Sharan Electrical System

Service
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Electrical system
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
27 - Starter, current supply, CCS
90 - Gauges, instruments
92 - Windscreen wash/wipe system
94 - Lights, bulbs, switches - exterior
96 - Lights, bulbs, switches - interior
97 - Wiring AG. Volkswagen AG d
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg 00056605520

Sharan 1996 ➤
Electrical system - Edition 12.2008
Contents
27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Battery A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Fundamentals for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Types of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Warning notices and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . .ge. n.A.G.. .Vo. lk. s.w.a.ge. n. A.G. . . . . . . . . . . . . . . . . 2
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3 Charging battery . . . . . . . . . . . . . . . . . . . . b.y.V.ol.k . . . . . . . . . . . . . . . . . . . . .n.ot.g.ua. . . . . . . . . . 3
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4 Disconnecting and reconnecting batteries ho
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4.1 Disconnecting and reconnecting battery, ss
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4.2 Disconnecting and reconnecting second battery on vehicles with two-battery concept . . . . 6
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4.3 Steps after connecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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5 Removing and installing battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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5.1 Removing and installing battery in engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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5.2 Removing and installing second battery under front right seat . . . . . . . . . . . . . . . . . . . . . . 11
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6 Specified torques: battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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7 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.1 Checking starter B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.2 Removing and installing starter, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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7.3 Removing and installing starter, vehicles 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8 Specified torques: starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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8.1 General specified torques for all vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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8.2 Vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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8.3 Vehicles 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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9 Alternator C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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9.1 Securing B+ (battery positive) wire to alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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9.2 Checking poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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9.3 Checking alternator C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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9.4 Characteristics of compact alternators with poly V-belt drive ▸ 05.00 . . . . . . . . . . . . . . . . 29
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9.5 Characteristics of compact alternators with poly V-belt drive 06.00 ▸ . . . . . . . . . . . . . . . . 29
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9.6 Alternator for 4-cylinder petrol injection engine ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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9.7 Alternator for 6-cylinder petrol injection engine ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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9.8 Alternator for 4-cylinder diesel engine ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9.9 Alternator for 1.8 l, 2.0 l 4-cylinder petrol injection engines and 1.9 l 4-cylinder diesel engines
06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.10 Alternator for 2.0 l 4-cylinder diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9.11 Alternator for 6-cylinder petrol injection engine 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.12 Removing and installing poly V-belt pulley on alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9.13 Voltage regulator for alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10 Specified torques: alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10.1 General specified torques for all vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10.2 4-cylinder fuel injection engine ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10.3 6-cylinder fuel injection engine ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10.4 4-cylinder diesel engine ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10.5 1.8 l, 2.0 l, 4-cylinder fuel injection engines and 1.9 l, 4-cylinder diesel engines 06.00 ▸ . . 57
10.6 2.0 l 4-cylinder diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10.7 6-cylinder fuel injection engine 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
11 Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
11.1 Cruise control system (CCS) for vehicles with petrol engine ▸ 05.00 . . . . . . . . . . . . . . . . 59
11.2 Cruise control system (CCS) for vehicles with a TDI diesel engine ▸ 05.00 . . . . . . . . . . . . 61
11.3 Cruise control system (CCS) for vehicles 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
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Sharan 1996 ➤
11.4 Activating and deactivating cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . 62
90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1 Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.1 Dash panel insert, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.2 Dash panel insert, vehicles 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2 Service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.1 Resetting service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

1 Windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.1 Removing windscreen wiper system (vehicles ▸ 09.98) . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.2 Dismantling windscreen wiper system (vehicles ▸ 09.98) . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.3 Installing windscreen wiper system (vehicles ▸ 09.98) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.4 Removing windscreen wiper system (vehicles 10.98 ▸ 05.00) . . . . . . . . . . . . . . . . . . . . . . 84
1.5 Dismantling windscreen wiper system (vehicles 10.98 ▸ 05.00) . . . . . . . . . . . . . . . . . . . . 87
1.6 Installing windscreen wiper system (vehicles 10.98 ▸ 05.00) . . . . . . . . . . . . . . . . . . . . . . 89
1.13 Removing windscreen wiper system (vehicles 11.03 ▸) . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.14 Dismantling windscreen wiper system (vehicles 11.03 ▸) . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.15 Installing windscreen wiper system (vehicles 11.03 ▸) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.16 Removing and installing wiper rubber blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.17 Removing and installing aerodynamic wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.18 Checking intermittent wiper regulator E38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2 Windscreen washer system . . . . . . . . . . . . . . . . . . . . . .n.A.G.. V. o.lk.s.w.ag. e.n.A. . . . . . . . . . . . . . . 120
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2.1 Assembly overview - windscreen washer system Vo.lk.sw . a. . . . . . . . . . . . . . . . .oe. s.n.ot. . . . . . . . . 120
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2.2 Removing and installing reservoir for windscreen d b and headlight washer system . u.ar.a . . . . . 121
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2.3 Removing and installing windscreen and urear tho window washer pump V59 . . . . . . . . .e.or. . 122
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2.4 Removing and installing windscreen washer ss fluid level sender G33 . . . . . . . . . . . . . . . . . c. 122
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2.5 Removing and installing windscreen washer jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

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2.6 Checking and adjusting windscreen washer system spray jets . . . . . . . . . . . . . . . . . . . . . . 126
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3 Rear window wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

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3.1 Removing and installing rear window wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

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3.2 Installing wiper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

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3.3 Adjusting rear window wiper park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

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4 Rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

4.1 Assembly overview - rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.2 Renewing washer jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
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4.3 Adjusting washer jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

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5 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

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5.1 Assembly overview - headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

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5.2 Removing and installing headlight washer system pump V11 . . . . . . . . . . . . . . . . . . . . . . 136
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5.3 Removing and installing pop-up washer jet cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

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5.4 Removing and installing washer jet assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

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5.5 Adjusting headlight washer system jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

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5.6 Bleeding headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

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6 Washer fluid line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

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6.1 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
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7 Hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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ii Contents
Sharan 1996 ➤
8 Specified torques: window wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

8.1 Specified torques for vehicles ▸ 09.98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8.2 Specified torques for vehicles 10.98 ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8.5 Specified torques for vehicles 11.03 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1 Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.1 Assembly overview - headlight, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.2 Assembly overview - headlight, vehicles 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.3 Removing and installing headlight housing, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . 146
1.4 Removing and installing headlight housing, vehicles 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . 146
1.5 Removing and installing headlight lens glass, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . 147
1.6 Removing and installing reflector, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.7 Removing and installing front turn signals, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . 149
1.8 Replacing headlight bulbs, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.9 Replacing headlight bulbs, vehicles 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.10 Removing and installing headlight range control motor, vehicles ▸ 05.00 . . . . . . . . . . . . . . 152
1.11 Removing and installing headlight range control motor, vehicles 06.00 ▸ . . . . . . . . . . . . . . 153
1.12 Converting headlights for use when driving on the left or right (vehicles 06.00 ▸) . . . . . . . . 154
1.13 Adjusting headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2 Headlights with gas discharge bulbs, vehicles 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2.1 Components and senders of headlights with gas discharge bulbs . . . . . . . . . . . . . . . . . . 158
2.2 Removing and installing headlight with gas discharge bulb . . . . . . . . . . . . . . . . . . . . . . . . 160
2.3 Renewing bulbs for gas discharge headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.4 Removing and installing control unit for gas discharge lamp bulb and headlight range
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2.5 Removing and installing front left vehicle level d b sender G78 on front axle . . . .u.ar.a . . . . . . . .
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2.6 Removing and installing rear left vehicle ho level sender G76 on rear axle . . . . . . . . e.o . . . . .
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2.7 Removing and installing headlight range ss
a control motor . . . . . . . . . . . . . . . . . . . . . . . a. c. . . . 167
2.8 Adapting components, headlights with gas discharge bulbs . . . . . . . . . . . . . . . . . . . . . . . . 168
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2.9 Converting headlights for use when driving on the left or right . . . . . . . . . . . . . . . . . . . . . . 169
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2.10 Adjusting headlights with gas discharge bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
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3 Fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

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3.1 Removing and installing front fog light, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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3.2 Removing and installing front fog light, vehicles 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . 172spec
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3.3 Replacing front fog light bulb, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 t to the co
3.4 Replacing front fog light bulb, vehicles 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

4 Side mounted repeater turn signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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4.1 Removing and installing side mounted repeater turn signal . . . . . . . . . . . . . . . . . . . . . . . . 174
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5 Removing and installing turn signal bulb in exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . 175

6 Rear lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
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6.1 Assembly overview - rear light in side panel, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . 176
6.2 Assembly overview - rear light in side panel, vehicles 06.00 ▸ 10.03 . . . . . . . . . . . . . . . . 177
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6.3 Assembly overview - rear light in side panel, vehicles 11.03 ▸ . . . . . . . . . . . . . . . . . . . . . . 178
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6.4 Removing and installing rear light, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

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6.5 Removing and installing rear light, vehicles 06.00 ▸ 10.03 . . . . . . . . . . . . . . . . . . . . . . . . 179
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6.6 Removing and installing rear light, vehicles 11.03 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

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6.7 Removing and installing rear light bulb holder, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . 181
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6.8 Removing and installing rear light bulb holder, vehicles 06.00 ▸ 10.03 . . . . . . . . . . . . . . . . 181
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6.9 Removing and installing rear light bulb holder, vehicles 11.03 ▸ . . . . . . . . . . . . . . . . . . . . 182
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6.10 Assembly overview - rear light in rear lid, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . Prote AG.
182
6.11 Assembly overview - rear light in rear lid, vehicles 11.03 ▸ . . . . . . . . . . . . . . . . . . . . . . . . 183
6.12 Removing and installing rear light bulb holder in rear lid, vehicles ▸ 05.00 . . . . . . . . . . . . 184
Contents iii
Sharan 1996 ➤
6.13 Removing and installing rear light bulb holder in rear lid, vehicles 06.00 ▸ 10.03 . . . . . . . . 184
6.14 Removing and installing rear light bulb holder in rear lid, vehicles 11.03 ▸ . . . . . . . . . . . . 184
6.15 Removing and installing rear light in rear lid, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . 185
6.16 Removing and installing rear light in rear lid, vehicles 06.00 ▸ 10.03 . . . . . . . . . . . . . . . . 185
6.17 Removing and installing rear light in rear lid, vehicles 11.03 ▸ . . . . . . . . . . . . . . . . . . . . . . 187
6.18 Dismantling rear light in rear lid, vehicles ▸ 10.03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
6.19 Dismantling rear light in rear lid, vehicles 11.03 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
7 Number plate light X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
7.1 Removing and installing number plate light X , vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . 190
7.2 Replacing number plate light X bulb, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
7.3 Removing and installing number plate light X , vehicles ▸ 06.00 . . . . . . . . . . . . . . . . . . . . 191
7.4 Removing and installing number plate light X , vehicles 11.03 ▸ . . . . . . . . . . . . . . . . . . . . 191
7.5 Replacing number plate light X bulb, vehicles 11.03 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
8 Additional brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
8.1 Removing and installing additional brake light bulb holder, vehicles ▸ 05.00 . . . . . . . . . . 193
8.2 Removing and installing additional brake light housing, vehicles ▸ 05.00 . . . . . . . . . . . . . . 194
8.3 Removing and installing additional brake light bulb holder, vehicles 06.00 ▸ . . . . . . . . . . 194
9 Steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
9.1 Assembly overview - steering wheel, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
9.2 Removing and installing steering wheel, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . 196
9.3 Removing and installing coil connector with slip ring, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . 197
9.4 Removing and installing steering column switch and steering lock housing with ignition
switch, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
9.5 Removing and installing steering column switch, vehicles 06.00 ▸ . . . . . . . . . . . . . . . . . . 199
9.6 Removing and installing signal horn activation, vehicles 06.00 ▸ .................... 202
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9.7 Pin assignment for steering column switch, vehicles w age06.00 ▸ . . . . . . . .e.s n. . . . . . . . . . . . . 203
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10 Ignition/starter switch and lock cylinder s.ed. . . . . . . . . . . . . . . . . . . . . . . . . . . . .ua.ra.n. . . . . . . .
b 205
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10.1 Removing and installing lock cylinder,uthvehicles
o ▸ 05.00 . . . . . . . . . . . . . . . . . . . e.e .or. . . . . 205
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10.2 Removing and installing lock cylinder, ss vehicles 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . c. . . . 206
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10.3 Removing and installing ignition switch, vehicles 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . 208

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10.4 Pin assignment for ignition/starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

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11 Parking aid, vehicles 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
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11.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

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11.2 Assembly overview - parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . h re

209
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11.3 Removing and installing parking aid control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
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11.4 Removing and installing front parking aid sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

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11.5 Removing and installing rear parking aid sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

11.6 Removing and installing rear parking aid warning buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . 212
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11.7 Removing and installing front parking aid warning buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . 212
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96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

1 Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
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1.1 Assembly overview - immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

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1.2 Removing and installing immobilizer control unit J362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

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1.3 Removing and installing immobilizer reader coil D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

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1.4 Ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

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2 Voltage converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

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2.1 Removing and installing voltage converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

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2.2 Pin assignment of voltage converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
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3 Anti-theft alarm (ATA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
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3.1 Removing and installing central locking and anti-theft alarm system control unit J379 . . Prote AG.
219
3.2 Removing and installing immobilizer warning lamp K117 . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3.3 Removing and installing alarm horn H12 for anti-theft alarm system . . . . . . . . . . . . . . . . . . 220
3.4 Removing and installing left ultrasonic sensor for anti-theft alarm system G170 and right
ultrasonic sensor for anti-theft alarm system G171 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
iv Contents
Sharan 1996 ➤
3.5 Removing and installing driver side central locking switch F59 and front passenger side
central locking switch F114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3.6 Removing and installing central locking/anti-theft alarm system switch -F218- in rear lid . . 222
3.7 Removing and installing rear lid release switch E165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3.8 Removing and installing engine compartment light switch F214 . . . . . . . . . . . . . . . . . . . . 223
3.9 Removing and installing door contact switch rear (rear lid) F160 . . . . . . . . . . . . . . . . . . . . 223
4 Interior lights and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
4.1 Removing and installing light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
4.2 Removing and installing headlight range control adjuster E102 . . . . . . . . . . . . . . . . . . . . 225
4.3 Removing and installing switches in centre of dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.4 Removing and installing interior light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
4.5 Removing and installing sliding sunroof switch E8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
4.6 Removing and installing glove compartment light W6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
4.7 Removing and installing door contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
4.8 Removing and installing power window switch and mirror adjustment switch in doors . . . .
230
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5 Horn and dual tone horn H1 . . . . . . . . . . .y V. o.lk.s. . . . . . . . . . . . . . . . . . . s. n.o.t g. u. . . . . . . . . . . 232
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5.1 Removing and installing treble horn H2riand se bass horn H7 . . . . . . . . . . . . . . .ra.nt.e . . . . . . .
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232
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t relay J4 . . . . . . . . . . . . . . . . . . . . . . . . . e.o.r . . . . .
5.2 Removing and installing dual tone horn au
h
ac 233
ss
6 Taxi equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
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7 Specified torques: lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
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7.1 Specified torque: dual tone horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
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7.2 Specified torque: alarm horn H12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
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97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
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1 Vehicle diagnosis, test and information systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
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1.1 Connecting vehicle diagnosis, testing and information system VAS 5051A and successor
units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
2 Relay carrier ▸ 08.97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
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2.1 Removing and installing relay carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
s
2.2 Removing and installing multi-pin connector on back of relay carrier . . . . . . . . . . . . . . . . 238
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3 Multifunction unit (electronic central electrics) 09.97 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
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3.1 Removing and installing multifunction unit with relay carriers and fuse holder . . . . . . . . . . 240
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3.2 Multifunction unit control unit J501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
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4 Wiring harness and connector repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
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5 Renewal of aerial wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

