– Remove poly V-belt ⇒ page 18 .
t. C rig
gh ht
pyri by
Vo
o
– Detach connecting hose of crankcase breather between cyl‐
c by lksw
cted agen
inder head cover and intake hose from cylinder head cover. Prote AG.

Note

Press buttons on hose couplings to do this.

– Remove air filter with intake hose: ⇒ Rep. gr. 24 ; Repairing

injection system .
– Remove lower rubber grommet for securing air filter lower
section.
– Drain coolant ⇒ page 107 .
– Remove battery.
– Remove both outer bolts of battery tray.
– Assemble engine support bracket 10-222 A together with
adapters 10-222 A/16, 10-222 A/14 and 10-222 A/15 as
shown.

116 Rep. gr.19 - Cooling

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Bolt leg 10-222 A/14 to battery tray with bolts M8x35

-arrows-. Specified torque: 25 Nm
– Attach adapter 10-222 A/16 of engine support bracket
10-222 A to right eye of cylinder head and slightly take up
strain on engine.
– Remove pendulum support: ⇒ Rep. gr. 40 ; Repairing front
wheel suspension .

– Unscrew right assembly mounting securing bolts -1-.

AG. Volkswagen AG d
agen oes
olksw not
– Remove bolts and nutsefromdb
y V
engine assembly mounting guara
-arrows- and completelyris remove assembly mounting. nte
utho eo
ra
s a c
s
ce
le

Note
un

pt
an
d
itte

y li
erm

ab

To remove securing bolts use a stepladder - VAS 5085- .

ility
ot p

wit
is n

– Lower engine on support bracket until coolant pump can be

h re
ole,

removed.
spec
urposes, in part or in wh

t to the co
rrectne

– Remove belt pulley. To do this, lock pulley using water pump

spanner - V.A.G 1590- .
ss o
cial p

Note
inform
mer

atio

If the engine has been removed it is not necessary to remove

om

pulley. The coolant pump securing bolts can be unscrewed via

n
c

i
or

the holes in the pulley.

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. Removing and installing parts of cooling system 117

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Unscrew coolant pump securing bolts -1- and remove coolant

pump -2-.

Note

To remove coolant pump, engine must be pushed aside slightly,

using an assembly lever if necessary.

Installing
Installation is carried out in the reverse order. When installing,
note the following:
– Moisten new O-ring with coolant.
– Insert coolant pump into cylinder block and tighten securing
bolts. Specified torque: 20 Nm
– Install pulley and tighten securing bolts. Specified torque: 20
Nm
– Align assembly mountings stress-free by rocking.

Note

Specified torques for engine and gearbox mountings ⇒ page 10 .

– Install pendulum support: ⇒ Rep. gr. 40 ; Repairing front

wheel suspension . AG. Volkswagen AG d
agen oes
lksw not
– Install battery. by Vo gu
a d ran
ise
– Install air filter with intakeut
hohose: ⇒ Rep. gr. 24 ; Repairing
r tee
or
injection system . ss
a ac
ce
le

– Install poly V-belt ⇒ page 18 .

un

pt
an
d
itte

y li

– Install noise insulation tray.

erm

ab
ility
ot p

Filling with new coolant ⇒ page 107 .

wit
is n

h re
ole,

spec
urposes, in part or in wh

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.

118 Rep. gr.19 - Cooling

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

20 – Fuel supply system agen

AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
1 Removing and installing parts of fuel uthorise nte
eo
ra
supply system ss a c

ce
e
nl

pt
du

an
itte

y li
Note
erm

ab
ility
ot p

wit
♦ Hose connections are secured with either spring-type or
, is n

h re
clamp-type clips.
hole

spec
♦ Always renew crimp-type clips with spring-type clips.
es, in part or in w

t to the co
♦ Fuel hoses on engine must be secured with spring-type clips
only. The use of crimp-type or screw-type clips is not permis‐
sible.

rrectness of i
♦ Hose clip pliers - VAS 5024- or hose clip pliers - V.A.G 1921-
l purpos

are recommended for installation of spring-type clips.

nf
ercia

Note safety precautions ⇒ page 123 .

orm
m

atio
m

Observe rules for cleanliness ⇒ page 123 .

o

n in
or c

Observe crash fuel shut-off ⇒ page 125 .

thi
te

sd
iva

Electronic power control (EPC) ⇒ page 140 .

o
r
rp

cu
o

m
f

en
ng

Activated charcoal filter system ⇒ page 132 .

t.
yi Co
Cop py
1.1 Removing and installing fuel tank with
t. rig
gh ht
pyri by

attachments and fuel filter

co Vo
by lksw
cted agen
Prote AG.

Note

♦ Ensure, on completion of all work on the fuel delivery unit and

fuel gauge that the fuel supply and fuel return hoses do not
touch the fuel tank (transfer of pumping noises).
♦ Fuel pump relay - J17- ⇒ page 123 , ⇒ page 123 .

1. Removing and installing parts of fuel supply system 119

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

1 - Cap
2 - Fastener
3 - Seal
❑ Renew if damaged
4 - Securing ring
5 - Rubber cup
6 - Gravity valve
❑ To remove valve unclip
upwards out of filler
neck
❑ Check valve for
through-flow valve verti‐
cal: open, valve tilted
45°: closed
7 - O-ring
❑ Renew if damaged
8 - Bleeder valve
❑ Cannot be removed, re‐
new only together with
filler neck

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

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.

120 Rep. gr.20 - Fuel supply system

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

⇒ Item 14 (page 121)

❑ Checking ⇒ page 122
9 - Pressure retention valve
❑ For fuel tank breather.
❑ Checking ⇒ page 122
10 - Return line
❑ blue
❑ Ensure firm seating
❑ Clipped onto fuel tank
❑ From fuel return pipe on
fuel rail: ⇒ Rep. Gr. 24; Repairing injection system; Removing and installing parts of the injection system .
11 - Supply line
❑ black
❑ Ensure firm seating
❑ Clipped onto fuel tank
12 - Connector
❑ Black, 4-pin
❑ For fuel gauge sender -G- and fuel pump - G6- .
13 - 6 Nm
14 - Filler neck
❑ With expansion tank and breather valve
15 - Breather line
AG. Volkswagen AG d
❑ Ensure firm seating agen oes
o lksw not
yV gu
❑ To branch-off piece between activated charcoal
ised b filter and activated charcoal filter asystem
ran solenoid valve
1 ⇒ Item 3 (page 133) . uthor tee
o
a ra
ss c
16 - Seal

ce
le
un

pt
❑ Renew if damaged

an
d
itte

y li
17 - Securing ring
rm

ab
pe

ility
ot

18 - Breather line
wit
, is n

h re
❑ Ensure firm seating
hole

spec
19 - Non-return valve
es, in part or in w

t to the co
❑ Check for ease of movement.
20 - 25 Nm
rrectness of i

21 - Fuel
l purpos

❑ When removing, support using engine and gearbox jack - V.A.G 1383 A- .
22 - Securing strap
nform
ercia

❑ Note different lengths.

m

a
com

❑ Observe installation position

ion in
r
te o

23 - 20 Nm
thi
s
iva

do

24 - Bracket
r
rp

cum
fo

❑ For fuel filter

en
ng

t.
yi Co
op py
25 - Supply line
. C rig
ht ht
rig by
❑ black copy Vo
by lksw
cted agen
❑ Ensure firm seating Prote AG.

❑ To fuel supply pipe on fuel rail: ⇒ Rep. Gr. 24; Repairing injection system; Removing and installing parts
of the injection system .

1. Removing and installing parts of fuel supply system 121

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

26 - Fuel filter
❑ Installation position: arrow points in direction of flow.
27 - Union nut, 75 Nm
❑ Remove and install with spanner 3217
28 - Fuel delivery unit
❑ Note installation position on fuel tank ⇒ page 122
❑ Removing and installing ⇒ page 124
❑ Checking fuel pump ⇒ page 126 .
❑ Clean strainer if soiled
29 - Seal
❑ When installing, fit dry in fuel tank opening.
❑ Renew if damaged
❑ Moisten with fuel only when installing flange.

Installation position of fuel delivery unit flange

Marking on sender must align with the marking on fuel tank
-arrows-.
Return line -1- (blue or with blue marking)
n AG. Volkswagto connection
en AG do marked
-R-. lkswage es n
Vo ot gu
y
db ara
Black supply lineori-2-
se to connection marked -V-. nte
th eo
au ra
c
ss
ce
e

Note
nl

pt
du

an
itte

y li

After installing fuel delivery unit flange, check that supply, return
erm

ab
ility

and breather lines are still clipped onto fuel tank.

ot p

wit
, is n

h re
hole

spec

Checking breather valve

es, in part or in w

t to the co

Valve in rest position: closed

Valve pushed in direction of arrow: open
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r

Checking pressure retention valve

rp

cu
o

m
f

en
ng

From gravity valve, the pressure retention valve is open in both

t.
yi Co
op
directions of flow - arrow -1-. C py
t. rig
gh ht
yri by
From junction between activated charcoal filter/activated char‐ cop Vo
by lksw
coal filter system solenoid valve 1, it is only open in one direction cted agen
Prote AG.
of flow -arrow 2-.

122 Rep. gr.20 - Fuel supply system

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Fuel pump relay - J17- - relay position 21 -

Relay is located on lower multifunctional unit relay holder.

Note

♦ If tools are necessary to pull relays or control units out of the

relay plate, first disconnect battery earth strap
♦ Before disconnecting battery earth strap obtain code for radios
with anti-theft coding.

1.2 Safety measures when working on fuel

supply
n AG. Volkswagen AG do
lkswage es n
o ot g
yV
WARNING ir se
d b ua
ran
o tee
th or
u
Observe the following points during all installation
ss
a
work, in par‐ ac
ticular in the engine compartment, due to the space limitations:

ce
le
un

pt
an
d

♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
itte

y li
rm

vated charcoal filter system, coolant, refrigerant, brake

ab
pe

ility
fluid and vacuum) and electrical wiring in their original po‐
ot

wit
sitions.
, is n

h re
hole

♦ Ensure that there is sufficient clearance to all moving or

spec
hot components.
es, in part or in w

t to the co
When removing and installing fuel gauge sender or fuel pump

rrectness of i
(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
l purpos

WARNING

nform
mercia

Fuel supply lines are under pressure! Wrap a cloth around the

a
com

tio
connection before loosening hose connections. Then release

n in
r

pressure by carefully pulling hose off connection.

te o

thi
s
iva

do
r
rp

cum
fo

♦ For safety reasons, fuse No. 14 must be removed from the

en
ng

t.
yi
fuse holder before opening the fuel system. Otherwise the fuel
Co
Cop py
pump can be activated by the driver door contact switch.
t. rig
gh ht
pyri by
Vo
o
♦ Even before work commences, the extraction hose of an ac‐
c by lksw
cted agen
tivated fume extraction system has to be placed in the vicinity
Prote AG.

of the assembly opening of the fuel tank to trap any escaping

fumes. If no exhaust gas extraction system is available, a ra‐
dial fan with a displacement greater than 15 m3/h can be used
providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!

1.3 Rules for cleanliness

When working on the fuel supply/injection system, carefully follow
the “5 rules” below:
♦ Thoroughly clean all unions and adjacent areas before dis‐
connecting.

1. Removing and installing parts of fuel supply system 123

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

♦ Place removed parts on a clean surface and cover them over.

Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ If system is open: do not use compressed air if possible. Try
not to move the vehicle.

1.4 Removing and installing fuel delivery

unit
Special tools and workshop equipment
agen
AG.required
Volkswagen AG
do w es n
olks ot g
♦ Union nut tool 3217 ed by V ua
ran
ris tee
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

♦ Torque wrench (40…200 Nm) -V.A.G 1332-

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
Removing
cted agen
Prote AG.

– Note safety precautions before beginning work ⇒ page 123 .

– First check whether a coded radio is fitted. If so, obtain anti-
theft coding.
– With the ignition switched off, disconnect battery earth strap.
– Remove cover from fuel delivery unit.
– Pull 4-pin connector and supply and return lines off flange.

WARNING

Fuel supply lines are under pressure! Wrap a cloth around the
connection before loosening hose connections. Then release
pressure by carefully pulling hose off connection.

124 Rep. gr.20 - Fuel supply system

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Note

Press buttons on hose couplings to do this.

– Remove union nut with spanner 3217.

– Pull fuel delivery unit and seal out of opening in fuel tank.

Note

If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.

Installing
– Installation of fuel delivery unit is carried out in reverse order.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Note rise nte
tho eo
au ra
ss c
♦ Do not bend fuel gauge sender when installing.

ce
e
nl

pt
du

an
♦ Insert seal for fuel delivery unit dry into opening of fuel tank.
itte

y li
erm

ab
♦ Moisten seal with fuel only when installing fuel delivery unit.

ility
ot p

wit
♦ Ensure fuel hoses are seated correctly.
, is n

h re
hole

♦ After installing fuel delivery unit, check that supply, return and

spec
breather lines are still clipped onto fuel tank.
es, in part or in w

t to the co
♦ Note installation position of fuel delivery unit flange: mark on
flange must align with mark -arrows- on fuel tank.

rrectness of i
l purpos

1.5 Removing and installing fuel gauge

sender

nf
ercia

orm
Removing
m

atio
om

– Remove fuel delivery unit ⇒ page 124 . n in

or c

thi
e

– Release connector lugs on lines -3- and -4- and pull off.
t

sd
iva

o
r
rp

cu

– Lift retaining tabs -1- and -2- using a screwdriver and pull fuel
o

m
f

en
ng

gauge sender off downwards -arrows-.

t.
yi Co
Cop py
Installing
t. rig
gh ht
pyri by
Vo
o
– Insert fuel gauge sender into guides on fuel delivery unit and
c by lksw
cted agen
press upwards until it engages.
Prote AG.

– Install fuel delivery unit ⇒ page 124 .

1.6 Crash fuel shut-off

Function
Vehicles with an airbag are fitted with a crash fuel shut-off. It re‐
duces the danger of a fire in a crash as the fuel pump is switched
off via the fuel pump relay. The system also improves the starting
characteristics of the engine. When door is opened, the fuel pump
is activated for 2 seconds to build up pressure in the fuel system.

1. Removing and installing parts of fuel supply system 125

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

When opening fuel system:

Note safety precautions ⇒ page 123 .
– Check activation of fuel pump relay referring to current flow
diagram and with -V.A.G 1466 A- , checking: ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.

1.7 Checking fuel pump

Special tools and workshop

equipment required

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
urposes, in part or in wh

t to the co
rrectness o
cial p

f i

♦ Key for union nut - 3217-

nform
mer

♦ Pressure tester - V.A.G 1318-

atio
om

n
c

♦ Adapter - V.A.G 1318/10-

i
or

n thi
te

sd

♦ Adapter - V.A.G 1318/11-

iva

o
pr

cum
r
fo

♦ Adapter - V.A.G 1318/16-

en
ng

t.
yi Co
♦ Torque wrench - V.A.G 1332- (40…200 Nm) Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

126 Rep. gr.20 - Fuel supply system

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

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

♦ Injection rate comparison meter - V.A.G 1348-

ab
ility
ot p

♦ Testing system - V.A.G 1466 A-

wit
is n

h re
ole,

♦ Voltage tester - V.A.G 1527B-

spec
urposes, in part or in wh

♦ Auxiliary measuring set - V.A.G 1594 A-

t to the co

♦ Multimeter - V.A.G 1715-

♦ Assembly tool for spring-type clips - VAS 5024-
rrectne

♦ Measuring beaker
ss

♦ Current flow diagram

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. Removing and installing parts of fuel supply system 127

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Test conditions
• All fuses must be OK.
• Battery voltage must be at least 11.5 V.
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
• If the vehicle is equipped with an air conditioner, it must be
switched off.

Note AG. Volkswagen AG d

agen oes
olksw not
Refer to the description of how the crash fuel shut-off works d by V gu
ara
⇒ page 125 . rise nte
tho eo
au ra
ss c

ce
le

1.7.1 Checking function and voltage supply

un

pt
an
d
itte

y li
rm

ab
pe

ility
Note
ot

wit
, is n

h re
hole

Before carrying out further work, battery earth strap may have to

spec
be disconnected. First check whether a coded radio is fitted. Ob‐
es, in part or in w

t to the co
tain anti-theft coding first if necessary.

– Remove cover from fuel delivery unit.

rrectness of i
– Briefly operate starter. Fuel pump must be heard to run.
l purpos

– Switch off ignition.

nform
ercia

If the fuel pump does not start:

m

a
– Pull 5-pin connector off air mass meter -G70- with intake air
com

tio
temperature sender -G42- -arrow-.

n in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

– Connect remote control -V.A.G 1348/3A- using adapter cable

-V.A.G 1348/3-2- and auxiliary cables from -V.A.G 1594 A- to
contact 2 of connector and to battery positive (+).
– Operate remote control.
If fuel pump runs:
– Check activation of fuel pump relay referring to current flow
diagram and with -V.A.G 1466 A- , checking: ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
If fuel pump does not run:
– Pull 4-pin connector off fuel delivery unit flange.

128 Rep. gr.20 - Fuel supply system

 Sharan 1996 ➤
6-cylinder injection engine
en AG(4-valve),
. Volkswagenmechanics
AG - Edition 06.2019
ag does
ksw not
Vol gu
– Connect diode test lamp -V.A.G 1527 B- with ed adapter cables
by ara
nte
from -V.A.G 1594 A- to the outer contacts
thorisof the connector. eo
au ra
– Operate remote control. LED must light
ss up. c

ce
le
un

pt
If LED does not light up:

an
d
itte

y li
erm
– Locate and eliminate open circuit referring to current flow di‐

ab
ility
agram: ⇒ Current flow diagrams, Electrical fault finding and

ot p

wit
Fitting locations.

is n

h re
ole,
If LED lights up (voltage supply OK):

spec
urposes, in part or in wh

t to the co
rrectne
– Remove union nut with spanner 3217.
– Check that electrical wires between flange and fuel pump are

s
connected.

s o
cial p

f in
If no open circuit can be found:

form
mer

– Fuel pump defective. Renew fuel delivery unit ⇒ page 124 ,

atio
m

removing and installing fuel delivery unit.

o

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by

1.7.2 Checking delivery rate

o Vo
by c lksw
cted agen
Prote AG.
Test conditions
• Voltage supply OK.
• Remote control -V.A.G 1348/3A- connected
Test sequence
– Remove filler cap from fuel tank filler neck.
– Remove engine cover panel.
– Remove air filter: ⇒ Rep. Gr. 24; Repairing injection system;
Dismantling and assembling air filter
– Pull supply line -1- off at fuel rail's fuel supply pipe and catch
escaping fuel with a cloth.

WARNING

Fuel system is under pressure! Before opening the system,

place a cloth around the connection. Then release pressure by
carefully loosening the connection.

1. Removing and installing parts of fuel supply system 129

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Connect pressure tester -V.A.G 1318- to fuel supply line with

adapter -V.A.G 1318/10- .
– Push hose -V.A.G 1318/16- onto adapter -V.A.G 1318/11- of
pressure gauge and hold hose in a measuring beaker.
en AG . Volkswage
– Open the pressure tester shut-off tap.
wagThe lever then npoints
AG do in
es n
the direction of flow -A-. Volks ot g
by ua d ran
ise
– Operate remote controlut-V.A.G
ho
r
1348/3A- . Then slowly close tee
or
shut-off tap until a pressure
ss
a of 3 bar is displayed on pressure ac
gauge. From this point on do not move position of shut-off tap.

ce
e
nl

pt
du

an
– Empty measuring container.
itte

y li
erm

ab
– The quantity delivered by the fuel pump depends on the bat‐

ility
ot p

tery voltage. Therefore, connect multimeter with adapter ca‐

wit
, is n

bles from -V.A.G 1594- to vehicle battery.

h re
hole

spec
– Operate remote control for 30 seconds while measuring bat‐
es, in part or in w

tery voltage.

t to the co
– Compare quantity of fuel delivered with specification.

rrectness of i
*) - Minimum delivery cm3/30 seconds
l purpos

**) - Voltage at fuel pump with engine not running and pump run‐
ning (approx. 2 volts less than battery voltage).

nform
ercia

Reading example:
m

at
om

i
During the test a voltage of 12.2 volts is measured at the battery.

on
c

As the voltage at the pump is approx. 2 volts less than the battery

in t
or

his
e

voltage, this will equate to a minimum delivery rate of 200 cm3/30

at

do
riv

s.
p

cum
for

en
g

If the minimum delivery rate is not attained:

n

t.
yi Co
Cop py
– Check fuel lines for possible restrictions (kinks) or blockages. ht. rig
rig ht
py by
co Vo
by lksw
cted
– Pull supply hose -1- off fuel filter inlet.
agen
Prote AG.