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Contents v
Sharan 1996 ➤
AG. Volkswagen AG d
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vi Contents
Sharan 1996 ➤
27 – Starter, current supply, CCS

1 Battery -A-
WARNING
Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 1 !
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Caution ir se
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To prevent damage tossthe battery and vehicle, the following
should be observed concerning types of battery ⇒ page 1 .
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1.1 Fundamentals for batteries
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All the instructions and information for this manual are found in
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the workshop manual “Electrical System, General Information”. A
spec
link to this workshop manual is not possible at present for tech‐
es, in part or in w
t to the co
nical reasons. Please select the workshop manual “Electrical
System, General Information” manually in ELSA.
1.2 Types of battery
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System, General Information” manually in ELSA. at

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1.3 Warning notices and safety regulations

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1. Battery A 1
Sharan 1996 ➤
2 Checking battery
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2 Rep. Gr.27 - Starter, current supply, CCS

Sharan 1996 ➤
3 Charging battery
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3. Charging battery 3
Sharan 1996 ➤
4 Disconnecting and reconnecting bat‐

teries
WARNING

tions ⇒ page 1 !
4.1 Disconnecting and reconnecting bat‐

tery, vehicles with one-battery concept
WARNING

tions ⇒ page 1 !
Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-
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Disconnecting battery
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– Switch off ignition and all electrical consumers and remove

ignition key.
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– Disconnect battery earth strap on battery negative terminal

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first.
To disconnect the battery positive cable, first remove the fuse
nf
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holder on the battery.

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Removing and installing fuse holder on battery

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– Press locking lugs -arrows- together to open fuse holder and

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take off cover.

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Sharan 1996 ➤
– Unscrew current conductor plate securing nut -1- on positive

terminal clamp.
– Remove securing nuts -2- to disconnect wiring to strip fuses.
– Pull off connector -3-.
– Release tension on fuse holder spring catch by pressing down

with a thumb and lever spring catch locking device off battery
using a suitable screwdriver.
– Remove fuse holder upwards off battery.
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– Then release the battery positive terminal clamp olksecuring
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Reconnecting battery ho eo
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– Fit positive cable clamp onto battery positive terminal.
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Caution
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Battery terminal clamps must be fitted only by hand without
, is n
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force to prevent damage to battery housing.
hole
Battery terminals must no longer be greased. spec

es, in part or in w
t to the co
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– Tighten battery positive terminal clamp securing bolt -arrow-

to 7 Nm.
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– Fit fuse holder onto battery, when doing this fit current con‐
ductor plate onto securing pins on battery positive terminal.
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– Engage fuse holder spring catch in battery.

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4. Disconnecting and reconnecting batteries 5

Sharan 1996 ➤
– Tighten current conductor plate securing nut -1- on positive

terminal clamp to 7 Nm.
– If wiring was disconnected, reconnect again to strip fuses and AG. Volkswagen AG d
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then tighten securing nuts -2- to 7 Nm. by Vol not
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Caution s au ra
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♦ If the securing nuts for the strip fuses are not correctly
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tightened, the wiring could burn, leading in turn to mal‐
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functions in the electrical system.
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♦ It is essential to ensure the securing nuts are tightened to
, is n
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the specified torque.
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es, in part or in w
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Note
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See connecting diagram in respective current flow diagram ⇒ Cur‐
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rent flow diagrams, Electrical fault finding and Fitting locations.
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– Reconnect connector -3-.

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– Fit fuse holder cover and close.
com
tion in
– Reconnect negative terminal clamp to battery negative termi‐
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nal and tighten to 7 Nm.
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– Perform steps according to table ⇒ page 7 .
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4.2 Disconnecting and reconnecting second
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battery on vehicles with two-battery con‐
cop Vo
by lksw
cted agen
cept
Prote AG.

Disconnecting battery
ignition key.
– Disconnect battery in engine compartment ⇒ page 4 .

Sharan 1996 ➤
– Release trim -1- by levering out the securing pins -arrows- and
remove the trim.
– Remove front passenger seat ⇒ General body repairs, interi‐
or; Rep. Gr. 72 ; Front seats; Removing and installing front
seat .
– Remove securing screws -1- and remove trim -2-.
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
– Disconnect battery positive terminal clamp -1- of second bat‐
hole
spec
tery.
es, in part or in w
t to the co
Reconnecting battery
Carry out installation in the reverse sequence, noting the follow‐
rrectness of i
ing:
l purpos
Caution
nform
ercia
Battery terminal clamps must be fitted only by hand without

force to prevent damage to battery housing.
m
at
om
ion
c
Battery terminals must not be greased.

in t
or
his
ate
do
priv
cum
for
en
g
– Fit battery earth clamp -1- to negative terminal of battery and

n
t.
yi Co
tighten securing bolt to specified torque setting ⇒ page 14 . Cop py
ht. rig
rig ht
– Reconnect battery in engine compartment ⇒ page 4 . py by
co Vo
by lksw
cted agen
– Carry out the procedures as detailed in the table Prote AG.
⇒ page 7 .
4.3 Steps after connecting battery

Procedure Performed
Read fault memory
⇒ Guided fault finding using -VAS 5051- .
4. Disconnecting and reconnecting batteries 7

Sharan 1996 ➤
Procedure Performed
Open all electric windows
completely and close again. AG. Volkswagen AG d
agen oes
olksw not
Radio or radio and navigation system ed by V gu
ara
check function, recode radio if necessary
horis nte
eo
ut ra
Clock ss a c
check time setting and reset if necessary
ce
le
un
pt
an
d
itte
If necessary, table can be printed out.
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
5 Removing and installing battery
WARNING

tions ⇒ page 1 !
AG. Volkswagen AG d
agen oes
olksw not
5.1 Removing and installing battery in en‐
V gu
d by ara
ise nte
gine compartment or eo
h
aut ra
ss c
ce
e
nl
pt
WARNING
du
an
itte
y li
erm
ab
ility
ot p
tions ⇒ page 1 !
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op py
Removing battery t. C rig
gh ht
yri by
– Disconnect battery ⇒ page 4 .
op Vo
by c lksw
cted agen
Prote AG.
– Once the battery positive terminal clamp has been loosened
and removed from the battery positive terminal the battery
heat insulation jacket -arrow- can be opened and removed (if
fitted).
5. Removing and installing battery 9

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
lksw not
– Remove hexagon bolt M8×25 byV
o -arrow-. gu
ara
ed
is nte
– Remove retaininguthstrap.
or eo
a ra
s c
– Remove battery from vehicle. s
ce
le
un
pt
Installing battery
an
d
itte
y li
erm
ab
ility
ot p
ing:
wit
is n
h re
ole,
spec
t to the co
Install battery so that the lug of the battery carrier -arrow- engages
rrectne
in the battery base strip recess -1-.
It must not be possible to move a battery to the left or to the right.
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
The battery is inserted correctly when the centre cut-out in the
py by
co Vo
by lksw
battery foot strip aligns with threaded hole in the battery carrier Prote
cted AG.
agen
-arrows-.
On batteries with a hose for central venting ensure that the hose
is not pinched. Only then can the battery vent freely.
Ensure that the opening on the upper side of the battery cover is
not blocked on batteries without a hose for central venting.

Sharan 1996 ➤
– Fit clamping bracket and tighten M8×25 securing bolt

-arrow- to 20 Nm.
– Reinstall the heat insulation jacket, if part of original equip‐
ment.
– After installing, check that battery is seated securely.
Caution
To guarantee the battery seats securely, only install batteries

with a 10.5 mm battery foot strip and adhere to the following
procedures
A loosely fitted battery creates the following dangers:
♦ Shortened service life due to damage from vibration (dan‐
ger of explosion).
♦ The plates in the battery cells will be damaged if the bat‐
tery is not secured correctly.
♦ Damage to battery housing by clamping bracket (possi‐
bility of acid leaking, with high consequential costs).
♦ Poor crash safety.
– Reconnect battery ⇒ page 4 .
5.2 Removing and installing second battery

under front right seat
WARNING
Danger of injury! Observe warning notices andolksafety
swa
ge regula‐ es n
ot g
tions ⇒ page 1 ! db
y V ua
ran
e
ris tee
tho or
s au ac
A battery may also be installed unders the front right seat of some
ce
e
vehicles, depending on the equipment.

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
c
Removing battery
or
thi
te
sd
a
– Disconnect second battery ⇒ page 6 .

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

Sharan 1996 ➤
– Remove positive terminal cover -A-.
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
– Disconnect battery positive terminal clamp -2- of second bat‐
hole
spec
tery. 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
– Remove the securing bolts -arrows- of the battery cover and
do
r
rp
c
remove the cover.
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
– Remove securing nuts -arrows- from the battery retaining

plate and remove the retaining plate upwards off the second
battery.
– Pull hose off battery for central gas venting.
– Remove second battery from vehicle.
Installing battery
ing: wage
es ks not
Vol gu
d by ara
e
Caution tho
ris nte
eo
au ra
ss c
A loosely fitted battery creates the following dangers:
ce
le
un
pt
an
d
♦ Shortened service life due to damage from vibration (dan‐
itte
y li
ger of explosion).
erm
ab
ility
ot p
♦ The plates in the battery cells will be damaged if the bat‐
wit
is n
tery is not secured correctly.
h re
ole,
spec
♦ Damage to battery housing by clamping bracket (possi‐
bility of acid leaking, with high consequential costs).
t to the co
♦ Poor crash safety.
rrectne
– Tighten securing bolts and nuts to specified torque setting
s
⇒ page 14 .
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
6 Specified torques:
wage battery
n AG . Volkswagen AG
does
olks not
yV gu
db ara
Threaded connection orise nteSpecified
eo
torques
th
au
Battery clamp to battery terminal M6
ra
7 Nmc
ss
ce
e
Additional clamp on battery terminal clamp M6 7 Nm

nl
pt
du
an
itte
Base clamping bracket to body (battery in M8 20 Nm
y li
erm
ab
engine compartment)
ility
ot p
Wiring to strip fuse M6 7 Nm
wit
, is n
h re
Bolts for second battery cover M6 0.5 Nm
hole
spec
Nuts for second battery cover M6 0.2 Nm
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
7 Starter
Caution
When batteries are disconnected and reconnected, the proce‐

dure described in the workshop manual must be strictly ob‐
served ⇒ page 4 .
The following starters are installed

Vehicles ▸ 05.00 with a manual gearbox
♦ 2.0 l petrol engine (12V - .1.1kW)
gen AG
Volkswagen AG
d wa oes
olks not
♦ 2.8 l petroldengine
by
V (12V - 1.8kW) gu
ara
e nte
ris
♦ 1.9 l diesel
tho engine (12V - 1.8kW) eo
s au ra
c
Vehicles ▸ 05.00 with an automatic gearbox
s
ce
le
un
pt
♦ 2.0 l petrol engine (12V - 1.1kW)
an
d
itte
y li
erm
ab
ility
ot p
wit
Vehicles 06.00 ▸ with a manual gearbox
is n
h re
ole,

spec
♦ 2.0 l petrol engine (12V - 1.1kW) t to the co
♦ 2.8 l petrol engine (12V -2.0kW)

rrectne
♦ 1.9 l diesel engine (12V -2.0kW)

Vehicles 06.00 ▸ with an automatic gearbox
ss o

cial p
f inform
♦ 2.8 l petrol engine (12V -2.3kW)

mer
atio
m
7.1 Checking starter -B-

o
n
c
i
or
n thi
te

sd
iva
o
pr
cum
r
♦ Vehicle diagnosis, testing and information system -VAS

fo
en
ng
5051A-
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
7. Starter 15
Sharan 1996 ➤
♦ Diagnosis cable -VAS 5051/6A- (5 m)
AG. Volkswagen AG d
agen oes
♦ Diagnosis cable -VAS 5051/5A- (3 m) Volksw not
gu
d by ara
– Connect vehicle diagnosis, testing and oris information system -
e nte
eo
h
VAS 5051A- or successor models a⇒ ut page 236 . ra
c
ss
– Select “guided fault finding” in the vehicle diagnosis, test and
ce
e
nl
pt
du
information system -VAS 5051A- .
an
itte
y li
erm
ab
– Using “GoTo” button, select “Functions/component” and the
ility
ot p
following menu options in succession:
wit
, is n
♦ Body
h re
hole
spec
♦ Electrical system
es, in part or in w
t to the co
♦ 27 - Starter, current supply
♦ Electrical components
rrectness of i
♦ B - Starter
l purpos
– Or select “Guided fault finding” on vehicle diagnosis, test and

nform
ercia
♦ Body
m
at
om
i
on
c
in t
or

his
ate
do
riv
p
cum
for
en
ng
t.
♦ B - Starter
yi Co
Cop py
t. rig
7.2 Removing and installing starter, vehi‐
gh ht
pyri by
Vo
o
by c
cles ▸ 05.00
lksw
cted agen
Prote AG.
7.2.1 Vehicles with a 2.0 l petrol injection or

1.9 l diesel engine with a manual gear‐
box

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
Removing
erm
ab
ility
ot p

wit
, is n
h re
– Remove all necessary components (battery, air filter housing,

hole
spec
engine cover) to gain access to the starter.

es, in part or in w
t to the co
– Pull black plastic cap -lower arrow- off solenoid switch.

– Release and disconnect connector -upper arrow-.
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.
– Release and disconnect connector for terminal 50
yi Co
op py
-upper arrow-. t. C rig
gh ht
pyri by
– Remove nut -lower arrow- and remove positive wire (terminal
o Vo
by c lksw
cted
30) from solenoid switch.
agen
Prote AG.
7. Starter 17
Sharan 1996 ➤
– Remove nut -arrow- from lower securing bolt then remove se‐
curing bolt.
– Remove nut -1- from upper starter securing bolt and remove
starter motor from vehicle.
Installing
Install in the reverse order of removal. When doing this, note the
following:
– Tighten threaded connections to specified torques
⇒ page 25 .
7.2.2 Vehicles with a 2.8 l petrol injection en‐

gine and manual gearbox
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
op
Removing
C py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤

– Release and disconnect connector for terminal 50

-upper arrow-.
30) from solenoid switch.
– Remove nut -1- from upper starter securing bolt.