– Connect K-Jetronic pressure tester -V.A.G 1318- to hose with

adapter 1318/10.
– Repeat delivery rate check.
If the minimum delivery rate is now attained:
– Renew fuel filter.
If the minimum delivery rate is again not attained
– Remove fuel delivery unit and check for dirt in filter strainer.
Only if still no fault has been detected:
– Fuel pump defective. Renew fuel delivery unit ⇒ page 124 ,
removing and installing fuel delivery unit.
If delivery rate has been attained, but nevertheless you suspect
a fuel supply system fault (e.g. intermittent failure of fuel supply
system):
– Check current draw of fuel pump as follows:
– Reconnect all disconnected fuel lines.
– Reconnect air mass meter connector.

130 Rep. gr.20 - Fuel supply system

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Connect multimeter -V.A.G 1715- to line of 4-pin connector -

contact 1 arrow- in wiring harness using current clamp.
– Start engine and run at idling speed.
– Measure current draw of fuel pump. Specification: max. 8
amps

Note

If the fuel system malfunction is intermittent, you can perform the

check during a road test, but a 2nd person is necessary.

If current draw is exceeded:

– Fuel pump defective. Renew fuel delivery unit ⇒ page 124 ,
removing and installing fuel delivery unit.

1.7.3 Checking non-return valve for fuel pump

Test conditions
• Remote control -V.A.G 1348/3A- still connected.
• Pressure tester -V.A.G 1318- still connected.
Test sequence

Note
. Volkswagen AG
At the same time, this test checks for leaks in the fuel supply line
ksw
agen
AG does
connections from the fuel delivery unit to the point at which
y V the
ol not
gu
db ara
pressure tester -V.A.G 1318- is connected. orise nte
th eo
s au ra
c
– Close pressure gauge shut-off tap (lever atsright angles to

ce
e

throughflow direction - position -B-).

nl

pt
du

an
itte

y li
– Operate remote control at short intervals until a pressure of
erm

ab
approx. 3 bar has built up.

ility
ot p

wit
, is n

– If pressure builds up too high, relieve excess pressure by

h re
carefully opening shut-off tap.
hole

spec
es, in part or in w

WARNING t to the co

Danger of spray when opening shut-off tap. Hold container

rrectness of i

over free connection of pressure tester.

l purpos

– Watch pressure drop on pressure gauge. Pressure must re‐

nf
ercia

main above 2.5 bar for 10 minutes.

orm
m

atio

If the pressure drops further:

om

n in
or c

– Check line connections for leaks.

thi
te

sd
iva

If no fault in lines is detected:

o
r
rp

cu
o

m
f

– Fuel pump defective. Renew fuel delivery unit ⇒ page 124 ,

en
ng

t.
yi Co
removing and installing fuel delivery unit. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Removing and installing parts of fuel supply system 131

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

2 Activated charcoal filter system

2.1 Function
Depending upon the air pressure and ambient temperature, fuel
vapour will form above the level of fuel in the tank.
The activated charcoal filter system prevents these HC emissions
escaping to the atmosphere.
In limited quantities, fuel vapours pass through a gravity valve
(which closes at an angle of 45°) located at the highest point in
the tank and through a pressure retention valve into the activated
charcoal filter.
The activated charcoal stores these vapours like a sponge.
When the car is being driven and Lambda control is active (engine
warm), active charcoal filter system solenoid valve 1 -N80- , also
known as regeneration valve, is activated (pulsed) by the engine
control unit depending upon load and engine speed. The opening
period depends on the input signals.
During the purging procedure (regeneration of activated char‐
coal), the intake manifold vacuum draws fresh air through the
ventilation hose of the activated charcoal filter. The fuel vapours
stored in the activated charcoal and fresh air are fed to combus‐
tion in metered quantities.
The pressure retention valve prevents fuel vapours from being
drawn from the fuel tank when active charcoal
AG. Volkswagenfilter
AG dosystem sole‐
noid valve 1 -N80- is open oand agen
lksw intake manifold vacuum es nis present.
ot g
It thus ensures that the
ed bpurging
yV of the activated charcoal filter
ua has
ran
priority. ho
ris tee
t or
au ac
Active charcoalss filter system solenoid valve 1 -N80- is closed
when it is not supplied with current (e.g. open circuit). The acti‐
ce
e
nl

pt
du

vated charcoal filter will not be purged.

an
itte

y li
erm

ab
ility
ot p

Note
wit
, is n

h re
hole

♦ Hose connections are secured with either spring-type or

spec

clamp-type clips.
es, in part or in w

t to the co

♦ Always renew crimp-type clips with spring-type clips.

♦ Spring-type clip pliers -VAS 5024- or hose clip pliers -
rrectness of i

V.A.G 1921- are recommended for fitting spring-type clips.

l purpos

Note safety precautions ⇒ page 123 .

nform
ercia

Observe rules for cleanliness ⇒ page 123 .

m

at

Check activated charcoal filter system ⇒ page 134 .

om

ion
c

in t

Checking fuel tank breather ⇒ page 138 .

or

his
ate

do
riv

2.2 Repairing parts of activated charcoal filter system

p

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

132 Rep. gr.20 - Fuel supply system

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

1 - Connector
2 - Bracket
❑ For activated charcoal
filter
3 - Junction
4 - Breather line
❑ From pressure retention
valve on fuel tank
⇒ Item 9 (page 121) .
5 - Activated charcoal filter
❑ Location: in front right
wheel housing
❑ Remove right wheel
housing to remove.
6 - 4 Nm
7 - Connector
❑ Black, 2-pin
❑ For activated charcoal
filter system solenoid
valve 1 - N80-
8 - Junction
9 - Breather line
❑ Ensure firm seating
❑ Press together at front
to release.
❑ To connecting hose of
crankcase breather be‐
tween cylinder head
AG. Volkswagen AG d
cover and intake hose ⇒ ksw
agen oes
not
l
Rep. gr. 24 ; Repairing by Vo gu
ara
injection system . rise
d
nte
o h eo
ut
10 - O-ring ss
a ra
c
❑ Renew if damaged
ce
e
nl

pt
du

an
itte

11 - Breather line
y li
erm

ab

❑ Ensure firm seating

ility
ot p

wit

❑ Press together at front to release.

, is n

h re

❑ To rear intake manifold ⇒ Rep. gr. 24 ; Removing and installing parts of injection system .
hole

spec
es, in part or in w

12 - Air filter lower part

t to the co

13 - Activated charcoal filter solenoid valve 1 - N80-

❑ The valve will be activated from the engine control unit (pulsed).
rrectness of i

❑ Note installation position: arrow points in direction of flow.

l purpos

❑ Checking activation ⇒ Rep. gr. 01 ; Performing final control diagnosis .

14 - Rubber bracket
nf
ercia

orm

15 - Breather line
m

atio
m

❑ To atmosphere.
o

n in
or c

❑ Secured to body
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.

2. Activated charcoal filter system 133

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

2.3 Checking activated charcoal filter sys‐

tem
n AG. Volkswagen AG do
wage
Special tools and workshop equipment required olks es n
ot g
byV ua
d ran
♦ -V.A.G 1551- Fault reader 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
♦ -V.A.G 1551/3- Cable
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.

Note

Vehicle system tester -V.A.G 1551- can be used instead of fault

reader -V.A.G 1552- , however a print-out is not possible.

134 Rep. gr.20 - Fuel supply system

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Test conditions
• Fuses must be OK.
• Battery voltage must be at least 11.5 V.
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
• Vacuum pipes and hose connections free of leaks.
• Vacuum pipes not blocked or kinked.
• No fault may be stored in fault memory ⇒ Rep. gr. 01 ; Read‐
ing and erasing engine control unit fault memory .
• Coolant temperature must be at least 80°C, ⇒ display group
01, display zone 2
• Catalytic converter temperature must be at least 350°C, ⇒ dis‐
play group 205, display zone 2
Test sequence
– Connect fault reader -V.A.G 1551- (V.A.G 1552). Start engine
and select “Address word” 01 of engine control unit. Connect
fault reader and select engine control unit ⇒ Rep. gr. 01 ;
Connecting fault reader V.A.G 1551 and selecting engine
electronics control unit .
Indicated on display:
Rapid data transfer HELP
Select function XX

– Press keys 0 and 4 for function “Initiate basic settings” and

confirm entry with Q key.
G. Volkswagen AG d
Indicated on display: lkswagen A oes
not
Vo gu
by ara
Basic setting ised nte
r
Enter display ho group number XXX eo
aut ra
ss c
ce
le
un

pt

Note
an
d
itte

y li
rm

ab

During certain tests, it may occur that a subsequent test has al‐
pe

ility
ot

ready been carried out successfully in the background. In this

wit
, is n

case, continue with the subsequent test.

h re
hole

spec
es, in part or in w

t to the co

2.3.1 Checking Lambda probe heating before

catalytic converter
rrectness of i

– Press buttons 2 , 0 and 5 for “Display group number 205” and

l purpos

confirm entry with Q button.

Indicated on display: (1…4 = display zones)
nform
ercia

System in basic setting 205 ->

1 2 3 4
m

Only continue with the test when:

com

tion in
r
te o

• Catalytic converter temperature is over 350°C, -display zone

thi
s

2-
iva

do
r
rp

cum

– Depress brake pedal and hold.

fo

en
ng

t.
yi Co
– Depress accelerator to full throttle position. Engine revolutions
Cop py
t. rig
are raised by engine control unit to approx. 2300 rpm.
opyri
gh by
Vo
ht
by c lksw
– Allow engine to run at idle speed until specification: x x x x x
Prote
cted agen
1 0 0 is displayed in display zone 4.
AG.

If readout is not as described:

2. Activated charcoal filter system 135

 AG. Volkswagen AG d
agen oes
olksw not
Sharan 1996 ➤ d by
V gu
ara
e nte
6-cylinder injection engine (4-valve), mechanics horis
- Edition 06.2019 eo
aut ra
ss c
– Press → button.

ce
e
nl

pt
du

an
– Read fault memory ⇒ Rep. gr. 01 ; Reading and erasing en‐

itte

y li
gine control unit fault memory .

erm

ab
ility
ot p
– Read readiness code ⇒ Rep. gr. 01 ; Reading readiness

wit
, is n
code .

h re
hole

spec
– If the fault memory has been cleared or the engine control unit

es, in part or in w
was separated from the continuous positive supply, the read‐

t to the co
iness code must be regenerated ⇒ Rep. gr. 01 ; Generating
readiness code .

rrectness of i
If the display indicates as described:
– Check Lambda probe ageing before catalytic converter (probe l purpos
dynamics) ⇒ page 136 .

nform
ercia

2.3.2 Checking Lambda probe ageing before

m

at
catalytic converter (probe dynamics)
om

ion
c

in t
or

– Change to display group 212 as follows:

his
ate

do
riv

– Press the C button.

p

cum
for

en
ng

Indicated on display:
t.
yi
Basic setting
Co
op py
t. C Enter display group number XXX rig
gh ht
yri by
– Press buttons 2 , 1 and 2 for “Display group number 212” and
op Vo
by c lksw
cted
confirm entry with Q button.
agen
Prote AG.

Indicated on display: (1…4 = display zones) System in basic setting 212 ->
1 2 3 4

– Depress brake pedal and hold.

– Depress accelerator to full throttle position. Engine revolutions
are raised by engine control unit to approx. 2300 rpm.
– Allow engine to run at idle speed until specification: x x x x x
1 0 0 is displayed in display zone 4 after approx. 80 seconds.
If readout is not as described:
– Press → button.
– Read fault memory ⇒ Rep. gr. 01 ; Reading and erasing en‐
gine control unit fault memory .
– Read readiness code ⇒ Rep. gr. 01 ; Reading readiness
code .
– If the fault memory has been cleared or the engine control unit
was separated from the continuous positive supply, the read‐
iness code must be regenerated ⇒ Rep. gr. 01 ; Generating
readiness code .
If the display indicates as described:
– Check fuel supply system at idle speed ⇒ page 136 .

2.3.3 Checking fuel supply system at idle

speed
– Change to display group 216 as follows:
– Press the C button.
Indicated on display: Basic setting
Enter display group number XXX

– Press buttons 2 , 1 and 6 for “Display group number 216” and

confirm entry with Q button.

136 Rep. gr.20 - Fuel supply system

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Indicated on display: (1…4 = display zones) AG. Volkswin

agen System
agebasic
n AG d setting 216 ->
oes
o lksw 1 2 3 4 not
y V gu
d b ara
e
– Allow engine to run at idle speed until specification:
thorisx x x x 1 nte
eo
x 0 0 is displayed in display zone 4 after approx.
s a 30 seconds.
u ra
c
s

ce
If readout is not as described:

le
un

pt
an
d
itte
– Press → button.

y li
erm

ab
ility
– Read fault memory ⇒ Rep. gr. 01 ; Reading and erasing en‐

ot p

wit
gine control unit fault memory .

is n

h re
ole,
– Read readiness code ⇒ Rep. gr. 01 ; Reading readiness

spec
urposes, in part or in wh
code .

t to the co
– If the fault memory has been cleared or the engine control unit
was separated from the continuous positive supply, the read‐
iness code must be regenerated ⇒ Rep. gr. 01 ; Generating

rrectne
readiness code .

s
If the display indicates as described:

s o
cial p

f i
– Check fuel supply system at partial load ⇒ page 137 .

nform
mer

2.3.4 Checking fuel supply system at partial

atio
om

load

n
c

i
or

n thi
te

sd
a

Indicated on display: (1…4 = display zones)

iv

o
r

System in basic setting 216 ->

p

cum
r

1 2 3 4
fo

en
ng

t.
yi
– Depress brake pedal and hold.
Co
Cop py
t. rig
gh
– Depress accelerator to full throttle position. Engine revolutions
ht
pyri by
Vo
o
are raised by engine control unit to approx. 2300 rpm.
c by lksw
cted agen
Prote AG.
– Allow engine to run at idle speed until specification: x x x x x
1 0 0 is displayed in display zone 4 after approx. 75 seconds.
If readout is not as described:
– Press → button.
– Read fault memory ⇒ Rep. gr. 01 ; Reading and erasing en‐
gine control unit fault memory .
– Read readiness code ⇒ Rep. gr. 01 ; Reading readiness
code .
– If the fault memory has been cleared or the engine control unit
was separated from the continuous positive supply, the read‐
iness code must be regenerated ⇒ Rep. gr. 01 ; Generating
readiness code .
If the display indicates as described:
– Check activated charcoal filter system (tank breather system)
⇒ page 137 .

2.3.5 Checking activated charcoal filter sys‐

tem (tank breather system)
– Change to display group 229 as follows:
– Press the C button.
Indicated on display: Basic setting
Enter display group number XXX

– Press buttons 2 , 2 and 9 for “Display group number 229” and

confirm entry with Q button.
Indicated on display: (1…4 = display zones) System in basic setting 229 ->
1 2 3 4

2. Activated charcoal filter system 137

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Allow engine to run at idle speed until specification: x x x x x

1 0 0 is displayed in display zone 4 after approx. 30 seconds.
– Press → button.
– Press buttons 0 and 6 for function “End output” and confirm
entry with Q button.
– Switch off ignition. n AG. Volkswagen AG do
lkswage es n
o ot g
If the display does not d by Vchange as described: ua
ran
ir se tee
– Initiate finaluthcontrol diagnosis and select active charcoal filter
o
or
system solenoid
ss
a
valve 1 - N80- , ⇒ Rep. gr. 01 ; Performing ac
final control diagnosis .

ce
le
un

pt
an
d
itte

2.4 Checking fuel tank breather

y li
erm

ab
ility
ot p

Special tools and workshop equipment required

wit
is n

h re
♦ Vacuum tester - V.A.G 1368-
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
a

♦ -V.A.G 1390- Hand vacuum pump

iv

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.

138 Rep. gr.20 - Fuel supply system

 agen
AG. Volkswagen AG d
oe
Sharan 1996 ➤
olksw 6-cylinders ninjection
ot g engine (4-valve), mechanics - Edition 06.2019
byV ua
ed ran
ris tee
Test sequence
au
tho or
ac
ss
– Pull breather hose -3- off active charcoal filter system solenoid

ce
le
un

valve 1 -1-.

pt
an
d
itte

y li
– Connect vacuum tester - V.A.G 1368- -connection A- to active
erm

ab
charcoal filter system solenoid valve 1 -1-.

ility
ot p

wit
is n

– Connect hand vacuum pump - V.A.G 1390- to vacuum tester

h re
ole,

- V.A.G 1368- -connection B-.

spec
urposes, in part or in wh

– Set vacuum tester to -A/B- position.

t to the co
– Initiate final control diagnosis and select active charcoal filter
system solenoid valve 1 - N80- , ⇒ Rep. gr. 01 ; Performing

rrectne
final control diagnosis .
– Operate hand vacuum pump - V.A.G 1390- several times.

ss
There must be no development of vacuum.

o
cial p

f in
If vacuum builds up:

form
mer

atio
– Check breather hose -4- on activated charcoal canister for
om

soiling and clean if necessary.

n
c

i
or

n thi
e

If vacuum does not build up:

t

sd
iva

o
pr

cum
r
fo

– Seal breather hose -arrow- from activated charcoal canister.

en
ng

t.
yi Co
op
– Initiate final control diagnosis again and select active charcoal
C py
ht. rig
filter system solenoid valve 1 - N80- , ⇒ Rep. gr. 01 ; Per‐
rig ht
py by
o Vo
forming final control diagnosis .
by c lksw
cted agen
Prote AG.
– Operate hand vacuum pump - V.A.G 1390- several times.
Vacuum must build up.
If vacuum does not build up:
– Check pressure retention valve ⇒ page 122 .

– Check breather hose -2- from fuel tank pressure retention

valve for leaks.

2. Activated charcoal filter system 139

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

3 Electronic power control (EPC)

3.1 Function of EPC system

With the EPC system, the throttle valve is not operated by a cable
from the accelerator There is no mechanical connection between
the accelerator and the throttle valve.
The position of the accelerator is transmitted to the engine control
unit by two accelerator position senders (variable resistors to‐
gether in one housing) connected to the accelerator.
The position of the accelerator (driver's requirement) is a main
input value for the engine control unit.
The throttle valve is operated over the complete engine speed
and load range by an electric motor (throttle valve positioner) in
the throttle valve module.
The throttle valve is operated by the throttle valve positioner which
is controlled by the engine control unit.
When the engine is not running and the ignition is switched on,
the engine control unit moves the throttle valve exactly as pre‐
scribed by the accelerator position sender. That is, when the
accelerator is depressed halfway, the throttle valve positioner
opens the throttle valve by the same amount. The throttle is then
approximately half open.
When the engine is running (under load), the engine control unit
can open or close the throttle valve independently of the accel‐
erator position sender.
This means that the throttle valve can already be completely open
even though the accelerator is depressed half way. This has the
advantage of preventing throttling losses at the throttle valve. AG. Volkswagen AG d
agen oes
ksw
After evaluating the torque requirements of various components by
Vol not
gu
ara
(e.g. air conditioning system, automatic gearbox, ABS/ESP risedand nte
so on), the engine control unit calculates the optimal throttle
ut
ho valve eo
ra
opening angle for the respective situation. ss a c
ce
e
nl

This also results in significantly improved consumption and ex‐

pt
du

an
haust emission values under certain load conditions.
itte

y li
erm

ab

It is incorrect to believe that the “E-Gas” is comprised of one or

ility
ot p

two components only. EPC is a system containing all components

wit
, is n

which have an influence on, or control and monitor, the position

h re
hole

of the throttle valve, such as the accelerator position sensor, the

spec

throttle valve control unit, the EPC warning lamp, the engine con‐
es, in part or in w

t to the co

trol unit…).
– EPC warning lamp function test ⇒ Rep. gr. 01 ; Significance
of EPC warning lamp (electronic power control fault lamp) in
rrectness of i

dash panel insert .

l purpos

Note safety precautions ⇒ page 123 .