G. Volkswagen nA AG do
wage e
– Remove hexagon
yV
olksbolt -2- and remove starter
s no
tmotor
gu from ve‐
hicle. ris
edb ara
nt ee
tho or
Installings au ac
s
ce
e
nl
pt
du
following:
an
itte
y li
erm
ab

ility
ot p
⇒ page 25 .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

gine and automatic gearbox
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
co Vo
by lksw
cted agen
Prote AG.
7. Starter 19
Sharan 1996 ➤
Removing
– Release and disconnect connector for terminal 50 AG. Volkswagen AG d

agen
-upper arrow-. Volksw
oes
not
by gu
d ara
orise nte
eo
30) from solenoid switch. aut
h
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove nut -arrow- and remove cable holder from lower se‐
curing bolt of starter.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Remove nut -arrow- from upper starter securing bolt.
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
– Remove nut -arrow- from lower starter securing bolt.
itte
y li
rm
ab
– Remove starter motor from vehicle.
pe
ility
ot
wit
, is n
Installing
h re
hole
spec
es, in part or in w
following:
t to the co
⇒ page 25 .
rrectness of i
l purpos
nform
ercia
7.3 Removing and installing starter, vehi‐

m
a
com
t
cles 06.00 ▸
ion in
r
te o
thi
s
iva
do
r
rp
c
7.3.1 Vehicles with a 1.8 l, 2.0 l, 2.8 l petrol
um
fo
en
ng
injection or 1.9 l diesel engine with a

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

7. Starter 21
Sharan 1996 ➤
– Remove nut -1- from upper starter securing bolt.

– Remove nut -2- from lower starter securing bolt.
Installing
following:
⇒ page 25 .
7.3.2 Vehicles with a 2.0 l diesel engine and

manual gearbox
Removing
AG. Volkswagen AG d
– Pull out engine oil dipstick -1-. ksw
agen oes
not
Vol
y gu
– Remove engine cover -2- from securing points,ise
d b by first pulling ara
nte
upwards -arrows A- then pull forwards -arrow
uthor
B-. eo
a ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Lever out protective cap -2- of positive cable attachment from
solenoid switch of starter.
rrectness of i
– Unscrew securing nut -3- and remove positive cable (terminal
l purpos
30) from solenoid switch of starter.

– Release and disconnect connector -1- (terminal 50) on sole‐
nform
ercia
noid switch of starter.

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
– To remove wiring retainer -1-, remove securing nut -2- from
t. rig
gh ht
yri
lower starter securing bolt -3-.
p by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Unscrew nut -2- from upper starter securing bolt -3- and re‐
move wiring retainer -1-.
– Remove upper starter securing bolt -3-.
– Remove lower starter securing bolt -3- and remove starter

motor downwards from vehicle. AG. Volkswagen AG d
agen oes
olksw not
Installing d by
V gu
ara
ise nte
r
Install in the reverse order of removal. When doing this,ut note the
ho eo
ra
following: ss a c
ce
le

un
pt
an
d
⇒ page 25 .
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
injection or 1.9 l diesel engine with an
rrectness of i
automatic gearbox
l purpos
Removing
nform
ercia

m
a
com
t
ion 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.
7. Starter 23
Sharan 1996 ➤
– Remove nut -arrow- from upper starter securing bolt.
– Remove nut -arrow- from lower starter securing bolt.

Installing
swage es
Install in the reverse order b
ofo removal. When doing this, nnote
yV
lk ot g the
ua
following: ir se
d ran
tee
tho
or
– Tighten threadedss
au
connections to specified torques ac
⇒ page 25 .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
8 Specified torques: starter
8.1 General specified torques for all vehicles

Threaded connections Specified torques
Nut for positive cable on solenoid switch M8 13 Nm
Nut for wiring retainer on starter securing bolt M8 10 Nm
8.2 Vehicles ▸ 05.00

olkswagen AG
en AG. V
8.2.1 Vehicles with y Voa 2.0
lksw
ag
l petrol injection
does
noor
t gu
1.9 l diesel engine with a manual gear‐
d b ara
se nte
ori eo
box ss a th
u ra
c
ce
le

un
pt
an
d
itte
y li
Upper starter securing bolt M10x155 45 Nm
erm
ab
to gearbox
ility
ot p
wit
Lower starter securing bolt M10x155 45 Nm
is n
h re
to gearbox
ole,
spec
t to the co
gine and manual gearbox
Threaded connections Specified torques rrectne
ss
to gearbox
o
cial p
f i

nform
to gearbox
mer
atio
om
8.2.3 Vehicles with automatic gearbox

n
c
i
or
n thi
te
sd
a

iv
o
pr
cum
r
fo

en
ng
t.
yi
to gearbox
Co
Cop py
t. rig
Lower starter securing bolt M10x35 yri
gh
60 Nm by
ht
to gearbox cop Vo
by lksw
cted agen
Prote AG.
8.3 Vehicles 06.00 ▸

injection or 1.9 l diesel engine with a
manual gearbox
to gearbox
to gearbox
8. Specified torques: starter 25

Sharan 1996 ➤
8.3.2 Vehicles with a 2.0 l diesel engine and

manual gearbox
to gearbox
to gearbox
8.3.3 Vehicles with automatic gearbox

to gearbox
to gearbox
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
9 Alternator -C-
Caution

served ⇒ page 4 .
9.1 Securing B+ (battery positive) wire to al‐

ternator
Caution
If the B+ wire is not secured to the specified torque setting, the

following may occur:
♦ The battery will not be charged fully.
♦ Vehicle electrics or electronics fail completely (break‐
down).
♦ Danger of fires from sparks.
♦ Damage to electronic components and control units due
to excessive voltage.
– The torque setting for the securing nut of the B+ wire -arrow-
can be gleaned from the “Specified torques” table
⇒ page 57 .
lkswage es n
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byV ua
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ss
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
9.2 Checking poly V-belt

spec
– Crank engine at vibration damper/belt pulley using a socket.

t to the co
– Check poly V-belt for:

rrectne
♦ Sub-surface cracks (cracks, core ruptures, cross sectional

breaks)
ss
♦ Layer separation (top layer, cord strands)

o
cial p
f in
♦ Base break-up
form
mer
♦ Fraying of cord strands

atio
om
n
c
♦ Flank wear (material wear, frayed flanks, flank brittleness -

or
n thi
e
glassy flanks-, surface cracks)

t
sd
iva
o
pr
♦ Traces of oil and grease

um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
9. Alternator C 27
Sharan 1996 ➤
Caution
If faults are found, it is essential for the poly V-belt to be re‐

newed. This will avoid possible breakdowns or operating prob‐
lems.
9.3 Checking alternator -C-

5051A- n AG. Volkswagen AG do
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tho
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ss
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le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
o
– Connect vehicle diagnosis, testing and information system -
c by lksw
cted agen
VAS 5051A- or successor models ⇒ page 236 . Prote AG.

♦ Body
♦ C - Alternator
– Or select “Guided fault finding” on vehicle diagnosis, test and
♦ Body

Sharan 1996 ➤
♦ C - Alternator
9.4 Characteristics of compact alternators

with poly V-belt drive ▸ 05.00
The alternator is driven by a poly V-belt belt.
In case of repair, the voltage regulator can be renewed individu‐
ally.
9.5 Characteristics of compact alternators

with poly V-belt drive 06.00 ▸
From model year 2001 compact alternators with a revised shape
and different terminal designation have been introduced.
External distinguishing features of new compact alternators com‐
pared to the previously used compact alternators are:
♦ Revised voltage regulator.
♦ Oval, radially sealed socket for 2-pin connector housing in‐
stead of previous square 2-pin socket.
♦ Revised terminal designation for connections ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
9.6 Alternator for 4-cylinder petrol injection

engine ▸ 05.00
9.6.1 Assembly overview - alternator for 4-cylinder

swa
gen AG
. Volkswapetrol
gen AG injection engine ▸ 05.00
does
k not
Vol gu
d by ara
e nte
ris
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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.
9. Alternator C 29
Sharan 1996 ➤
1 - Bracket
2 - Tensioning element for ten‐
sioning roller
3 - M8 hexagon nuts
❑ 30 Nm
4 - Alternator
❑ Removing and installing
⇒ page 30
❑ Renewing poly V-belt
pulley ⇒ page 50
5 - Voltage regulator
⇒ page 54
6 - M4×25 fillister head bolt
with cross-head
7 - Protective cap
8 - Cross-head screws agen
AG. Volkswagen AG d
oes
olksw not
V
9 - Poly V-belt d by gu
ara
rise nte
❑ Poly V-beltutrouting
ho eo
ra
⇒ page 33ss a c
ce
le
❑ Checking ⇒ page 27
un
pt
an
d
itte
10 - M8×85 hexagon bolts

y li
rm
ab
pe
❑ 25 Nm
ility
ot
wit
, is n
11 - Tensioning roller
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
9.6.2 Removing and installing alternator for 4-

nform
ercia
cylinder petrol injection engine ▸ 05.00

m
a
com
tion in
r
te o
Caution
thi
s
iva
do
r
rp

um
fo
en
g

n
t.
yi Co
served ⇒ page 4 . Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
agen
Prote AG.

lkswage es n
d byV
o ot g
ua Sharan 1996 ➤
ran
o
ir se Electrical system tee - Edition 12.2008
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
♦ poly V-belt lever -VAS 3299-
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.
Removing
Caution
Before removing, mark the top side and direction of rotation of

the poly V-belt. When installing, ensure correct fitting position
and direction of rotation. If the belt is installed in the wrong
position or against direction of rotation, the belt will be de‐
stroyed!
– Lift tensioning roller with poly V-belt lever -VAS 3299- and re‐
move poly V-belt from alternator belt pulley.
– Remove V-belt for power steering vane pump ⇒ Running
gear; Rep. Gr. 48 ; Assembly overview - hydraulic lines, res‐
ervoirs
9. Alternator C 31
Sharan 1996 ➤
– Release and separate the connector of the DF cable -2-.

– Remove protective cap and unscrew B+ cable -1- from alter‐
nator.
– Unscrew wiring retainer -3-.
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
– Remove both securing bolts -arrows- and remove alternator
ility
ot p
from vehicle.
wit
, is n
h re
Installing
hole
spec
es, in part or in w
t to the co
following:
rrectness of i
Caution
l purpos
♦ When installing used poly-V-belts observe the direction of

rotation marked on removal!
nf
ercia
♦ Before installing poly V-belt, ensure that all ancillaries (al‐

ternator, air conditioning compressor) are secure. orm
m
atio
om
n in
♦ When fitting belt, ensure that poly V-belt seats correctly in

or c
thi
pulleys!
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
– Drive threaded sleeves -A- about 4 mm in Cop py
-direction of arrow- out of alternator housing.
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote
⇒ page 57 .
AG.
Caution
Observe notes for battery pole terminal clamp bolt ⇒ page 4 .

– Start engine and check belt is running correctly.
– Switch off engine.

Sharan 1996 ➤
9.6.3 Poly V-belt routing, 4-cylinder petrol in‐

jection engine ▸ 05.00
Vehicles with no air conditioner
1- Belt pulley - alternator
2- Poly V- belt - alternator, cooling system pump, crankshaft
and tensioning roller
3- Belt pulley - cooling system pump
olkswagen AG
en AG. V
4- V-belt - crankshaft and power steering
olks
wag vane pump does
not
V gu
by ara
5- Belt pulley - power steering
ris vane
ed pump nte
ho eo
ut
6- Belt pulley - crankshaft
ss
a ra
c
ce
le
7- Tensioning roller
un
pt
an
d
itte
y li
rm
ab
Vehicles with an air conditioner
pe
ility
ot
wit
, is n
h re
hole
spec
2- Poly V-belt - alternator, crankshaft, air conditioner compres‐
es, in part or in w
sor and tensioning roller
t to the co
3- Belt pulley - air conditioner compressor
rrectness of i
5- V-belt - crankshaft, power steering vane pump and cooling
l purpos
system pump
6- Belt pulley - power steering vane pump
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
do

r
rp
cum
fo
engine ▸ 05.00
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
9.7.1 Assembly overview - 6-cylinder petrol injection engine ▸ 05.00
c by lksw
cted agen
Prote AG.
9. Alternator C 33
Sharan 1996 ➤
1 - M8 hexagon nuts
❑ 25 Nm
2 - Bracket
3 - Washer
4 - M8×28 fitted bolt
❑ 25 Nm
5 - Alternator
⇒ page 34 AG. Volkswagen AG d
agen oes
❑ Renewing poly V-belt olksw not
yV gu
pulley ⇒ page 50 rised b ara
nte
ho eo
6 - Voltage regulator aut ra
ss c
ce
le
un
pt
⇒ page 54
an
d
itte
y li
rm
ab
pe
ility
with cross-head
ot
wit
, is n
8 - Protective cap
h re
hole
spec
9 - Cross-head screws
es, in part or in w
t to the co
10 - Poly V-belt
❑ Poly V-belt routing
⇒ page 34
rrectness of i
11 - M8×30 socket head bolt
l purpos
with collar
❑ 25 Nm
nform
ercia

m
a
with collar
com
tion in
❑ 25 Nm
r
te o
thi
s
iva
do

r
rp
cum
fo
❑ 25 Nm
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
cylinder petrol injection engine ▸ 05.00
AG.
The removal and installation procedure for the alternator on a 6-

cylinder petrol injection engine ▸ 05.00 is identical to a 6-cylinder
petrol injection engine 06.00 ▸ ⇒ page 47 .

jection engine ▸ 05.00
2- Poly V-belt - alternator, power steering vane pump, crank‐
shaft, cooling system pump and tensioning roller

Sharan 1996 ➤

2- Poly V-belt - alternator, air conditioner compressor, power
steering vane pump, crankshaft, cooling system pump and
tensioning roller
6- Belt pulley - cooling system
gen AG
. Vpump
olkswagen AG
a does
lksw not
7- Tensioning droller
by
Vo gu
ara
e nte
ris
tho eo
9.8 Alternator for 4-cylinder diesel engine
au ra
ss c
▸ 05.00
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
9.8.1 Assembly overview - 4-cylinder diesel engine ▸ 05.00
wit
, is n
h re
hole
spec
1 - Bracket
es, in part or in w
t to the co
2 - Tensioning element for ten‐
sioning roller
rrectness of i
3 - M8 hexagon nut
❑ 30 Nm
l purpos
4 - Alternator
nform
ercia