Observe rules for cleanliness ⇒ page 123 .
nf
ercia

orm

3.2 Repairing parts of electronic power control (EPC)

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.

140 Rep. gr.20 - Fuel supply system

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
tho tee
or Sharan 1996 ➤
u
ss
a
6-cylinder injection engine (4-valve),ac
mechanics - Edition 06.2019

ce
e
nl

pt
du
1 - Mounting bracket

an
itte

y li
erm

ab
2 - Connector

ility
ot p

❑ Black, 6-pin

wit
, is n

h re
3 - 10 Nm
hole

spec
es, in part or in w

4 - Acceleration pedal position

t to the co
sender - G79-
❑ Not adjustable.

rrectness of i
❑ The accelerator position
sender passes the posi‐
l purpos

tion of the accelerator

on to the engine control
unit.

nf
ercia

or
❑ Checking ⇒ page 142

m
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

3. Electronic power control (EPC) 141

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

3.3 Checking accelerator position sender

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

Special tools and workshop equipment required

♦ Hand multimeter - V.A.G 1526 A-
nform
ercia

♦ Auxiliary measuring set - V.A.G 1594 A-

m

a
com

tio

♦ Test box - V.A.G 1598/31-

n in
r
te o

thi

♦ Vehicle diagnostic tester

s
iva

do
r
rp

♦ Current flow diagram

um
fo

en
ng

t.
Function
yi Co
Cop py
t. rig
Both accelerator position senders -G79- and -G185- are located
gh ht
yri by
on the accelerator pedal and pass the driver's requirements on to
cop Vo
by lksw
cted
the engine control unit independently of one another. Both send‐
agen
Prote AG.
ers are installed together in a housing.

142 Rep. gr.20 - Fuel supply system

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Test conditions
• Fuses must be OK.
• Battery voltage must be at least 11.5 V.
Volkswa AG. gen AG
agen do
• All electricalVconsumers,
olks
w
e.g. lights and erear
s no window heating,
t gu
y
must beseswitched off.
d b ara
n
ri tee
ho
• If theau vehicle is equipped with an air conditioner, it must
t or
ac be
switched
ss off.

ce
e
nl

pt
du

Test sequence

an
itte

y li
erm

ab
– Connect fault reader -V.A.G 1551- (V.A.G 1552) and select

ility
ot p

engine control unit with “address word” 01. Ignition must be

wit
switched on for this ⇒ Rep. gr. 01 ; Connecting fault reader .
, is n

h re
hole

Indicated on display:

spec
es, in part or in w

t to the co
Rapid data transfer HELP
Select function XX

– Press keys 0 and 8 for “Read measured value block” function

rrectness of i
and confirm with Q key.
l purpos

Indicated on display:

nform
ercia

Read measured value block

Enter display group number XXX
m

at
om

io
– Press buttons 0 , 6 and 2 for “Display group number 62” and
n
c

in t
r

confirm entry with Q button.

o

his
ate

do
riv

Indicated on display: (1…4 = display zones)

p

cum
for

en
ng

t.
Read measured value block 62 -> yi Co
1 2 3 4 Cop py
t. rig
gh ht
yri by
– Check specification of sender 1 -G79- at idling stop in display
op Vo
by c lksw
zone 3. Specification: 12…97% cted agen
Prote AG.

– Check specifications of sender 2 -G185- at idling stop in dis‐

play zone 4. Specification: 4…49%

Note

The engine control unit calculates the angle sender voltage value
as a percent of 5 Volts and displays this percentage. (5 volt supply
voltage equals 100%).

– Operate the accelerator slowly until fully depressed and ob‐

serve the percentage display in display zones 3 and 4: The
percent display in display zone 3 must rise evenly. The toler‐
ance range of 12…97% is not completely exploited. The per‐
cent figures in display zone 4 must rise evenly. The tolerance
range of 4…49% is not completely exploited.

Note

The figure displayed in display zone 3 must always be approxi‐

mately double that displayed in display zone 4.

– Press → button.
– Press buttons 0 and 6 for function “End output” and confirm
entry with Q button.
– Switch off ignition.

3. Electronic power control (EPC) 143

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

If the display does not indicate as described:

– Check accelerator position sender voltage supply and wiring
connections ⇒ page 144 .

3.3.1 Checking voltage supply and wiring to

control unit
– Pull 6-pin connector off accelerator position sender.
– Switch ignition on. AG. Volkswagen AG d
agen oes
olksw not
– Connect multimeter todmeasure by
V voltage using auxiliary cablesgu
ara
from -V.A.G 1594 A- oristo the following connector contacts. Con‐
e nte
eo
tact 1 + ground contact
aut
h
1 + 5 contact 2 + ground contact 2 + ra
3 specification:s at least 4.5 V
s c

ce
e
nl

pt
– Switch off ignition.
du

an
itte

y li
erm

If no voltage is present:

ab
ility
ot p

– First check whether a coded radio is fitted. If so, obtain anti-

wit
, is n

theft coding.

h re
hole

spec
– Remove battery.
es, in part or in w

t to the co
– Connect test box - V.A.G 1598/31- to control unit wiring har‐

rrectness of i
ness. The engine control unit remains disconnected.
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.

144 Rep. gr.20 - Fuel supply system

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Check cables between test box and 6-pin connector for open
circuit using current flow diagram. Contact 1 and test box
socket 72, contact 2 and test box socket 73, contact 3 and test
box socket 36, contact 4 and test box socket 35, contact 5 and
test box socket 33, contact 6 and and test box socket 34, line
resistance : max. 1.5 Ω
– Additionally check wires for short to one another, to vehicle
earth and to battery positive. Specification: ∞ Ω.
If no fault in lines is detected:
AG. Volkswagen
– Renew accelerator position
lksw
agesender
n
⇒ Item 4AG(page
does 141) .
n
o ot g
yV u
– Read and eraserisefault
d b memory ⇒ Rep. gr. 01 ; Reading
ara
and
nt
erasing engine tho control unit fault memory .
ee
or
s au ac
– Read readiness code ⇒ Rep. gr. 01 ; Reading readiness
s

ce
le

code .
un

pt
an
d
itte

y li
– If the fault memory has been cleared or the engine control unit
erm

ab
was separated from the continuous positive supply, the read‐

ility
ot p

iness code must be regenerated: ⇒ Rep. gr. 01 ; Generating

wit
is n

readiness code .

h re
ole,

spec
Vehicles with automatic gearbox:
urposes, in part or in wh

t to the co
– On vehicles with an automatic gearbox the gearbox control
unit must be additionally adapted: ⇒ Self-diagnosis for 5-
speed automatic gearbox 09B; Rep. gr. 01 ; Initiating basic

rrectne
setting .

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

3. Electronic power control (EPC) 145

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

26 – Exhaust system
1 Removing and installing parts of ex‐
haust system AG. Volkswagen A n G do
wage es n
Special tools and workshop equipment required y Volks ot g
ua
b
ed ran
♦ 3337 Lambda probe open ring spannerthoset
ris tee
or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
♦ Torque wrench (40…200 Nm) -V.A.G 1332-
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 Exhaust manifold, front exhaust pipe

and catalytic converter with attachments

Note

♦ Components marked with * are checked via self-diagnosis ⇒

Rep. gr. 01 ; Reading and erasing engine control unit fault
memory .
♦ After working on the exhaust system, ensure that the system
is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen clamps and align silencer and
exhaust pipe so that sufficient clearance is maintained to the
bodywork and the mountings are evenly loaded.
♦ Renew self-locking nuts.

146 Rep. gr.26 - Exhaust system

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

1 - Shield
2 - 20 Nm
3 - Exhaust manifold
❑ 2-part
4 - Seal
❑ Renew
5 - Heat shield
6 - Panel nut
❑ Must be screwed on/off
7 - Front exhaust pipe
8 - Connector
❑ For Lambda probe after
catalytic converter -
G130- and Lambda
probe heating 1 after
catalytic converter -
Z29- .
❑ Black, 4-pin
❑ Contacts 3 and 4 gold-
plated
9 - Connector
❑ For Lambda probe -
G39- and Lambda
probe heating - Z19- .
❑ Black, 6-pin
❑ Gold-plated contacts
olkswagen AG
en AG. V
10 - Lambda probe after cata‐ ksw
ag does
not
Vol
lytic converter - G130- * 50 Nm d by gu
ara
ise nte
❑ Remove and install us‐ uthor eo
ing ring spanner for ss a ra
c
lambda probe 3337
ce
e
nl

pt
du

❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” cannot get into the slots on the probe body.
an
itte

y li

❑ If seal is leaking, nip open and renew.

erm

ab
ility
ot p

❑ Checking ⇒ Rep. gr. 24 ; Checking Lambda probe and Lambda control after catalytic converter .
wit
, is n

h re

11 - Catalytic converter
hole

spec

❑ Checking ⇒ page 148

es, in part or in w

t to the co

12 - To front silencer
❑ ⇒ Item 6 (page 148)
rrectness of i

13 - Securing clip
l purpos

14 - 8 Nm
15 - 20 Nm
nf
ercia

❑ Renew
rm
m

atio
m

16 - Lambda probe - G39- * 50 Nm

o

n in
or c

❑ Remove and install using ring spanner for lambda probe 3337
thi
te

sd
iva

❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” cannot get into the slots on the probe body.
o
r
rp

cu
o

❑ If seal is leaking, nip open and renew.

f

en
ng

t.
yi Co
❑ Checking ⇒ Rep. gr. 24 ; Checking Lambda probe and Lambda control before catalytic converter . t. Cop py
rig
gh ht
yri
17 - 45 Nm p by
co Vo
by lksw
❑ Renew
cted agen
Prote AG.

1. Removing and installing parts of exhaust system 147

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

1.2 Silencer with mountings

Note

Longitudinally, the exhaust system must be aligned so that the

dimensions -a- and -b- are adhered to.