⇒ page 36
m
at
om
io

n
c
in t
r
pulley ⇒ page 50
o
his
ate
do
riv
p
cum
or

f
en
ng
t.
yi
⇒ page 54
Co
Cop py
t. rig
gh ht
pyri by
with cross-head
co Vo
by lksw
cted agen
Prote AG.
7 - Protective cap
9 - Poly V-belt
⇒ page 38
10 - M8 internally threaded
sleeve
11 - Tensioning roller
12 - M8×85 hexagon bolt
❑ 25 Nm
13 - Hexagon bolt
❑ 25 Nm
9. Alternator C 35
Sharan 1996 ➤

cylinder diesel engine ▸ 05.00
Caution

served ⇒ page 4 .

lkswage es n
o ot g
byV ua
d ran
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tho
u or
a ac
♦ poly V-belt lever -VAS 3299-
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nform
ercia

m
a
com
tion in
Caution
r
te o
thi
s
iva
do

r
rp
cum

fo
en
g

n
t.
yi Co
op
position or against direction of rotation, the belt will be de‐ C py
t. rig
stroyed!
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
– Lift tensioning roller with poly V-belt lever -VAS 3299- and re‐
move poly V-belt from alternator belt pulley.
– Remove V-belt for power steering vane pump ⇒ Running
gear; Rep. Gr. 48 ;wAssembly
agen
AG. Volkoverview
swagen AG
-dohydraulic
es n lines, res‐
s
ervoirs yV
olk ot g
u
b ara
ed nte
oris e
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
nator.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a

iv
o
pr
from vehicle.
um
r
fo
en
ng
t.
yi
Installing
Co
Cop py
t. rig
gh
ht
pyri by
Vo
o
following:
c by lksw
cted agen
Prote AG.
Caution

ternator, air conditioning compressor) are secure.
pulleys!
– Drive threaded sleeves -A- about 4 mm in

⇒ page 57 .
Caution

9. Alternator C 37
Sharan 1996 ➤
9.8.3 Poly V-belt routing, 4-cylinder diesel en‐

gine ▸ 05.00
2- Poly V- belt - alternator, cooling system pump, crankshaft
and tensioning roller
AG. Volkswagen AG d
agen
4- V-belt - crankshaft and power steering vane pump olksw
oes
not
byV gu
ara
d
5- Belt pulley - power steering vane pump orise nte
eo
h
ut ra
6- Belt pulley - crankshaft ss a c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
2- Poly V-belt - alternator, crankshaft, air conditioner compres‐
spec
sor and tensioning roller
es, in part or in w
t to the co
rrectness of i
5- V-belt - crankshaft, power steering vane pump and cooling
l purpos
system pump
nform
ercia

m
a
com
tio
n in
r
te o
thi
s
iva
do
9.9 Alternator for 1.8 l, 2.0 l 4-cylinder petrol
r
rp
cum
fo
injection engines and 1.9 l 4-cylinder

en
ng
t.
yi Co
op
diesel engines 06.00 ▸ C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
9.9.1 Assembly overview - 1.8 l, 2.0 l 4-cylinder petrol injection engines and 1.9
l, 4-cylinder diesel engines 06.00 ▸

Sharan 1996 ➤
1 - Tensioner for poly V-belt

2 - Compact bracket
3 - Hexagon socket head bolts
❑ M10×45 mm
❑ 45 Nm
4 - Fillister head screw with
cross-head
5 - Hexagon nuts
❑ M8
❑ 15 Nm
6 - Protective cap
7 - Fillister head screw with
cross-head
❑ M4×25 mm
⇒ page 54
9 - Alternator
⇒ page 39
pulley ⇒ page 50
10 - Poly V-belt AG. Volkswagen AG d
agen oes
ksw
❑ Poly V-belt by V routing
ol not
gu
ara
⇒ pagerise 42
d
nte
ho eo
❑ Checking
aut ⇒ page 27 ra
c
ss
11 - Hexagon bolts
ce
le
un
pt
an
d
❑ M8×85 mm
itte
y li
rm
ab
❑ 25 Nm
pe
ility
ot
wit
12 - Hexagon bolts
, is n
h re
❑ M8×45 mm
hole
spec
❑ 25 Nm
es, in part or in w
t to the co
9.9.2 Removing and installing alternator for

rrectness of i
1.8 l, 2.0 l 4-cylinder petrol injection en‐

l purpos
gines and 1.9 l 4-cylinder diesel engines

06.00 ▸
nform
mercia

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.
9. Alternator C 39
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Sharan 1996 ➤ autho eo
ra
Electrical system - Edition 12.2008 ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ Locking pin -T10060 A-

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.
Removing
Caution

stroyed!
– Swivel tensioner in direction of -arrow- to release tension on

poly V-belt.

Sharan 1996 ➤
. Volkswagen AG
gen AG does
– Lock tensioning device with locking
Vol
pin
ksw -T10060 A-
a
not
y gu
db ara
– Remove poly V-belt from alternator
or
ise belt pulley. nte
th eo
s au 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
nator.
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
from vehicle.
co Vo
by lksw
cted agen
Prote AG.
Installing
following:
Caution

pulleys!

⇒ page 57 .
Caution

9. Alternator C 41
Sharan 1996 ➤
9.9.3 Poly V-belt routing, 1.8 l, 2.0 l 4-cylinder

petrol injection engines and 1.9 l 4-cyl‐
inder diesel engines 06.00 ▸
3- Poly V-belt - tensioning roller, alternator, power steering
vane pump, crankshaft/vibration damper and cooling sys‐
tem pump
5- Crankshaft/vibration damper/belt pulley
9.10 Alternator for 2.0 l 4-cylinder diesel en‐

gine
9.10.1 Assembly overview - 2.0 l 4-cylinder diesel engine
1 - Hexagon bolts with collar

❑ M8x45
❑ 20 Nm
2 - Poly V-belt tensioning ele‐
ment
3 - Compact bracket
❑ Tightening sequence agen
AG. Volkswagen AG d
oes
when installing Volksw not
gu
⇒ page 58 ed by ara
nte
ris
ho eo
4 - Hexagon bolts with collar aut ra
c
ss
❑ M10×45 mm
ce
e
nl
pt
du
❑ 45 Nm
an
itte
y li
erm
ab
5 - Hexagon nut with flange

ility
ot p
❑ M8
wit
, is n
h re
6 - Hexagon nut, flat

hole
spec
❑ M8
es, in part or in w
t to the co
7 - Cross-head screw
❑ M5x21
rrectness of i
❑ 4.5 Nm
l purpos
8 - Washer
❑ M5
nform
ercia
9 - Protective cap
m
at
om
on
c
in t
or
❑ M4x19
his
ate
do
riv
❑ 2 Nm
p
cum
for
11 - Cross-head screw
en
ng
t.
yi Co
op
❑ M4x13 C py
t. rig
gh ht
yri
❑ 2 Nm p by
o Vo
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
ksw
agen oes
not
Sharan 1996 ➤
ol
byV Electrical system - gEdition
ua 12.2008
ed ran
oris tee
th
12 - Voltage regulator au
or
ac
ss
❑ Removing and installing ⇒ page 54
ce
le
un
pt
an
d
13 - Alternator
itte
y li
rm
ab
pe
ility
ot
❑ Renewing poly V-belt pulley ⇒ page 50
wit
, is n
h re
14 - Poly V-belt
hole
spec
❑ Poly V-belt routing ⇒ page 42
es, in part or in w
t to the co
15 - Hexagon bolts with collar
rrectness of i
❑ M8×90mm
l purpos
❑ 20 Nm
nform
ercia
9.10.2 Removing and installing alternator for

m
a
com
tio
2.0 l 4-cylinder diesel engine
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Locking pin -T10060 A-
Removing
Caution

stroyed!
9. Alternator C 43
Sharan 1996 ➤
– Pull out engine oil dipstick -1-.

– Remove engine cover -2- from securing points, by first pulling
upwards -arrows A- then pull forwards -arrow B-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
– Swing poly V-belt tensioner in -direction ofs arrow- using a
s c
16 mm open-jaw spanner.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectnes
– Lock tensioning device with locking pin -T10060 A-
s o
cial p
f i
– Remove poly V-belt from alternator belt pulley.
nform
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.
– Release and disconnect DF cable connector -1- and pull off

protective cap -2-.

Sharan 1996 ➤
– Remove securing nut -3-.

– Open wiring retainer -1- and remove B+ cable -2- from alter‐
nator.

upwards from vehicle.
Installing
following:
Caution
AG. Volkswagen AG d
agen oes
olksw not
yV
♦ When dinstalling used poly-V-belts observeuthe ara direction of
b g
e
ris nte
ho eo
aut ra
♦s Before installing poly V-belt, ensure that all ancillaries
s c
(al‐
ce
e

nl
pt
du
an
itte

y li
erm
ab
pulleys!
ility
ot p
wit
, is n
h re
hole
spec

es, in part or in w

t to the co

⇒ page 57 .
rrectness of i
l purpos
Note
nf
ercia
♦ Observe following notes when fitting belt:

orm
m
atio
♦ Vehicles with an air conditioner compressor, place poly V-belt

om
over air conditioner compressor belt pulley last.

n in
or c
thi
e
♦ Vehicles with no air conditioner compressor, place poly V-belt

t
sd
iva
over alternator belt pulley last.

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

9. Alternator C 45
Sharan 1996 ➤
9.10.3 Poly V-belt routing, 2.0 l 4-cylinder die‐

sel engine
2- Poly V-belt pulley - alternator AG. Volkswagen AG d
agen oes
lksw not
3- Poly V-belt pulley - power steering vane pump byV
o gu
ara
ed
is nte
4- Poly V-belt pulley - crankshaft ut
hor eo
a 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
2- Poly V-belt pulley - alternator
3- Poly V-belt pulley - air conditioner compressor
rrectness of i
4- Poly V-belt pulley - power steering vane pump
l purpos
5- Poly V-belt pulley - crankshaft
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
engine 06.00 ▸
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
9.11.1 Assembly overview - 6-cylinder petrol injection engine 06.00 ▸
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d Sharan 1996 ➤
agen
Volksw
oes
not Electrical system - Edition 12.2008
by gu
d ara
ise nte
1 - M8 hexagonut
hor
nuts eo
a ra
❑ 25 Nmss c
ce
le
un
pt
2 - Bracket
an
d
itte
y li
3 - Washer
rm
ab
pe
ility
ot
wit
, is n
h re
❑ 25 Nm
hole
spec
5 - Alternator
es, in part or in w
t to the co
⇒ page 47
rrectness of i
pulley ⇒ page 50
l purpos
nform
ercia
⇒ page 54
m
a
com
tion in
with cross-head
r
te o
thi
s
8 - Protective cap
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
10 - Hexagon nuts Cop py
t. rig
gh
❑ M8
ht
pyri by
Vo
o
by c lksw
❑ 15 Nm Prote
cted AG.
agen
11 - Poly V-belt
⇒ page 50
with collar
❑ 25 Nm
with collar
❑ 25 Nm
❑ 25 Nm

cylinder petrol injection engine 06.00 ▸
9. Alternator C 47
Sharan 1996 ➤
♦ Spring-type clip pliers -VAS 5024A-
♦ M8 bolt
Removing
Caution
Before removing, mark the top side

agen
AG.and
Volksdirection
wagen AG of rotation of
does
the poly V-belt. When installing,
olksw ensure correct fittingnoposition
t gu
yV
and direction of rotation.
ed b If the belt is installed in the wrong
ara
ris nte
tho eo
stroyed! s au ra
c
s
ce
e
nl
pt
du
an
itte
– Remove air filter housing ⇒ engine - mixture preparation; Rep.

y li
erm
ab
Gr. 24 ; Repairing petrol injection system; Dismantling and

ility
ot p
assembling air filter .

wit
, is n
h re
– Remove engine cover.

hole
spec
– Pull off fuel return hose -1- (with blue marking) and collect
es, in part or in w
t to the co
leaking fuel with a cloth.

– Seal lines to prevent soiling of fuel system.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
– Screw a M8 bolt into threaded hole -A- of tensioning element

for
en
g
until there is no tension on poly V-belt.

n
t.
yi Co
Cop py
ht. rig
rig ht
Caution py by
co Vo
by lksw
cted agen
Prote AG.
Screw bolt into tensioning element only sufficiently to allow re‐
moval of poly V-belt. Otherwise housing of tensioning element
could become damaged.
– Remove poly V-belt from alternator belt pulley.

Sharan 1996 ➤

nator.

from vehicle.
Installing
following: gen AG
. Volkswagen AG
d
a oes
ksw not
y Vol gu
b ara
Caution ed nte
oris eo
th
au ra
c
♦ ss observe the direction of
When installing used poly-V-belts
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
pulleys!
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
⇒ page 57 .
nform
ercia
Caution
m
at
om
io

n
c
in t
or
his
ate
do
riv
– Unscrew M8 bolt from tensioning element.

p
cum
for
en
ng
t.
– Reconnect battery ⇒ page 4 . Cop
yi Co
py
t. rig
– Start engine and check belt is running correctly. gh ht
pyri by
Vo
co lksw
by
– Switch off engine. Prote
cted AG.
agen
9. Alternator C 49
Sharan 1996 ➤

jection engine 06.00 ▸
2- Poly V-belt - alternator, air conditioner compressor, power
steering vane pump, crankshaft, cooling system pump and
tensioning roller
wage
9.12 Removing and installing poly V-belt pul‐ lks es n
o ot g
byV ua
ley on alternator
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
9.12.1 Removing and installing poly V-belt pul‐
an
d
itte
y li
ley with no freewheel
rm
ab
pe
ility
ot
wit
, is n
h re
hole
♦ Insert tool -VAS 3310-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do

r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Remove alternator ⇒ page 27 .
– Clamp alternator on bracket points in bench vice.

AG. Volkswagen AG d
agen oes
olksw Sharan
not 1996 ➤
byV gu
ara
rised
nte
ho eo
aut ra
– Use socket -VAS 3310- to unscrew poly V-belts pulley securing
s c
ce
e
nut from alternator shaft.
nl
pt
du
an
itte
Installing
y li
erm
ab
ility
ot p
wit
ing:
, is n
h re
hole
spec
⇒ page 57 .
es, in part or in w
t to the co
rrectness of i
l purpos
9.12.2 Removing and installing poly V-belt pul‐
nf
ley with freewheel, manufacturer: Bosch
ercia
orm
m
atio
om
n in
or c
♦ Adapter -VAS 3400-
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.
Removing
– Remove protective cap from poly V-belt pulley with freewheel.
– Insert adapter -VAS 3400- with 17 mm ring spanner in poly V-
belt pulley with freewheel of alternator.
9. Alternator C 51
Sharan 1996 ➤
– Insert a M10 multi-point bit -1- into alternator shaft.