1 - From catalytic converter

❑ ⇒ Item 11 (page 147)
n AG. Volkswagen AG do
2 - Clip lkswage es n
o ot g
byV ua
3 - Retaining ring ir se
d ran
tee
o
❑ Renew if damaged auth or
ac
ss
❑ Observe installation po‐

ce
le
un

sition

pt
an
d
itte

y li
4 - Panel nut
erm

ab
ility
ot p

❑ Must be screwed on/off

wit
is n

h re
5 - Heat shield
ole,

spec
urposes, in part or in wh

6 - Front silencer

t to the co
7 - Rear silencer
8 - Dimension -b- = approx. 50

rrectne
mm
9 - Dimension -a- = approx. 5

ss
mm

o
cial p

f in
10 - 40 Nm

form
mer

❑ Renew

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.

1.3 Checking catalytic converter

Special tools and workshop equipment required

148 Rep. gr.26 - Exhaust system

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

♦ -V.A.G 1551- Fault reader

♦ -V.A.G 1551/3- Cable

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
urposes, in part or in wh

t to the co

Note
rrectne

Vehicle system tester -V.A.G 1551- can be used instead of fault

reader -V.A.G 1552- , however a print-out is not possible.
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.

1. Removing and installing parts of exhaust system 149

 Sharan 1996 ➤ agen
AG. Volkswagen AG d
oes
ksw not
6-cylinder injection engine
by V (4-valve), mechanics - Edition
ol
gu06.2019
a
ed ran
oris tee
Test conditions au
th or
ac
ss
• Fuses must be OK.

ce
le
un

pt
an
d
• Battery voltage must be at least 11.5 V. itte

y li
rm

ab
pe

• Exhaust system between catalytic converter and cylinder head

ility
ot

must be free of leaks

wit
, is n

h re
• No fault may be stored in fault memory ⇒ Rep. gr. 01 ; Read‐
hole

spec
ing and erasing engine control unit fault memory .
es, in part or in w

t to the co
• Coolant temperature must be at least 80°C, ⇒ display group
01, display zone 2

rrectness of i
• Catalytic converter temperature must be at least 350°C, ⇒ dis‐
play group 205, display zone 2
l purpos

Test sequence

nform
ercia

– Connect fault reader -V.A.G 1551- (V.A.G 1552). Start engine

and select “Address word” 01 of engine control unit. Connect
m

a
fault reader and select engine control unit: ⇒ Rep. Gr. 01;
com

tion in
General notes for self-diagnosis: Connecting fault reader
r
te o

V.A.G 1551 and selecting engine electronics control unit .

thi
s
iva

do
r

Indicated on display:
rp

cum
fo

en
ng

t.
Rapid data transfer HELP
yi Co
op py
Select function XX t. C rig
gh ht
yri by
– Press keys 0 and 4 for function “Initiate basic settings” and cop Vo
by lksw
cted
confirm entry with Q key.
agen
Prote AG.

Indicated on display:
Basic setting
Enter display group number XXX

Note

During certain tests, it may occur that a subsequent test has al‐
ready been carried out successfully in the background. In this
case, continue with the subsequent test.

1.3.1 Checking Lambda probe heating before

catalytic converter
– Press buttons 2 , 0 and 5 for “Display group number 205” and
confirm entry with Q button.
Indicated on display: (1…4 = display zones) System in basic setting 205 ->
1 2 3 4

Only continue with the test when:

• Catalytic converter temperature is over 350°C, -display zone
2-
– Depress brake pedal and hold.
– Depress accelerator to full throttle position. Engine revolutions
are raised by engine control unit to approx. 2300 rpm.
– Allow engine to run at idle speed until specification: x x x x x
1 0 0 is displayed in display zone 4.
If readout is not as described:
– Press → button.

150 Rep. gr.26 - Exhaust system

 n AG. Volkswagen AG do
wage es n
yV
olks ot g Sharan 1996 ➤
b ua
6-cylinderir se injection engine (4-valve), mechanicsan-teEdition 06.2019
d r
ho eo
a ut ra
– Read fault memory ⇒ Rep. gr. 01ss ; Reading and erasing en‐ c
gine control unit fault memory .

ce
le
un

pt
an
d
itte
– Read readiness code ⇒ Rep. gr. 01 ; Reading readiness

y li
rm

ab
code .

pe

ility
ot

wit
– If the fault memory has been cleared or the engine control unit

, is n

h re
was separated from the continuous positive supply, the read‐

hole
iness code must be regenerated ⇒ Rep. gr. 01 ; Generating

spec
es, in part or in w
readiness code .

t to the co
If the display indicates as described:
– Check Lambda probe ageing before catalytic converter (probe

rrectness of i
dynamics) ⇒ page 151 .
l purpos

1.3.2 Checking Lambda probe ageing before

catalytic converter (probe dynamics)

nform
mercia

– Change to display group 212 as follows:

a
com

tion in
– Press the C button.
r
te o

thi
s
iva

Indicated on display:

do
Basic setting
r
rp

cum
Enter display group number XXX
fo

en
ng

t.
yi
– Press buttons 2 , 1 and 2 for “Display group number 212” and
Co
Cop py
confirm entry with Q button.
t. rig
gh ht
pyri by
Vo
co
Indicated on display: (1…4 = display zones)
by lksw
cted System in basic setting 212 ->
agen
Prote AG.
1 2 3 4

– Depress brake pedal and hold.

– Depress accelerator to full throttle position. Engine revolutions
are raised by engine control unit to approx. 2300 rpm.
– Allow engine to run at idle speed until specification: x x x x x
1 0 0 is displayed in display zone 4 after approx. 80 seconds.
If readout is not as described:
– Press → button.
– Read fault memory ⇒ Rep. gr. 01 ; Reading and erasing en‐
gine control unit fault memory .
– Read readiness code ⇒ Rep. gr. 01 ; Reading readiness
code .
– If the fault memory has been cleared or the engine control unit
was separated from the continuous positive supply, the read‐
iness code must be regenerated ⇒ Rep. gr. 01 ; Generating
readiness code .
If the display indicates as described:
– Check fuel supply system at partial load ⇒ page 151 .

1.3.3 Checking fuel supply system at partial

load
– Change to display group 216 as follows:
– Press the C button.
Indicated on display: Basic setting
Enter display group number XXX

– Press buttons 2 , 1 and 6 for “Display group number 216” and

confirm entry with Q button.
Indicated on display: (1…4 = display zones) System in basic setting 216 ->
1 2 3 4

1. Removing and installing parts of exhaust system 151

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Depress brake pedal and hold.

– Depress accelerator to full throttle position. Engine revolutions
are raised by engine control unit to approx. 2300 rpm.
– Allow engine to run at idle speed until specification: x x x x x
1 0 0 is displayed in display zone 4 after approx. 75 seconds.
If readout is not as described:
– Press → button.
– Read fault memory ⇒ Rep. gr. 01 ; Reading and erasing en‐
gine control unit fault memory .
– Read readiness code ⇒ Rep. gr. 01 ; Reading readiness
code .
– If the fault memory has been cleared or the engine control unit
was separated from the continuous positive supply, the read‐
iness code must be regenerated ⇒ Rep. gr. 01 ; Generating
readiness code . AG. Volkswagen n AG do
wage es n
If the display indicates as described: Volks ot g
by ua
ed ran
– Check Lambda probe heating afteroris catalytic converter tee
th or
⇒ page 152 . au ac
ss

ce
e

1.3.4 Checking Lambda probe heating after

nl

pt
du

an
itte

catalytic converter

y li
erm

ab
ility
ot p

– Change to display group 220 as follows:

wit
, is n

h re
– Press the C button.
hole

spec
Indicated on display:
es, in part or in w

Basic setting

t to the co
Enter display group number XXX

– Press buttons 2 , 2 and 0 for “Display group number 220” and

rrectness of i
confirm entry with Q button.
l purpos

Indicated on display: (1…4 = display zones) System in basic setting 220 ->
1 2 3 4
nform
ercia

– Depress brake pedal and hold.

m

at

– Depress accelerator to full throttle position. Engine revolutions

om

ion

are raised by engine control unit to approx. 2300 rpm.

c

in t
or

his
e

– Allow engine to run at idle speed until specification: x x x x x

at

do
riv

1 0 0 is displayed in display zone 4.

p

cum
for

en
g

If readout is not as described:

n

t.
yi Co
Cop py
– Press → button.
t. rig
gh ht
pyri by
Vo
co
– Read fault memory ⇒ Rep. gr. 01 ; Reading and erasing en‐
by lksw
cted agen
Prote
gine control unit fault memory .
AG.

– Read readiness code ⇒ Rep. gr. 01 ; Reading readiness

code .
– If the fault memory has been cleared or the engine control unit
was separated from the continuous positive supply, the read‐
iness code must be regenerated ⇒ Rep. gr. 01 ; Generating
readiness code .
If the display indicates as described:
– Check Lambda probe after catalytic converter ⇒ page 152 .

1.3.5 Lambda probe after catalytic converter

– Change to display group 222 as follows:

152 Rep. gr.26 - Exhaust system

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Press the C button.

Indicated on display: Basic setting
Enter display group number XXX

– Press buttons 2 , 2 and 2 for “Display group number 222” and

confirm entry with Q button.
Indicated on display: (1…4 = display zones) System in basic setting 222 ->
1 2 3 4

– Depress brake pedal and hold.