– Loosen threaded connection by turning clockwise. Counter‐
hold with ring spanner when doing this.
– Hold poly V-belt pulley with freewheel by hand. Turn drive
shaft of alternator until poly V-belt pulley with freewheel can
be removed.
Installing
following:
– First screw poly V-belt pulley with freewheel on drive shaft of
alternator by hand as far as limit stop.
The torque wrench -V.A.G 1332- must be modified for assembly
of poly V-belt with freewheel as follows:
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
– Release connector -1- and pull it off grip
oris -2-.
ed
nte
h eo
ut ra
– Turn grip -2- of torque wrench through
ss a 180 degrees and rein‐ c
sert socket drive.
ce
le
un
pt
an
d
– Set turning direction of torque wrench to anti-clockwise on

itte
y li
socket drive.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Insert a M10 multi-point bit -1- into alternator shaft.
– Counterhold using adapter -VAS 3400- and 17 mm ring span‐ ss
ner.
o
cial p
f inform
– Tighten poly V-belt with freewheel by turning drive shaft of al‐

mer
ternator clockwise using torque wrench -V.A.G 1332- .

atio
om
n
c

i
or
n thi
⇒ page 57 .
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.
9.12.3 Removing and installing poly V-belt pulley with freewheel, manufacturer:
Valeo

Sharan 1996 ➤
agen
AG. Volkswagen AG d
oes Electrical system - Edition 12.2008
o lksw not
V gu
by ara
Special toolsriseand
d workshop nte
equipmentut required
ho eo
ra
s a c
s
♦ Adapter -VAS 3400-
ce
e
nl
pt
du
an
♦ Torque wrench -V.A.G
itte
y li
1332-
erm
ab
ility
ot p
♦ TORX driver bit -V.A.G
wit
, is n
1603/1-
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.
Removing
– Remove protective cap from poly V-belt pulley with freewheel.
– Insert adapter -VAS 3400- with 17 mm ring spanner in poly V-
belt pulley with freewheel of alternator.
9. Alternator C 53
Sharan 1996 ➤
– Insert TORX driver bit -V.A.G 1603/1- in alternator shaft.

olkswagen AG
en AG. V
– Loosen threaded connection ksw by turning clockwise. e
ag doCounter‐
s no
Vol
hold with ring spanner
ed
bywhen doing this. t gu
ara
ris nte
– Hold poly V-belt au
thpulley
o
with freewheel by hand. Turn drive eo
ra
shaft of alternator
ss until poly V-belt pulley with freewheel can c
be removed.
ce
e
nl
pt
du
an
itte
Installing
y li
erm
ab
ility
ot p
following:
wit
, is n
h re
hole
– First screw poly V-belt pulley with freewheel on drive shaft of
spec
alternator by hand as far as limit stop.
es, in part or in w
t to the co
The torque wrench -V.A.G 1332- must be modified for assembly
of poly V-belt with freewheel as follows:
rrectness of i
l purpos
nf
ercia
– Release connector -1- and pull it off grip -2-.
orm
m
atio
– Turn grip -2- of torque wrench through 180 degrees and rein‐
om
n in
sert socket drive.
or c
thi
te
– Set turning direction of torque wrench to anti-clockwise on

sd
iva
o
r
socket drive.
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.
– Insert TORX driver bit -V.A.G 1603/1- in alternator shaft.

– Counterhold using adapter -VAS 3400- and 17 mm ring span‐
ner.
– Tighten poly V-belt with freewheel by turning drive shaft of al‐
ternator clockwise using torque wrench -V.A.G 1332- .
⇒ page 57 .
9.13 Voltage regulator for alternator
9.13.1 Removing and installing voltage regula‐

tor, manufacturer: Bosch

Sharan 1996 ➤
♦ Torque screwdriver -V.A.G 1624-
Removing
– Remove securing bolt and nuts -arrows- and take protective
cap off alternator.
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
– Remove securing bolts for voltage regulator -arrows-.
y li
erm
ab
ility
– Remove voltage regulator from alternator.
ot p
wit
, is n
Installing
h re
hole
spec
Install in reverse order of removal.
es, in part or in w
t to the co
⇒ page 57 .
rrectness of i
l purpos
nf
ercia
or
9.13.2 Removing and installing voltage regula‐

m
m
atio
m
tor, manufacturer: Valeo

o
n in
or c
thi
te

sd
iva
o
r
rp
cu
♦ Torque wrench -V.A.G 1783/-

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.
9. Alternator C 55
Sharan 1996 ➤
Removing
– Remove spring clips -arrows- and take protective cap off al‐
ternator.
– Remove securing bolts for voltage regulator -arrows-.

AG. Volkswagen AG d
agen oes
– Remove voltage regulator from alternator. olksw not
V gu
d by ara
e
Installing horis nte
eo
aut ra
Install in the reverse order of removal. When doing this,s note the
s c
following:
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
– Release locking lugs -arrows- and pull protective cap off volt‐
age regulator.
rrectness of i
– Push carbon brushes in housing of voltage regulator and place
voltage regulator in alternator.
l purpos

⇒ page 57 .
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
– Push protective cap in guides -arrows- until it can be heard to Cop py
t. rig
engage. gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
10 Specified torques: alternator
10.1 General specified torques for all vehicles

B+ wire to alternator M8 15 Nm
Cable holder to alternator M5 3.2 Nm
Voltage regulator to alternator (Bosch, Valeo) M4 2 Nm
Protective cap to alternator (Bosch) M5 4.5 Nm
Poly V-belt pulley with freewheel to alternator M10 80 Nm
Poly V-belt pulley without freewheel to alternator M10 wagen AG. 65 Nm
Volkswagen AG
does
olks not
yV gu
edb ara
ris nte
tho eo
au ra
10.2 4-cylinder fuel injection engine
ss ▸ 05.00 c
ce
le
un
pt
an
d
itte
y li
erm
ab
Alternator to bracket M8x85 25 Nm
ility
ot p
Bracket to cylinder head M8 30 Nm
wit
is n
h re
ole,
10.3 6-cylinder fuel injection engine ▸ 05.00
spec
t to the co
Alternator to compact M8 25 Nm
bracket
rrectne
Compact bracket to cylin‐ M8 25 Nm
der block
ss o
cial p
f in
10.4 4-cylinder diesel engine ▸ 05.00
form
mer
atio
m

o
n
c
i
or
n
Alternator to compact M8x85 25 Nm
thi
te
sd
bracket
iva
o
pr
cum
r
fo
en
ng
der block
t.
yi Co
Cop py
ht. rig
10.5 1.8 l, 2.0 l, 4-cylinder fuel injection en‐ rig ht
py by
co Vo
gines and 1.9 l, 4-cylinder diesel en‐
by lksw
cted agen
Prote AG.
gines 06.00 ▸
bracket
Compact bracket to cylin‐ M10x45 45 Nm
der block
Tensioning element to com‐ M8x45 25 Nm
pact bracket
10. Specified torques: alternator 57

Sharan 1996 ➤
10.6 2.0 l 4-cylinder diesel engine
10.6.1 Specified torques

bracket
Tensioning element to com‐ M8x45 20 Nm
pact bracket
der block
10.6.2 Tightening sequence for compact lksw

brack‐
agen
AG. Volkswagen AG d
oes
not
et, vehicles with air conditioning system
Vo gu
by ara
d
ise n r tee
ho
Compact bracket to cylinder block tightening
sa
ut sequence or
ac
s
Procedure
ce
e
nl
pt
du
an
itte
– Place compact bracket on cylinder block.
y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
Before tightening to specified torque setting, screw in all bolts by
es, in part or in w
hand.
t to the co
– Tighten securing bolts of compact bracket in following se‐
rrectness of i
quence:
l purpos
A - Hexagon bolt with collar, M10x45, 45 Nm

B - Hexagon bolt with collar, M10x45, 45 Nm
nform
ercia
C - Hexagon bolt with collar, M10x45, 45 Nm

m
at
om
D - Hexagon bolt with collar, M10x45, 45 Nm ion

c
in t
or
E - Hexagon bolt with collar, M10x45, 45 Nm

his
ate
do
priv
F - Hexagon bolt with collar, M10x45, 45 Nm

um
for
en
ng
t.
yi Co
op
10.7 6-cylinder fuel injection engine 06.00 ▸
C py
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.
Alternator to compact M8 25 Nm
bracket
der block

Sharan 1996 ➤
11 Cruise control system (CCS)
11.1 Cruise control system (CCS) for vehi‐

cles with petrol engine ▸ 05.00
Note
Observe current respective ⇒ Current flow diagrams, Electrical

fault finding and Fitting locations.
1 - Accelerator
2 - Accelerator positioning ele‐
ment
❑ Removing ⇒ page 60
❑ Adjusting ⇒ page 60
3 - Vacuum line junction piece
4 - Cruise control system con‐
trol unit -J213-
⇒ page 61
5 - Relay plate
6 - Cruise control system wir‐ n AG. Volkswagen AG do
lkswage es n
ing harness byV
o ot g
ua
d ran
ir se
7 - Cruise control system uth o tee
or
switch -E45- ss
a ac
ce
e
8 - Vacuum pump for automat‐

nl
pt
du
an
ic distance control system -

itte
y li
V18-
erm
ab
ility
ot p

wit
, is n
⇒ page 60
h re
hole
9 - Vacuum lines
spec
es, in part or in w
❑ Leak test ⇒ page 61

t to the co
10 - Vent valve with clutch ped‐

al switch -F36-
rrectness of i
❑ (Not with automatic

l purpos
gearbox)
⇒ page 60
nf
ercia
orm
11 - Vent valve with brake ped‐

m
atio
m
al switch -F47-
o
n in
or c

thi
te
⇒ page 60
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.
11. Cruise control system (CCS) 59

Sharan 1996 ➤
11.1.1 Removing positioning element

– Remove M8 securing nut -1- on bracket for positioning ele‐
ment -2-.
– Carefully pull positioning element push rod -4- out of ball cup.
3 - Adjustment sleeve
4 - Pull rod
5 - Accelerator
11.1.2 Adjusting positioning element

– Loosen adjustment sleevewa-2-
genon
AG.positioning
Volkswagen Aelement
G do
es n -1- and
slide forwards. y Volks ot g
u
b ara
ed nte
3 - Pull rod thoris e or
au ac
4- Accelerator
ss
ce
e
nl
pt
– Adjust accelerator cable.
du
an
itte
y li
erm
– Pull adjustment sleeve to rear until there is a max. play of

ab
ility
1 mm, then lock sleeve by turning sleeve clockwise to stop.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
11.1.3 Removing and installing breather valve

t to the co
Removing
rrectness of i
– Pull off connector and vacuum line.

l purpos
– Remove breather valve -1- from bracket.

Installing
nform
ercia
– Screw breather valve into bracket until there is no play.

m
at
om
– Valve is adjusted.
on
c
in t
or
– Reconnect connector and vacuum line.

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.
11.1.4 Removing and installing vacuum pump
for automatic distance control system -
V18-
The vacuum pump for automatic distance control system -V18- is
located in the front left wheel housing behind the wheel housing
liner.
Removing
– Remove front left wheel housing liner.

Sharan 1996 ➤
– Pull vacuum pump for automatic distance control system -

V18- along with retaining plate and rubber bushes out of
retainer.
– Disconnect 3-pin connector.
– Pull off vacuum line.
Installing
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
11.1.5 Removing and installing cruise control
erm
ab
ility
ot p
system (CCS) control unit -J213-
wit
, is n
h re
Removing
hole
spec
es, in part or in w
t to the co
– Remove dash panel ⇒ Rep. Gr 70 .
– Disconnect 12-pin connector from cruise control system
rrectness of i
(CCS) control unit -J213- -2-, located on right of dash panel
l purpos
below radio.
– Remove securing bolt -1-.
nform
ercia
– Push cruise control system (CCS) control unit -J213- -2- up‐
m
wards slightly and unhook from retainer.

at
om
ion
c
Installing
in t
or
his
ate

do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
11.1.6 Checking vacuum system for leaks
co Vo
by lksw
cted agen
Prote AG.
– Pull vacuum line off vacuum pump and seal.
– Push positioning element diaphragm inwards and at the same
time press the brake pedal down to the point of resistance.
– Then release brake pedal.
The diaphragm must not move.

cles with a TDI diesel engine ▸ 05.00
In vehicles with a direct injection diesel engine the function of the
cruise control system is controlled by the injection system control
unit.
Apart from the cruise control system operating switch in turn sig‐
nal lever there are no additional components.
Removing and installing steering column switch, vehicles 06.00 ▸
⇒ page 199 .
11. Cruise control system (CCS) 61

Sharan 1996 ➤
Repairing cruise control system in vehicles with a TDI diesel en‐

gine ⇒ Vehicle diagnosis, test and information system VAS 5051
in function "Guided fault finding" .
Activating and deactivating cruise control system ⇒ page 62 .

cles 06.00 ▸
olkswagen AG
en AG. V
In all Sharan models the function of the cruise control
ksw
ag system is does
not
Vol
controlled by the injection system control unit.
ed
by gu
ara
ris nte
Apart from the cruise control system operating
autho
switch in the steer‐ eo
ra
ing column switch there are no additional
ss components. c
ce
le
un
Removing and installing steering column switch, vehicles 06.00 ▸
pt
an
d
itte
⇒ page 199 .
y li
erm
ab
Repairing cruise control system (CCS) ⇒ Vehicle diagnosis, test
ility
ot p
and information system VAS 5051 in function "Guided fault find‐
wit
is n
h re
ing" ⇒ Current flow diagrams, Electrical fault finding and Fitting
ole,
locations.
spec
Activating and deactivating cruise control system ⇒ page 62 .
t to the co
11.4 Activating and deactivating cruise con‐
rrectne
trol system (CCS)
ss
o
cial p
f i
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
90 – Gauges, instruments
1 Dash panel insert
1.1 Dash panel insert, vehicles ▸ 05.00
1.1.1 Fault detection and fault display

The dash panel insert is equipped with self-diagnosis, which
makes fault finding easier.
For fault finding use vehicle diagnosis, testing and information
wage
system -VAS 5051A- and in successor units inV“self-diagnosis”
olks
es n
ot g
y
mode. sed b ua
ran
ri tee
ho
Carry out self-diagnosis of dash panelauinsert
t ⇒ Electrical system, or
ac
self-diagnosis; Rep. Gr. 01 ; Carrying out self-diagnosis of dash
ss
ce
e
panel insert .
nl
pt
du
an
itte
y li
1.1.2 Renewing dash panel insert
erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
The values for service interval display, odometer and the coding
t to the co
must be read first, before removing the dash panel insert if the
dash panel insert is to be renewed.
rrectness of i
– Read the values in the service interval display, the trip meter
l purpos
display and the coding with the vehicle diagnosis, testing and
information system -VAS 5051A- and successor units and
note or print out these values ⇒ Electrical system, self-diag‐
nform
ercia
nosis; Rep. Gr. 01 ; Adapting service interval data when

m
changing the dash panel insert ⇒ Electrical system, self-di‐

at
om
agnosis; Rep. Gr. 01 ; Adapting odometer display data ⇒ ion

c
in t
Electrical system, self-diagnosis; Rep. Gr. 01 ; Coding control
or
his
e
unit
at
do
priv
cum
– Remove old dash panel insert and install new one

for
en
g
⇒ page 64 .
n
t.
yi Co
Cop py
– Code dash panel insert ⇒ Electrical system, self-diagnosis; ht. rig
rig ht
Rep. Gr. 01 ; Coding control unit . py by
co Vo
by lksw
cted agen
Prote AG.
Note
The service interval display is only installed in dash panel inserts

with a multifunction display.
– Adapt the values for the service interval display ⇒ Electrical

system, self-diagnosis; Rep. Gr. 01 ; Adapting service interval
data when changing the dash panel insert .
– Adapting odometer display data⇒ Electrical system, self-di‐
agnosis; Rep. Gr. 01 ; Adapting odometer .
1. Dash panel insert 63