– Depress accelerator to full throttle position. Engine revolutions
are raised by engine control unit to approx. 2300 rpm.
– Allow engine to run at idle speed until specification: x x x x x
1 0 0 is displayed in display zone 4 after approx. 30 seconds.
If readout is not as described:
– Press → button.
olkswagen AG
en AG. V
– Read fault memory
olks
wag ⇒ Rep. gr. 01 ; Reading
does
not and erasing en‐
gine control
ed by Vunit fault memory . gu
ara
is nte
or
– Readau
th readiness code ⇒ Rep. gr. 01 ; Reading readiness
eo
ra
code
ss . c
ce
le
un

pt

– If the fault memory has been cleared or the engine control unit
an
d
itte

was separated from the continuous positive supply, the read‐

y li
erm

ab

iness code must be regenerated ⇒ Rep. gr. 01 ; Generating

ility
ot p

readiness code .
wit
is n

h re

If the display indicates as described:

ole,

spec
urposes, in part or in wh

– Check Lambda probe ageing after catalytic converter (probe

dynamics) ⇒ page 153 .
t to the co

1.3.6 Checking Lambda probe ageing after

rrectne

catalytic converter (probe dynamics)

– Change to display group 225 as follows:
ss o
cial p

– Press the C button.

inform
mer

Indicated on display:
atio

Basic setting
m

Enter display group number XXX

o

n
c

i
or

n thi

– Press buttons 2 , 2 and 5 for “Display group number 225” and

te

sd
va

confirm entry with Q button.

i

o
pr

cum
r
fo

Indicated on display: (1…4 = display zones)

en
ng

t.
yi Co System in basic setting 225 ->
Cop py 1 2 3 4
t. rig
gh ht
yri
– Depress brake pedal and hold.
p by
co Vo
by lksw
cted agen
– Depress accelerator to full throttle position. Engine revolutions
Prote AG.
are raised by engine control unit to approx. 2300 rpm.
– Allow engine to run at idle speed until specification: x x x x x
1 0 0 is displayed in display zone 4 after approx. 15 seconds.
If readout is not as described:
– Press → button.
– Read fault memory ⇒ Rep. gr. 01 ; Reading and erasing en‐
gine control unit fault memory .
– Read readiness code ⇒ Rep. gr. 01 ; Reading readiness
code .
– If the fault memory has been cleared or the engine control unit
was separated from the continuous positive supply, the read‐

1. Removing and installing parts of exhaust system 153

 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Sharan 1996 ➤ ut
ho eo
ra
a
6-cylinder injection engine (4-valve), mechanics
s - Edition 06.2019
s c

ce
e
nl

pt
du

an
iness code must be regenerated ⇒ Rep. gr. 01 ; Generating

itte

y li
readiness code .

erm

ab
ility
ot p
If the display indicates as described:

wit
, is n

h re
– Check catalytic converter ⇒ page 154 .

hole

spec
1.3.7 Checking catalytic converter

es, in part or in w

t to the co
– Change to display group 227 as follows:

rrectness of i
– Press the C button.

l purpos
Indicated on display: Basic setting
Enter display group number XXX

nf
ercia
– Press buttons 2 , 2 and 7 for “Display group number 227” and

orm
confirm entry with Q button. m

atio
om

n in
Indicated on display: (1…4 = display zones)
or c
System in basic setting 227 ->

thi
e
1 2 3 4
t

sd
iva

o
r
rp

cu
– Depress brake pedal and hold.
o

m
f

en
ng
t.
– Depress accelerator to full throttle position. Engine revolutions
yi Co
op py
are raised by engine control unit to approx. 2300 rpm. t. C rig
gh ht
yri by
– Allow engine to run at idle speed until specification: x x x x x
op Vo
by c lksw
cted
1 0 0 is displayed in display zone 4 after approx. 60 seconds.
agen
Prote AG.

– Press → button.
– Press buttons 0 and 6 for function “End output” and confirm
entry with Q button.
– Switch off ignition.
If the display does not change as described:
– Renew catalytic converter ⇒ Item 11 (page 147) .

154 Rep. gr.26 - Exhaust system

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
rised
Sharan
nte 1996 ➤
o eo
6-cylinderaut injection engine (4-valve), mechanics - Edition
h
r a06.2019
ss c

ce
e
nl

pt
du
2 Secondary air system

an
itte

y li
erm

ab
ility
ot p
WARNING

wit
, is n

h re
hole

spec
Observe the following points during all installation work, in par‐

es, in part or in w
ticular in the engine compartment, due to the space limitations:

t to the co
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake

rrectness of i
fluid and vacuum) and electrical wiring in their original po‐
sitions. l purpos

♦ Ensure that there is sufficient clearance to all moving or

hot components.

nf
ercia

orm
m

atio
m

Function
o

n in
or c

thi
During a cold start, air is blown in behind the exhaust valve by the
te

sd
a

secondary air system. This produces an oxygen rich exhaust gas,

iv

o
r
rp

cu
causing afterburning and reducing the heat-up phase of the cat‐
o

m
f

en
ng

alytic converter. Activation is initiated by the Motronic control unit

t.
yi Co
-J220- via the secondary air pump relay -J299- to combination Cop py
. rig
valve.
ht ht
rig by
copy Vo
Checking secondary air system ⇒ page 158 .
by lksw
cted agen
Prote AG.

2.1 Removing and installing parts of secon‐

dary air system

Note

♦ Components marked with an * are checked by self-diagnosis:

⇒ Rep. Gr. 01; Fault memory; Reading and erasing engine
control unit fault memory .
♦ Components marked with ** are checked by final control di‐
agnosis: ⇒ Rep. Gr. 01; Final control diagnosis; Performing
final control diagnosis .
♦ Secondary air pump relay -J299- ** ⇒ page 157

2. Secondary air system 155

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

1 - Intake manifold
2 - Vacuum actuator
❑ For intake manifold
change-over.
3 - To intake manifold
AG. Volkswagen AG d
agen
4 - To fuel pressure regulator. olksw
oes
not
byV gu
ara
d
5 - O-ring orise nte
eo
h
ut
❑ Renew if damaged ss a ra
c

ce
e
6 - Combination valve

nl

pt
du

an
itte
❑ Checking ⇒ page 163

y li
erm

ab
7 - Seal

ility
ot p

wit
, is n

❑ Renew

h re
hole

8 - Air duct

spec
es, in part or in w

❑ In cylinder head

t to the co
9 - 10 Nm

rrectness of i
10 - Connection
❑ For combination valve
l purpos

and coolant hose

❑ Coolant hose schematic

nf
ercia

diagram ⇒ page 105 .

orm
m

atio
11 - 5 Nm
om

n in
or c

12 - Pressure hose

thi
te

sd
a

❑ Ensure firm seating

iv

o
r
rp

cu
❑ Press together at front
o

m
f

en
ng

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

156 Rep. gr.26 - Exhaust system

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

to release.
13 - Connection
14 - Bracket
❑ For secondary air pump
motor.
❑ Attached to sump and cylinder block
15 - 20 Nm
16 - Connector
❑ Black, 2-pin
❑ For secondary air pump motor.
AG. Volkswagen AG d
agen
17 - Rubber bush olksw
oes
not
byV gu
ara
d
18 - Secondary oris air pump motor - V101- **
e nte
eo
h
ut
❑ Checking
ss a ⇒ page 162 ra
c

ce
e

19 - Air filter
nl

pt
du

an
itte

❑ Clean if soiled.

y li
erm

ab
20 - Clamp

ility
ot p

wit
, is n

21 - Intake hose

h re
hole

❑ Ensure firm seating

spec
es, in part or in w

❑ Press together at front to release.

22 - Connector t to the co
❑ Black, 2-pin
rrectness of i

❑ Before pulling off, mark allocation of connector to component

l purpos

23 - Non-return valve
❑ Observe installation position
nform
ercia

❑ White connection points to secondary air inlet valve - N112- / variable intake manifold changeover valve
m

at

- N156-
om

ion
c

in t
or

24 - Intake manifold changeover valve - N156- */**

his
ate

do
riv

❑ The valve will be activated from the engine control unit (pulsed).
p

cum
for

25 - Secondary air inlet valve - N112- */**

en
ng

t.
yi Co
op
❑ The valve will be activated from the engine control unit (pulsed). C py
ht. rig
rig ht
26 - Vacuum reservoir
py by
co Vo
by lksw
cted
❑ Clipped in bracket ⇒ Item 28 (page 157) and secured with bolt
agen
Prote AG.

27 - 13 Nm
28 - Bracket
❑ For vacuum reservoir, intake manifold changeover valve and secondary air inlet valve

Relay for secondary air pump - J299- ** - relay position 22 -

Relay is located on lower multifunctional unit relay holder.

Note

♦ If tools are necessary to pull relays or control units out of the

relay plate, first disconnect battery earth strap
♦ Before disconnecting battery earth strap obtain code for radios
with anti-theft coding.

2. Secondary air system 157

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

2.2 Checking secondary air system

Special tools and workshop equipment required
♦ -V.A.G 1551- Fault reader

AG. Volkswagen AG d
agen oes
♦ -V.A.G 1551/3- Cable yV
olksw not
gu
d b ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
Note rrectness of i
l purpos

Instead of fault reader - V.A.G 1551- , vehicle system tester -

nform
ercia

V.A.G 1552- can also be used, though a print-out is not possible.

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

158 Rep. gr.26 - Exhaust system

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Test conditions
• Fuses must be OK.
• Battery voltage must be at least 11.5 V.
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
• Vacuum pipes and hose connections free of leaks.
• Vacuum pipes not blocked or kinked.
• No fault may be stored in fault memory: ⇒ Rep. Gr. 01; Fault
memory; Reading and erasing engine control unit fault mem‐
ory
• Coolant temperature must be at least 80°C, ⇒ display group
01, display zone 2
• Catalytic converter temperature must be at least 350°C, ⇒ dis‐
play group 205, display zone 2
Test sequence
– Connect fault reader -V.A.G 1551- (V.A.G 1552). Start engine
and select “Address word” 01 of engine control unit. Connect
fault reader and select engine control unit: ⇒ Rep. Gr. 01;
General notes for 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

– Press keys 0 and 4 for function “Initiate basic settings” and

confirm entry with Q key.
n AG. Volkswagen AG do
Indicated on display:
olks
wage es n
ot g
V
d by ua
ran
e
oris
Basic setting tee
th
Enter display group number XXX or
au ac
ss
ce
e
nl

pt
du

Note
an
itte

y li
erm

ab
ility

During certain tests, it may occur that a subsequent test has al‐
ot p

ready been carried out successfully in the background. In this

wit
, is n

h re

case, continue with the subsequent test.

hole

spec
es, in part or in w

t to the co

2.2.1 Checking Lambda probe heating before

catalytic converter
rrectness of i

– Press buttons 2 , 0 and 5 for “Display group number 205” and

l purpos

confirm entry with Q button.