Sharan 1996 ➤
1.1.3 Removing and installing dash panel in‐

sert
Note
Observe the notes and work procedure instructions for fault rec‐
ognition and fault displays as well as replacing dash panel n AG. Volkswagen AG do
ageinsert
ksw es n
before removing the dash panel insert ⇒ page 63by. V ol ot g
ua
ed ran
oris tee
h
Before beginning dismantling work, performau the following
t
proce‐ or
ac
dures: ss
ce
le
un
pt
an
d
itte
y li
ignition key.
rm
ab
pe
ility
Removing
ot
wit
, is n
h re
– Remove steering wheel ⇒ Running gear; Rep. Gr. 48 ; Re‐
hole
moving and installing steering wheel .
spec
es, in part or in w
– Remove cross-head screws -arrows-.
t to the co
– Then plastic trim can be pulled out forwards.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
g
– Remove the two securing screws on left and right -arrows-.

n
t.
yi Co
Cop py
– Remove clip - 1-.
t. rig
gh ht
pyri by
Vo
o
– Fold dash panel insert out forwards. by c lksw
cted agen
Prote AG.
– Disconnect multi-pin connectors on back of dash panel insert.
– Take out dash panel insert.
Installing
1.1.4 Warning lamp symbols and instruments

in dash panel insert
Note
♦ The employment of the warning lamps in the dash panel insert

is dependent upon the equipment level, engine and country
version.
♦ For a detailed explanation of the individual instruments and
warning lamp symbols, see the appropriate owner's manual
for vehicle.
64 Rep. Gr.90 - Gauges, instruments

Sharan 1996 ➤
1.1.5 Description of back of dash panel insert
Note
♦ The dash panel insert must not be dismantled.

♦ Fault finding programs for specific systems and current circuits
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.
1 - 28-pin connector
❑ Black
❑ Pin assignment
⇒ page 66
2 - Bulb with holder ( bulb for
dash panel insert illumination -
L10- )
❑ 14 V/3.7 W
3 - Bulb with holder ( right turn
signal warning lamp -K94- ) agen AG. Volkswagen AG do
ksw es n
❑ 14 V/1.2 W Vol ot g
by ua d ran
ise
4 - Bulb with holder
ut
ho ( vehicle
r tee
or
symbol illumination
ss
a -L95- ) ac
ce
❑ 14 V/1.2 W
e
nl
pt
du
an
itte
5 - Bulb with holder ( left turn

y li
erm
ab
signal warning lamp -K65- )

ility
ot p
❑ 14 V/1.2 W
wit
, is n
h re
hole
spec
❑ Red
es, in part or in w
t to the co
❑ Pin assignment
⇒ page 66
rrectness of i
7 - Bulb with holder ( cooling

system temperature/cooling
l purpos
system shortage warning lamp

-K28- )
nform
ercia
❑ 14 V/1.2 W
m
8 - Bulb with holder ( digital dis‐

at
om
io
play illumination -L75- )

n
c
in t
or
❑ 14 V/1.2 W
his
ate
do
riv
9 - Bulb with holder ( main

p
cum
or
beam warning lamp -K1- )

f
en
ng
t.
yi Co
❑ 14 V/1.2 W Cop py
t. rig
gh ht
yri
10 - Bulb with holder ( digital display illumination -L75- ) p by
co Vo
by lksw
cted
❑ 14 V/1.2 W
agen
Prote AG.
11 - Bulb with holder ( fuel reserve warning lamp -K105- )

❑ 14 V/1.2 W

Sharan 1996 ➤
1.1.6 Pin assignment of connections on dash

panel insert
Red connector
1- Terminal 31, electronics earth
2- Cooling system low level indicator
3- Terminal 31, earth
4- Airbag, terminal 31
5- Airbag, functional check
6- Airbag, connector check
7- Signal from electronic speedometer
8- Oil pressure switch 1.8 bar
9- Oil pressure switch 0.3 bar
10 - RPM signal
11 - Terminal 30, battery positive
12 - Terminal 58b, dash panel insert illumination
13 - Terminal 15, general
14 - Airbag, terminal 15
15 - Seat belt warning system (only certain countries)
16 - Alternator warning lamp, terminal 61
17 - Vacant
18 - Twin circuit brakes and handbrake system warning lamp
19 - ABS warning lamp
20 - Glow period warning lamp agen
AG. Volkswagen AG d
oes
olksw not
V
21 - Fuel gauge d by gu
ara
rise nte
o
22 - Left turn signal warning lamp auth eo
ra
ss c
23 - Coolant temperature gauge ce
e
nl
pt
du
an
24 - Right turn signal warning lamp
itte
y li
erm
ab
25 - Main beam warning lamp
ility
ot p
wit
, is n
26 - Trailer operation warning lamp

h re
hole
spec
27 - Signal to electronic speedometer

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

Sharan 1996 ➤
Black connector
1- Front left door open warning lamp
2- Front right door open warning lamp
3- Rear left door open warning lamp
4- Rear right door open warning lamp
5- Rear lid open warning lamp
6- Right dipped beam bulb failure warning lamp
7- Left dipped beam bulb failure warning lamp
8- Right brake and rear light bulb failure warning lamp
9- Left brake and rear light bulb failure warning lamp
10 - Temperature warning lamp, 4 °C
11 - Temperature warning lamp, 0 °C
12 - Vacant
13 - Washer fluid low warning lamp
14 - MFI - call-up button 1 for trip recorder memory
15 - MFI - call-up button 2 for total distance recorder memory
16 - MFI - oil temperature signal
17 - Vacant
18 - MFI - ambient temperature signal
19 - Vacant
20 - Ambient temperature sensor lkswage es n
o ot g
byV ua
d ran
21 - MFI - fuel consumption signal o
ir se tee
th or
u
22 - Vacant ss
a ac
ce
e
nl
23 - Vacant
pt
du
an
itte
y li
24 - Vacant
erm
ab
ility
ot p
25 - Vacant
wit
, is n
h re
26 - Vacant
hole
spec
27 - Vacant
es, in part or in w
t to the co
28 - Vacant
rrectness of i
1.2 Dash panel insert, vehicles 06.00 ▸

l purpos

nf
ercia
orm
m
The dash panel insert is equipped with self-diagnosis, which

atio
m

o
n in
or c
thi
e

t
sd
iva
system -VAS 5051A- and successor units in “guided fault finding”

o
r
rp
cu
mode.
o
m
f
en
ng
t.
yi Co
1.2.2 Renewing dash panel insert Cop py
t. rig
gh ht
yri by
Special tools and workshop equipment required cop Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤

5051A-
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
– Connect vehicle diagnosis, testing and information system - wit

, is n
VAS 5051A- or successor models ⇒ page 236 . h re

hole
spec
es, in part or in w

t to the co

rrectness of i
♦ Body
l purpos
♦ 01 - On Board Diagnostic capable systems
nf
ercia
orm
♦ Dash panel insert

m
atio
om
n in
c
♦ Functions
or
thi
te
sd
a
♦ Renewing dash panel insert

iv
o
r
rp
cu
o
1.2.3 Removing and installing dash panel in‐

f
en
ng
t.
yi Co
sert Cop py
ht. rig
rig ht
py by
Special tools and workshop equipment required co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
♦ Insert tool -T10113-
Removing
Note
AG. Volkswagen AG d
agen oes
lksw not
Observe the notes byand work procedure instructions gfor
Vo
ua fault rec‐
ognition and fault
oris displays before removing the dash panel
ed ran
teeinsert
⇒ page 63 a.uth or
ac
ss
ce
e
nl
Before beginning dismantling work, perform the following proce‐

pt
du
dures: an
itte
y li
erm
ab
– Switch off ignition and all electrical consumers and remove ility
ot p
ignition key.
wit
, is n
h re
– Lower steering column and pull out towards own torso.

hole
spec
es, in part or in w
– Remove cover on relay plate located on left next to steering

t to the co
column.
rrectness of i
Note
l purpos
There is no need to remove the steering wheel. For clarity the

steering wheel is not shown in the following illustration.
nform
mercia
– Remove the two securing screws on left and right next to the
at
om
io
steering column -arrows- using socket -T10113- .

n
c
in t
or
his
e
– Fold dash panel insert out forwards.

at
do
priv
– Disconnect multi-pin connectors on back of dash panel insert.

um
for
en
ng
t.
yi
– Take out dash panel insert.
Co
Cop py
t. rig
Installing
gh ht
pyri by
Vo
o
by c lksw
Installation is carried out in the reverse sequence. cted agen
Prote AG.

Sharan 1996 ➤
1.2.4 Description of back of dash panel insert
Note
♦ The dash panel insert is equipped with a self-diagnosis which

eases fault finding.
♦ The dash panel insert must not be dismantled.
♦ Fault finding programs for specific systems and current circuits
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.
❑ Green
❑ Pin assignment
⇒ page 73
2 - Warning buzzer
❑ Oil pressure warning
❑ Lights switched on
warning
❑ Handbrake warning
❑ Seat belt warning (only
certain countries)
❑ Speed warning (only
certain countries)
❑ Blue
AG. Volkswagen AG d
❑ Pin assignment lksw
agen oes
not
⇒ page 73 d byV
o gu
ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
1.2.5 Warning lamp symbols in dash panel in‐

om
n
c
sert
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
Note
t.
yi Co
Cop py
ht. rig
The employment of the warning lamps in the dash panel insert is rig ht
py by
dependent upon the equipment level, engine and country version.
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
1 - Airbag
2 - Trailer turn signal warning
AG. Volkswagen AG d
agen
3 - Cruise control system Volksw
oes
not
gu
d by ara
4 - Selector lever lock orise nte
eo
h
ut ra
5 - Rear fog light ss a c
ce
e
6 - Glow period warning nl
pt
du
an
itte
y li
7 - Electric throttle
erm
ab
ility
ot p
8 - Left turn signal
wit
, is n
h re
9 - Main beam
hole
spec
10 - Right turn signal
es, in part or in w
t to the co
11 - Exhaust gas warning lamp
12 - ESP
rrectness of i
13 - ABS
l purpos
14 - Immobilizer
nform
ercia
15 - Brake warning/brake sys‐

tem fault warning
m
at
om
io
16 - Alternator charge warning
n
c
in t
or
lamp
his
ate
do
riv
17 - Seat belt
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.

Sharan 1996 ➤
1.2.6 Description of instruments
1 - Oil temperature gauge

2 - Clock
3 - Rev. counter
4 - Press button for setting
clock
5 - Cooling system tempera‐
ture gauge
6 - Cooling system tempera‐
ture warning
7 - Brake pad wear indicator
8 - Bonnet open AG. Volkswagen AG d
agen oes
olksw not
9 - Fuel reserve d by V gu
ara
rise nte
10 - Oil level /oil upressure
tho eo
ra
s a c
s
11 - Door(s) open
ce
e
nl
pt
du
12 - Washer fluid level an

itte
y li
erm
13 - Bulb failure; for failure of ab

ility
ot p
headlight range control wit

, is n
h re
14 - Gear selected display;
hole
spec
multifunction display
es, in part or in w
t to the co
15 - Fuel gauge
16 - Press button to zero trip
recorder
rrectness of i
17 - Speedometer
l purpos
18 - Trip recorder
nform
ercia
19 - Odometer
m
at
20 - Battery voltage gauge

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

Sharan 1996 ➤

panel insert, vehicles 06.00 ▸ 10.03
Note
All pins not listed are vacant.
32-pin connector T32a, green

1 - Radio-controlled clock (+5V)
3 - Radio-controlled clock (data)
4 - CAN data bus, screening for input signals
6 - Washer fluid low
7 - Brake pad wear
8 - Infotainment CAN data bus, high input signal
9 - Infotainment CAN data bus, low input signal
10 - Radio-controlled clock (earth)
13 - Handbrake warning lamp
18 - Oil temperature sender, RPM signal
19 - CAN data bus, high input signal
20 - CAN data bus, low input signal
21 - Bulb failure and failure of headlight range control
22 - Bonnet switch agen
AG. Volkswagen AG d
oes
olksw not
23 - MFI call-up button - left d by
V gu
ara
ise nte
r
24 - MFI call-up button - right ut ho eo
ra
s a c
s
25 - MFI save switch - reset
ce
le
un
pt
an
26 - Ambient temperature sensor input signal

d
itte
y li
erm
ab
27 - CAN data bus, high output signal

ility
ot p
wit
28 - CAN data bus, low output signal

is n
h re
ole,
30 - Radio/navigation - clock
spec
31 - Radio/navigation - data
t to the co
32 - Radio/navigation - enable
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
32-pin connector T32, blue

1 - Terminal 15, positive
3 - Electronic speedometer output signal
4 - Trailer turn signal warning lamp
5 - Fuel gauge
7 - Terminal 31, sender earth
8 - Coolant temperature gauge
9 - Terminal 31, earth
10 - Oil pressure switch
11 - Front passenger door contact switch
swage es n
12 - Alternator warning lamp, terminal 61 yV
olk ot g
ua
b
ed ran
13 - Glow period warning lamp (only diesel engines) orthocatalytic
ris tee
or
converter monitor warning lamp (only certain countries)
au ac
ss
ce
le
14 - Rear fog light warning lamp

un
pt
an
d
itte
15 - Rear left door contact
y li
rm
ab
pe
ility
16 - Rear lid open warning lamp
ot
wit
, is n
17 - Main beam warning lamp, terminal 56a
h re
hole
spec
18 - Left turn signal warning lamp
es, in part or in w
t to the co
19 - Fuel consumption signal
20 - Dash panel insert illumination, terminal 58d
rrectness of i
21 - Driver door contact switch
l purpos
22 - Cooling system low level indicator

nform
ercia

m
a
com
tion in
r
te o
thi
s
26 - Right parking light
iva
do
r
rp
cum
27 - Left parking light

fo
en
ng
t.
yi Co
28 - Input signal to electronic speedometer Cop py
t. rig
gh ht
yri
29 - Brake system warning lamp p by
co Vo
by lksw
cted agen
30 - S-contact Prote AG.

32 - Rear right door contact

Sharan 1996 ➤

panel insert, vehicles 11.03 ▸
Note
All pins not listed are vacant.
32-pin connector T32a, green

4 - CAN data bus, screening for input signals
6 - Washer fluid low
7 - Brake pad wear
10 - Radio-controlled clock (earth)
13 - Handbrake warning lamp
18 - Oil temperature sender, RPM signal
19 - CAN data bus, high input signal
20 - CAN data bus, low input signal
AG. Volkswagen AG d
agen
21 - Bulb failure and failure of headlight range control olksw
oes
not
byV gu
ara
d
22 - ESI orise nte
eo
h
ut ra
23 - MFI call-up button - top ss a c
ce
e
nl
24 - MFI call-up button - bottom
pt
du
an
itte
y li
25 - MFI save switch - reset
erm
ab
ility
ot p
26 - Ambient temperature sensor input signal
wit
, is n
h re
27 - CAN data bus, high output signal
hole
spec
28 - CAN data bus, low output signal
es, in part or in w
t to the co
30 - Radio/navigation - clock
31 - Radio/navigation - data
rrectness of i
32 - Radio/navigation - enable
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.

Sharan 1996 ➤
32-pin connector T32, blue

3 - Electronic speedometer output signal
4 - Trailer turn signal warning lamp
5 - Fuel gauge
6 - Electronic throttle
7 - Terminal 31, sender earth
8 - Coolant temperature gauge
10 - Oil pressure switch
11 - Front passenger door contact switch
wage es n
12 - Alternator warning lamp, terminal 61y Volks ot g
ua
b
ed ran
14 - Rear fog light warning lamp horis tee
t or
au ac
15 - Rear left door contact ss
ce
le
un
pt
16 - Rear lid open warning lamp
an
d
itte
y li
17 - Main beam warning lamp, terminal 56a
rm
ab
pe
ility
ot
18 - Left turn signal warning lamp
wit
, is n
h re
20 - Dash panel insert illumination, terminal 58b
hole
spec
es, in part or in w
21 - Driver door contact switch
t to the co
22 - Cooling system low level indicator
rrectness of i
l purpos
nform
ercia
26 - Right parking light

m
27 - Left parking light

com
tion in
r
28 - Input signal to electronic speedometer

te o
thi
s
iva
do
29 - Brake system warning lamp

r
rp
cum
fo
en
g
30 - S-contact
n
t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
32 - Rear right door contact
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
2 Service interval display
2.1 Resetting service interval display

⇒ Maintenance ; Booklet 10.1
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
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.
2. Service interval display 77

Sharan 1996 ➤
92 – Windscreen wash/wipe systemAG. Volkswagen

agen AG do
ksw es n
Vol ot g
1 Windscreen wiper system ris
ed
by ua
ran
tee
tho
or
au ac
ss
Note
ce
e
nl
pt
du
an
itte
y li
Additional information
erm
ab
ility
ot p
wit
⇒ Self-study programme No. 169 ; The VW Sharan , is n
h re
hole
⇒ Owner's manual
spec
es, in part or in w
t to the co
Caution
rrectness of i
To disconnect and reconnect the battery, the procedure de‐
scribed in the workshop manual should be strictly adhered to
l purpos
⇒ page 4 .
nf
ercia
o
1.1 Removing windscreen wiper system
rm
m
atio
m
(vehicles ▸ 09.98)
o
n in
or c
thi
e

t
sd
iva
o
r
rp
cu
♦ Puller -T10369-
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.1.1 Removing wiper arms
Note
♦ The wiper arm and cowl panel must be removed to remove the
wiper frame with rods and wiper motor.
♦ Before the wiper arms are removed, ensure that the wiper
motor is in the end position. Only then can the wiper arm park
position be correctly set when installing.
♦ Run motor to park position by switching ignition on and oper‐
ating wiper switch briefly.
78 Rep. Gr.92 - Windscreen wash/wipe system

Sharan 1996 ➤
– Remove securing nut -arrow-.
– Slide legs of puller -T10369/1- -2- under wiper arm -4- as

shown in the illustration.
Caution
The wiper shaft may be damaged.

Always use the thrust piece -3- to loosen the wiper arm.
– Turn thrust bolt -1- of puller clockwise until thrust piece -3-
comes into contact with wiper shaft. Turn thrust bolt -1- of
puller clockwise using a 6 mm Allen key until wiper arm -4- is
loosened off shaft.
– Remove puller and wiper arm. AG. Volkswagen AG d
agen oes
lksw no
– If required, repeat work dsequence
by
Vo
for second wiper arm. t guar
e an
ris tee
tho or
au ac
Note ss
ce
le
un
pt
an
d
Removal of the wiper arm on the right side of the vehicle is per‐
itte
y li
erm
formed in the same way.

ab
ility
ot p
wit
is n
h re
1.1.2 Removing cowl panel

ole,
spec
– Remove plastic screws -arrows-.

t to the co
– Carefully lever out both parts of the cowl panel upwards.

rrectne
– Renew damage plastic clips as necessary.

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.
1. Windscreen wiper system 79

Sharan 1996 ➤
1.1.3 Removing air ducting trim

– Unscrew securing bolts (8 mm) -arrows- and pull wiper frame
forwards out of vehicle.
1.1.4 Removing wiper frame with linkage and

wiper motor olkswagen A
G. Volkswagen AG d
oes
no t gu
V
by ara
– Pull connector -1- off
ris wiper motor.
ed nte
ho eo
ut
– Prise off right rod
ss -2-.
a ra
c
ce
le
– Remove securing bolts (13 mm) -3- and remove washers.

un
pt
an
d
itte
y li
– Remove securing nuts (32 mm) -4- from wiper shafts and re‐
rm
ab
move washers.
pe
ility
ot
wit
, is n
– Remove complete wiper frame.

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
1.2 Dismantling windscreen wiper system (vehicles ▸ 09.98)

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

Sharan 1996 ➤
1 - Wiper arm with wiper blade

❑ Adjusting park position
⇒ page 84
wiper rubber blade
⇒ page 118
2 - 15 mm securing nut
❑ 20 Nm
3 - Washer
❑ 20 Nm
5 - Washer AG. Volkswagen AG d
agen oes
6 - Rubber grommet olksw not
V gu
d by ara
e nte
7 - Wiper motor horis
eo
ut ra
❑ Removing ⇒ page 81 ss a c
ce
e
nl
8 - Wiper frame with linkage
pt
du
an
itte
y li
9 - Rubber grommet
erm
ab
ility
ot p
10 - Plastic washer
wit
, is n
h re
11 - 13 mm securing bolt
hole
spec
❑ 20 Nm
es, in part or in w
t to the co
12 - Wiper arm
rrectness of i
⇒ page 84
l purpos

wiper rubber blade
nform
ercia
⇒ page 118
m
at
om
ion
c
in t
or
his
e
1.2.1 Removing wiper motor

at
do
priv
cum
or
– Prise right rod in illustration completely off ball joints

f
en
ng
t.
-arrows-. Cop
yi Co
py
t. rig
– Prise left rod in illustration off outer ball joints -arrows-. gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Mark position of lever -1- to wiper frame.

– Lock lever - 1-.
– Remove securing nut (13 mm) -2-.
– Release lever -1- from taper by moving lever up and down then
remove it.
– Remove securing bolts (10 mm) and take wiper motor off wiper
frame.
1.2.2 Repairing wiper mounting

1- Circlip agen
AG. Volkswagen AG d
oes
olksw not
V
2- Washer ed by gu
ara
nte
ris
o eo
3- Seal aut
h
ra
ss c
4- Corrugated washer
ce
le
un
pt
an
d
5- Toggle lever
itte
y li
erm
ab
– Check running surfaces of ball joints for wear and renew ball
ility
ot p
joint if necessary.
wit
is n
h re
ole,
– Grease toggle lever before installing.
spec
t to the co
1.3 Installing windscreen wiper system (ve‐
hicles ▸ 09.98)
rrectne
♦ Torque wrench -V.A.G 1331- ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.3.1 Installing wiper motor in wiper frame

– Run wiper motor to park position by connecting connector to
wiper motor and briefly operating wiper switch.
– Disconnect connector again and secure wiper motor to wiper
frame using securing bolts (10 mm).
– Tighten threaded connection to specified torque setting
⇒ page 142 .

Sharan 1996 ➤
– Align lever -1- to marks on wiper frame and fit onto motor drive
shaft, then tighten securing nut -2- hand-tight.
– Tighten securing nut -2- on motor shaft.
⇒ page 142 .
– Unclip both ball joints of right rod in illustration -arrows-.

– Unclip outer ball joint of left rod in illustration -arrow-.
1.3.2 Installing wiper frame with linkage and

wiper motor ksw
agen
AG. Volkswagen AG d
oes
n ol ot g
yV
– Install wiper frame with linkage
ise
dand
b wiper motor. ua
ran
r tee
ho
– Fit washers and secure sthe
au wiper frame with securing bolts
t or
ac
-3-. s
ce
le
un
pt

an
d
itte
y li
⇒ page 142 .
rm
ab
pe
ility
– Unclip right rod -2- at ball joint.

ot
wit
, is n
h re
– Fit washers and secure the wiper shafts with securing nuts (32
hole
mm) -4-.
spec
es, in part or in w
t to the co

⇒ page 142 .
rrectness of i
l purpos
nform
ercia
1.3.3 Installing air ducting trim

m
a
com
ti
– Install air ducting trim and secure with securing screws (8 mm)
on in
-arrows-.
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
1.3.4 Installing cowl panel

– Install cowl panel.
– Tighten plastic screws -arrows-.
1.3.5 Installing wiper arms

G. Volkswage nA n AG d
wage oe
– Place the wiper arms y-1-Vol in approximate park positionoton
ks sn
gu the
wiper arm shafts and
ise
d btighten securing nuts -2- hand-tight ara
n r tee
ho
aut or
ac
ss
Note ce
e
nl
pt
du
an
itte
y li
The wiper arm securing nuts -arrows- are not tightened to speci‐
erm
ab
fied torque until after wiper blade rest position has been adjusted.
ility
ot p
wit
, is n
h re
– Adjust windscreen wiper blade park position ⇒ page 84 .

hole
spec
es, in part or in w
t to the co
1.3.6 Adjusting wiper blade park position

rrectness of i
– Allow wiper to move to rest position.

l purpos
A - 20 mm
nf
ercia
B - 45 mm
orm
m
atio
– Remove wiper arm if necessary and adjust according to the

om
n in
above specified dimensions.

or c
thi
te
sd

iva
o
r
⇒ page 142 .
rp
cu
o
m
f
en
ng
– Install black cover cap.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
AG.
(vehicles 10.98 ▸ 05.00)


Sharan 1996 ➤
AG. Volkswagen AG d
lksw
agen Electrical
oessystem - Edition
not 12.2008
Vo gu
d by ara
e
♦ Puller -T10369- horis nte
eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Note
m
at
om
io
n
c
in t
or
his
ate
do
riv
p
cum
or
f
en
ng
t.
position be correctly set when installing. Cop
yi Co
py
t. rig
♦ Run motor to park position by switching ignition on and oper‐ gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.


Sharan 1996 ➤

Caution

loosened off shaft.
– Remove puller and wiper arm.
– If required, repeat work sequence for second wiper arm.
Note
1.4.2 Removing cowl panel grille

– Carefully lever outer parts of cowl panel grille upwards
-arrows-.
Note
Removal of the cowl panel grille on the right side of the vehicle is
performed in the same way.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
– Carefully lever middle part -1- of cowl panel grille upwards
ce
le
un
pt
-arrows-.
an
d
itte
y li
rm
ab

pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
86
Prote AG.
Rep. Gr.92 - Windscreen wash/wipe system
Sharan 1996 ➤

– Remove right trim part -2- next to battery.
– Unclip wiring and hose -1- to windscreen washer jets from air
duct trim.
– Unscrew securing bolts (10 mm) -arrows- and pull wiper frame
forwards out of vehicle.

wiper motor wage
e
olks s no
yV t gu
– Disconnect battery ⇒ page 4 . edb ara
ris nte
– Pull connector -2- off wiper motor. ho eo
aut ra
ss c
– Remove securing screws (13 mm) -1-.
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
– Release cable guide from wiper linkages from rear -arrows-.
l purpos
Bend locking tabs slightly upwards for this.

nform
ercia
Note
m
a
com
tion in
For reasons of clarity the cable guide is shown removed.

r
te o
thi
s
iva
do
r
rp
– Remove cable guide from wiper frame.

um
fo
en
ng
t.
yi
– Remove wiper frame with linkage and wiper motor.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.5 Dismantling windscreen wiper system (vehicles 10.98 ▸ 05.00)

Sharan 1996 ➤

⇒ page 92
wiper rubber blade
⇒ page 118
2 - 16 mm securing nuts
❑ 32 Nm
❑ 22 Nm
4 - 10 mm securing bolts
❑ 7 Nm
❑ 10 Nm
6 - Wiper motor
❑ Removing wiper frame
⇒ page 87
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
– Prise right rod in illustration off at ball joint -arrow-.

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

Sharan 1996 ➤

– Remove securing nut (13 mm) on motor shaft.
remove it.
frame.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
1.5.2 Repairing wiper mounting ss c
ce
le
un
pt
1- Circlip
an
d
itte
y li
rm
ab
2- Washer
pe
ility
ot
wit
3- Seal
, is n
h re
hole
spec
es, in part or in w
5- Toggle lever
t to the co
– Check running surfaces of toggle lever for wear and renew
toggle lever if necessary.
rrectness of i
l purpos
nform
ercia
hicles 10.98 ▸ 05.00)

m
a
com
tio
n in
r
te o
thi
♦ Torque wrench -V.A.G 1331- 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.
♦ Puller -T10369-

Sharan 1996 ➤

⇒ page 142 .
– Align lever -1- to marks on wiper frame and fit onto motor drive
shaft, then tighten securing nut (13 mm) hand-tight.
– Tighten securing nut (13 mm) arrow.
⇒ page 142 .
– Unclip ball joint of right rod -arrow- in illustration.
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
wiper motor
ility
ot p
wit
is n
– Install wiper frame with linkage and wiper motor.

h re
ole,
spec
– Fit washers and secure the wiper frame with securing bolts
-1-.
t to the co

⇒ page 142 .
rrectne
– Clip cable guide back on.

s
– Reconnect connector -2- to wiper motor.

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

Sharan 1996 ➤

en AG. V
olkswagen AG
does ag
ol not ksw
– Install air ducting trim and secure
y V with securing screws (10 gu
db ara
mm) -arrows-. rise nte
tho eo
u
– Clip wiring and hosess-1-
a for windscreen washer jets on air duct ra
c
trim.
ce
e
nl
pt
du
an
– Install right trim part -2- next to battery.
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
1.6.4 Installing cowl panel
rrectness of i
l purpos
– Clip middle part -1- of cowl panel grille in position -arrows-.
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.
– Clip outer parts of cowl panel grille in position -arrows-.
Note
Installation of the cowl panel grille on the right side of the vehicle
is performed in the same way.