Indicated on display: (1…4 = display zones)
nf
ercia

System in basic setting 205 ->

o

1 2 3 4
rm
m

atio
m

Only continue with the test when:

o

n in
or c

• Catalytic converter temperature is over 350°C, -display zone

thi
te

sd
a

2-
iv

o
r
rp

cu
o

– Depress brake pedal and hold.

f

en
ng

t.
yi Co
op
– Depress accelerator to full throttle position. Engine revolutions
C py
t. rig
are raised by engine control unit to approx. 2300 rpm.
gh ht
pyri by
Vo
o
by c lksw
– Allow engine to run at idle speed until specification: x x x x x
cted agen
Prote AG.
1 0 0 is displayed in display zone 4.

2. Secondary air system 159

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

If readout is not as described:

– Press → button.
– Read fault memory ⇒ Rep. gr. 01 ; Reading and erasing en‐
gine control unit fault memory .
– Read readiness code ⇒ Rep. gr. 01 ; Reading readiness
code .
– If the fault memory has been cleared or the engineecontrol
AG. Volunit
kswagen AG
was separated from the continuous positiveolsupply,ag n the read‐ does
ksw not
iness code must be regenerated ⇒ Rep. d b gr. 01 ; Generating
y V gu
ara
readiness code . rise nte
ho e t or
au ac
If the display indicates as described:
ss

ce
e
nl

pt
– Check Lambda probe ageing before catalytic converter (probe
du

an
itte

dynamics) ⇒ page 160 .

y li
erm

ab
ility
2.2.2 Checking Lambda probe ageing before
ot p

wit
, is n

catalytic converter (probe dynamics)

h re
hole

spec
– Change to display group 212 as follows:
es, in part or in w

t to the co
– Press the C button.
Indicated on display:

rrectness of i
Basic setting
Enter display group number XXX
l purpos

– Press buttons 2 , 1 and 2 for “Display group number 212” and

confirm entry with Q button.

nform
ercia

Indicated on display: (1…4 = display zones) System in basic setting 212 ->
m

at
1 2 3 4
om

ion
c

in t
– Depress brake pedal and hold.
or

his
ate

– Depress accelerator to full throttle position. Engine revolutions do

priv

c
are raised by engine control unit to approx. 2300 rpm.
um
for

en
ng

t.
yi
– Allow engine to run at idle speed until specification: x x x x x
Co
op py
1 0 0 is displayed in display zone 4 after approx. 80 seconds.
t. C rig
gh ht
pyri by
Vo
o
If readout is not as described:
c by lksw
cted agen
Prote AG.
– Press → button.
– Read fault memory ⇒ Rep. gr. 01 ; Reading and erasing en‐
gine control unit fault memory .
– Read readiness code ⇒ Rep. gr. 01 ; Reading readiness
code .
– If the fault memory has been cleared or the engine control unit
was separated from the continuous positive supply, the read‐
iness code must be regenerated ⇒ Rep. gr. 01 ; Generating
readiness code .
If the display indicates as described:
– Check fuel supply system at partial load ⇒ page 151 .

2.2.3 Checking fuel supply system at idle

speed
– Change to display group 216 as follows:
– Press the C button.
Indicated on display: Basic setting
Enter display group number XXX

160 Rep. gr.26 - Exhaust system

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Press buttons 2 , 1 and 6 for “Display group number 216” and

confirm entry with Q button.
Indicated on display: (1…4 = display zones) System in basic setting 216 ->
1 2 3 4

– Allow engine to run at idle speed until specification: x x x x 1

x 0 0 is displayed in display zone 4 after approx. 30 seconds.
If readout is not as described:
– Press → button.
– Read fault memory ⇒ Rep. gr. 01 ; Reading and erasing en‐
gine control unit fault memory .
– Read readiness code ⇒ Rep. gr. 01 ; Reading readiness
code .
– If the fault memory has been cleared or the engine control unit
was separated from the continuous positive supply, the read‐
iness code must be regenerated ⇒ Rep. gr. 01 ; Generating
readiness code .
If the display indicates as described:
– Check fuel supply system at partial load ⇒ page 161 .

2.2.4 Checking fuel supply system at partial

load
Indicated on display: (1…4 = display zones) System in basic setting 216 ->
1 2 3 4

– Depress brake pedal and hold.

– Depress accelerator to full throttle position. Engine revolutions
are raised by engine control unit to approx. 2300 rpm.
– Allow engine to run at idle speed until specification: x x x x x
1 0 0 is displayed in display zone 4 after approx. 75 seconds.
If readout is not as described: n AG. Volkswagen AG do
swage es n
– Press → button. byV
olk ot g
ua
d ran
ir se tee
– Read fault memory ⇒ Rep. ugr. th 01 ; Reading and erasing en‐
o
or
gine control unit fault memory
ss
a . ac
ce
le

– Read readiness code ⇒ Rep. gr. 01 ; Reading readiness

un

pt
an
d

code .
itte

y li
erm

ab

– If the fault memory has been cleared or the engine control unit
ility
ot p

was separated from the continuous positive supply, the read‐

wit
is n

iness code must be regenerated ⇒ Rep. gr. 01 ; Generating

h re
ole,

readiness code .
spec
urposes, in part or in wh

If the display indicates as described:

t to the co

– Check secondary air system ⇒ page 161 .

rrectne

2.2.5 Checking secondary air system

– Change to display group 231 as follows:
ss o
cial p

– Press the C button.

inform
mer

Indicated on display:
atio

Basic setting
m

Enter display group number XXX

o

n
c

i
or

– Press buttons 2 , 3 and 1 for “Display group number 231” and

thi
te

sd
a

confirm entry with Q button.

iv

o
pr

cum
r
fo

Indicated on display: (1…4 = display zones)

en
ng

t.
System in basic setting 231 ->
yi Co
Cop 1 2 3 4 py
t. rig
gh ht
pyri by

161
co Vo
by lksw
cted 2. Secondary air system
agen
Prote AG.
 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

– Allow engine to run at idle speed until specification: x x x x x

1 0 0 is displayed in display zone 4 after approx. 40 seconds.
AG. Volkswagen AG d
– Press → button. lksw
agen oes
not
o
byV gu
ara
– Press buttons 0 and ris 6 for function “End output” and confirm
ed
nte
o
entry with Q button.
aut
h eo
ra
ss c
– Switch off ignition.

ce
e
nl

pt
du

an
If the display does not change as described:
itte

y li
erm

ab
– Initiate final control diagnosis and select secondary air inlet

ility
ot p

valve -N112- and secondary air pump relay -J299- , ⇒ Rep.

wit
, is n

gr. 01 ; Performing final control diagnosis .

h re
hole

spec
2.3 Checking secondary air pump motor
es, in part or in w

t to the co
Special tools and workshop equipment required
♦ -V.A.G 1551- Fault reader

rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
♦ -V.A.G 1551/3- Cable
co Vo
by lksw
cted agen
Prote AG.

Note

Instead of fault reader - V.A.G 1551- , vehicle system tester -

V.A.G 1552- can also be used, though a print-out is not possible.

162 Rep. gr.26 - Exhaust system

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

Test conditions
• Fuses must be OK.
• Battery voltage must be at least 11.5 V.
• Secondary air pump intake hose not blocked or kinked.
• No fault may be stored in fault memory ⇒ Rep. gr. 01 ; Read‐
ing and erasing engine control unit fault memory .
• Secondary air pump relay -J299- fuse OK: ⇒ Current flow di‐
agrams, Electrical fault finding and Fitting locations.
Test sequence
– Remove noise insulation tray.
n AG. Volkswagen AG do
lkswage es n
– Remove pressure hose -arrow- from secondary d by V air pump mo‐
o ot g
ua
tor. o
ir se
ran
tee
th or
au ac
ss

ce
le

Note
un

pt
an
d
itte

y li
To release, press buttons on hose coupling together.
rm

ab
pe

ility
ot

wit
, is n

– Activate secondary air pump relay - J299- via final control di‐

h re
agnosis ⇒ Rep. gr. 01 ; Performing final control diagnosis .
hole

spec
The secondary air pump motor should run at intervals and air
es, in part or in w

should escape from the outlet point.

t to the co
If the motor runs but no or little air is delivered:

rrectness of i
– Proceed with final control diagnosis until completed.
l purpos

– Press buttons 0 and 6 for function “End output” and confirm

entry with Q button.

nform
ercia

– Switch off ignition.

m

a
– Renew secondary air pump motor - V101-
com

tio
⇒ Item 18 (page 157) .
n in
r
te o

thi
If secondary air pump motor does not run at intervals:
s
iva

do
r
rp

cum

– Check activation of secondary air pump motor - V101- ⇒ Rep.

fo

en
g

gr. 01 ; Performing final control diagnosis .

n

t.
yi Co
Cop py
t. rig
gh ht
2.4 Checking combination valve pyri by
Vo
co lksw
by
cted agen
Prote
Special tools and workshop equipment required
AG.

♦ -V.A.G 1390- Hand vacuum pump

Test conditions
• No fault may be stored in fault memory ⇒ Rep. gr. 01 ; Read‐
ing and erasing engine control unit fault memory .

2. Secondary air system 163

 Sharan 1996 ➤
6-cylinder injection engine (4-valve), mechanics - Edition 06.2019

• Final control diagnosis has been performed ⇒ Rep. gr. 01 ;

Performing final control diagnosis .
• Vacuum pipes and hose connections free of leaks.
• Vacuum pipes not blocked or kinked.
Test sequence

Note

Do not use compressed air during the following check!

– Remove engine cover panel.

– Remove intake hose and intake manifold between air mass
meter and throttle valve module ⇒ Rep. gr. 24 ; Dismantling
and assembling intake manifold .
– Pull vacuum hose from secondary air inlet valve -N112- off
combination valve -arrow-.

n AG. Volkswagen AG do
wage e n
– Connect hand vacuum pump yV
o -V.A.G 1390- to vacuum scon‐
lks ot g
nection on combinationir se
dvalve -arrow-.
b ua
ran
o tee
th or
au ac
ss
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co

– Detach pressure hose to combination valve at connection

rrectne

-arrow- and blow in softly. Combination valve must be closed.

– Operate hand vacuum pump. Combination valve must open.
ss o

If the combination valve does not open, or is constantly open:

cial p

f inform

– Renew combination valve ⇒ Item 6 (page 156) .

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.

164 Rep. gr.26 - Exhaust system