– Place the wiper arms -1- in approximate park position on the
wiper arm shafts and tighten securing nuts -2- hand-tight
Note
The wiper arm securing nuts -2- are not tightened to specified
torque until after wiper blade rest position has been adjusted.
Note
Installation of the wiper arm on the left side of the vehicle is per‐

Sharan 1996 ➤

A - 15 - 20 mm agen
AG. Volkswagen AG d
oes
olksw not
B - 35 mm ed byV gu
ara
ris nte
– Remove wiper arm if necessary and
aut adjust according to the
ho eo
ra
above specified dimensions. ss c
ce
e
nl
pt
du
an
itte
⇒ page 142 .
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
(vehicles 06.00 ▸ 04.01)
rrectness of i
♦ Puller -T10369-
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
co Vo
by lksw
cted agen
Prote AG.
Note


Sharan 1996 ➤

Caution
AG. Volkswagen AG d
agen oes
lksw not
The wiper shaft dmayby V be damaged.
o gu
ara
ise n
o thrust piece -3- to loosen the wiper arm.tee
r
Always useuththe or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
loosened off shaft.
wit
is n
h re
ole,
spec
t to the co
Note
rrectne
s
s o
cial p
f inform
mer

atio
om
n
c

i
or
n thi
e
-arrows-.
t
sd
iva
o
pr
cum
r
fo
en
ng
t.
Note Cop
yi Co
py
t. rig
gh ht
Removal of the cowl panel grille on the right side of the vehicle is
pyri by
Vo
co
by lksw
cted agen
Prote AG.

-arrows-.

Sharan 1996 ➤
1.7.3 Removing battery cover

– Remove plastic screws -1- and -2- and pull battery cover off
forwards.

– Unscrew securing screws (10 mm) -arrows- and pull air duct
trim forwards out of vehicle.

wiper motor
AG. Volkswagen AG d
– Pull connector -2- off wiper motor. agen oes
olksw not
y V gu
b ara
– Remove securing screws (13 mm) -1-. rise
d
nte
tho eo
au ra
ss c ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co

rrectness
Note
o
cial p
f inform

mer
atio
om
n
c

i
or
n thi
te
sd
a

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.

Sharan 1996 ➤

⇒ page 98
wiper rubbersblade n AG. Volkswagen AG do
wage es n
⇒ page b118
yV
olk ot g
ua
d ran
se
2 - 16 mmtho securing nuts
ri tee
or
au ac
❑ ss32 Nm
ce
e
nl
pt
du
an
itte
y li
❑ 22 Nm
erm
ab
ility
ot p
wit
, is n
❑ 7 Nm
h re
hole
spec
es, in part or in w
t to the co
❑ 10 Nm
6 - Wiper motor
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.

– Prise right rod in illustration off at ball joint -arrow-.

Sharan 1996 ➤

olkswagen AG
en AG. V
– Remove securing nut (13 mm) from motor
olks shaft.
wag does
not
byV gu
ara
– Release lever -1- from taper by moving
rised
lever up and down then nte
remove it. aut
ho eo
ra
ss c
ce
e
nl
frame.
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
1- Circlip
rrectness of i
2- Washer
l purpos
3- Seal
nform
ercia
m
5- Toggle lever
at
om
ion
c
in t
or
his
e

at
do
priv
c
um
for
en
ng
t.
yi Co
op
C py
ht. rig
rig ht
by
hicles 06.00 ▸ 04.01) copy Vo
by lksw
cted agen
Prote AG.

⇒ page 142 .

AG. Volkswagen AG d Sharan 1996 ➤
agen oes Electrical system - Edition 12.2008
olksw not
byV gu
ara
ed
is nte
– Align lever t-1-
hor to marks on wiper frame and fit onto motor edrive
or
shaft, then
ss au
tighten securing nut (13 mm) hand-tight. ac
ce
– Tighten threaded connections to specified torques e
nl
pt
du
an
⇒ page 142 .
itte
y li
erm
ab
ility
ot p
wit
– Tighten securing nut (13 mm).
, is n
h re
hole
spec
⇒ page 142 .
es, in part or in w
t to the co
rrectness of i
– Unclip ball joint of right rod -arrow- in illustration.
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
co Vo
by lksw
cted agen
Prote AG.
wiper motor
-1-.
⇒ page 142 .

– Install air ducting trim and secure with securing screws (10
mm) -arrows-.

Sharan 1996 ➤
1.9.4 Installing cowl panel grille

– Clip spray jet in position.
– Install battery cover and secure.

. Volkswage AG n AG d
agen oes
olksw not
yV gu
db ara
Note rise nte
tho eo
s au ra
c
Installation of thes cowl panel grille on the right side of the vehicle
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
Note
nform
mercia
a
com
tio
n in
r
te o
thi
s
iva

do
r
rp
cum
fo
en
ng
t.
yi Co
Note Cop py
t. rig
gh ht
pyri by
Installation of the wiper arm on the left side of the vehicle is per‐
o Vo
by c lksw
cted agen
formed in the same way. Prote AG.

The dimensions -A- are measured from the top edge of the cowl
panel grille:
A - 30 mm
B - 75 mm
⇒ page 142 .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
thor Sharan 1996 e➤
or
u
ss a Electrical system - Edition 12.2008 ac
ce
e
nl
pt
du
an
itte
y li
erm
(vehicles 05.01 ▸ 10.03)
ab
ility
ot p
wit
, is n
h re
hole
♦ Puller -T10369-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
c
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Note yri
p by
co Vo
by lksw
cted agen
Prote AG.


Sharan 1996 ➤

Caution

loosened off shaft.
Note

olkswagen AG
en AG. V
– Remove plastic screws -1- and -2- and pull battery cover off olks
wag does
not
forwards. d byV gu
ara
e nte
ris
– Remove engine compartment bonnet so that it is not damaged
aut
ho eo
ra
when removing the wiper system. 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
-arrows-. nform
ercia
Note
m
a
com
tion in
♦ Removal of the cowl panel grille on the right side of the vehicle
r
te o

thi
s
iva
do
♦ The securing clips are destroyed when removing the outer

r
rp
cum
fo
parts of the cowl panel grille, these must be renewed when

en
ng
t.
reinstalling the grille.
yi Co
Cop py
t. rig
gh ht
yri by
– Unclip spray jet from cowl panel grille. cop Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤

-arrows-.
Note
The securing clip in the middle of the retaining plate for the cowl
panel grille can become loose/lost if care is not exercised during
removal. Ensure this clip is installed correctly before installing the
cowl panel grille. Otherwise the cowl panel grille retaining plate
may rattle.

– Unscrew securing screws (10 mm) -arrows- and pull air duct
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
wiper motor
pe
ility
ot
wit
, is n
– Pull connector -2- off wiper motor.

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


Sharan 1996 ➤
When removing the wiper frame, ensure that the washers on the
threaded connections -A- between the wiper frame and the body
do not fall into the engine compartment.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
⇒ page 108
nform
ercia
wiper blade
⇒ page 119
m
at
om
io
n
c
in t
or
❑ 32 Nm his
ate
do
riv
p
cum
for
en
❑ 22 Nm
ng
t.
yi Co
op py
. C rig
ht ht
rig by
py
❑ 7 Nm co Vo
by lksw
cted agen
Prote
AG.
❑ 10 Nm
6 - Wiper motor
8 - Wiper mounting
❑ Repairing ⇒ page 105

Sharan 1996 ➤

– Remove securing nut -1-, counterhold on the lever -2- with a
30 mm open jaw spanner for this.
remove it.
– Move lever -2- together with wiper linkages to side.
– Remove securing bolts (10 mm)aand
gen Atake
G. Volwiper
kswagemotor
n AG d off wiper
oes
frame. V olksw not
g y ua
db ran
rise tee
tho 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
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
– Insert wiper motor in wiper frame and secure it with the 3 se‐
rp
cum
fo
curing screws.
en
ng
t.
yi Co
op
C py
t. rig
gh
⇒ page 142 .
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
♦ New wiper motors are supplied set to the “zero position”.

♦ If the old wiper motor is reinstalled, set wiper motor to park
position before reconnecting the linkages to the motor.

– Pull connector off wiper motor again.

Sharan 1996 ➤
Volkswa
– Install crank -1- on wiper motor ashaft.
gen AGEnsure position
. gen AG
doeof
s nmotor
ksw
shaft does not change when
by Vol doing this. ot g
ua d ran
se
– Set wiper rods in athostraight
ri line as illustrated. tee
or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Distance from lever -1- to stop -2- must be 7 mm (distance -A-).
rrectne
– Tighten lever -1- securing nut sufficiently to stop lever turning.
Counterhold on lever with a 30 mm open jaw spanner for this.
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
op py
– Turn lever -1- through approx. 90° using a 30 mm open jaw
t. C rig
gh ht
yri
spanner. p by
o Vo
by c lksw
cted agen
– Tighten securing nut of lever -1- to torque setting. Counterhold Prote AG.
on lever with a 30 mm open jaw spanner for this.
⇒ page 142 .
Note
Check system runs to park position correctly before installing

wiper frame.

Sharan 1996 ➤
– Disconnect connectors for horn and temperature sensor

-arrows-.
The wiring connections to the wiper motor are otherwise too short
for a test run without installing the wiper frame.
WARNING
♦ Danger from pinching!

♦ Danger of becoming caught/pinched in the rotating parts
♦ Do not hold wiper motor in area of rotating parts when
wiper motor is removed.
n AG. Volkswagen AG
olks
wageconnector to wiperdomotor.
– With ignition switched off, reconnect es n
o V t gu
by ara
– With the aid of a secondrisperson,
ed position wiper system so that nte
the wiper rods haveausufficient
tho
clearance. eo
ra
ss c
ce
le
un
pt
an
d
– Run wiper motor to park position by switching ignition on and

itte
y li
briefly operating wiper switch.
rm
ab
pe
ility
– Switch ignition off again once wiper motor has reached the
ot
wit
, is n
park position.
h re
hole
spec
es, in part or in w
t to the co
– Distance from lever -1- to stop -2- must be 4-10 mm (distance
“A”).
rrectness of i
If the dimension does not lie within the tolerance, adjust position
of lever -1- again. Repeat test on completion of adjustments.
l purpos
If dimension lies within tolerance, install wiper frame

⇒ page 105 .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
1- Circlip
co Vo
by lksw
cted agen
Prote AG.
2- Washer
3- Seal
5- Toggle lever

hicles 05.01 ▸ 10.03)

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
wiper motor
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
-1-.
spec
t to the co
⇒ page 142 .
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e

t
sd
iva
o
pr
cum
r
fo
en
ng
mm) -arrows-.
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
When installing air duct trim, ensure that both sides of the trim lie
under the retaining plate -arrow-.

Sharan 1996 ➤
1.12.3 Installing cowl panel grille

– Clip washer spray jets into cowl panel grille.
– Install new securing clips in outer parts of cowl panel grille

-arrows-.
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
Note
Installation of the cowl panel grille on the right side of the vehicle rrectness of i
l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
1.12.4 Installing battery cover

p
cum
for
en
ng
t.
yi
– Install battery cover and secure with plastic screws -1- and
Co
Cop py
-2-.
t. rig
gh ht
pyri by
Vo
o
– Install engine cover.
c by lksw
cted agen
Prote AG.

Sharan 1996 ➤

Note
AG. Volkswagen AG d
– Adjust windscreen wiper blade park position ⇒ page 108 . agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Note aut ra
ss c
ce
le
Installation of the wiper arm on the left side of the vehicle is per‐ un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
The measurements for adjusting the park position of the wiper
es, in part or in w
blades are made at the ends of the wiper blades.
t to the co
panel grille:
rrectness of i
A - 16 mm, tolerance +10 mm
l purpos
B - 64 mm, tolerance +10 mm
nform
ercia
C - 19 mm, tolerance +10 mm

m
D - 56 mm, tolerance +10 mm
a
com
tion in
r
te o
thi
s
iva
do
r
rp
c
um
fo
en
g
⇒ page 142 .
n
t.
yi Co
Cop py
t. rig
gh
ht
pyri by
Vo
o
by c lksw
(vehicles 11.03 ▸)
cted agen
Prote AG.

♦ Puller -T10369-

Sharan 1996 ➤
Note
♦ In order to be able to remove wiper frame with linkage and

wiper motor, you must remove the wiper arms and plenum
chamber cover.

lkswage es n
o ot g
byV ua
d ran
ir se tee
– Slide legs of puller -T10369/1- -2-uthunder wiper arm -4- as
o
or
shown in the illustration. ss
a ac
ce
le
un
pt
an
d
Caution
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
loosened off shaft.

l purpos

nform
mercia
a
com
Note
ion in
r
te o
thi
s
iva
do

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

Sharan 1996 ➤

– Remove plastic screws -1- and -2- and pull battery cover off
forwards.
– Remove engine compartment bonnet so that it is not damaged
when removing the wiper system.
1.13.3 Removing plenum chamber cover

– Pull plenum chamber seal -1- off over the complete length
-arrows-.
– Lift plenum chamber cover -2- at edges of windscreen.
Note
Do not use tools to help in the removal of the plenum chamber

cover.
– Tilt plenum chamber cover into plenum chamber.
– Pull hose connectors -2- apart.

Vehicles with heated washer jets only
AG. Volkswagen AG d
– Separate connector -1-. lksw
agen oes
not
Vo gu
by
Continuation for all vehicles rise
d ara
nte
tho eo
– Unclip spray jets and remove splenum
au chamber cover from ve‐ ra
c
hicle. s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec

t to the co
– Remove securing screws (10 mm) -arrows- and pull air duct
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.

lkswage es n
o ot g
byV ua
d ran
ir se tee
o
auth Sharan 1996 or
ac ➤
ss Electrical system - Edition 12.2008
ce
le
un
pt
an
d
itte
y li
rm
ab
wiper motor
pe
ility
ot
wit
, is n
– Pull connector -2- off wiper motor.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
Note C py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.

When removing the wiper frame, ensure that the washers on the
threaded connections -A- between the wiper frame and the body
do not fall into the engine compartment.
1.14 Dismantling windscreen wiper system (vehicles 11.03 ▸)

Sharan 1996 ➤

⇒ page 108
wiper blade
⇒ page 119
❑ 32 Nm
❑ 22 Nm
❑ 7 Nm agen
AG. Volkswagen AG d
oes
olksw not
V
5 - 13 mm securing bolts d by gu
ara
rise nte
❑ 10 Nm utho eo
ra
s a c
6 - Wiper motor s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
8 - Wiper mounting
hole
spec
❑ Repairing ⇒ page 115
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
g
– Remove securing nut -1-, counterhold on the lever -2- with a

n
t.
yi Co
op
30 mm open jaw spanner for this. C py
t. rig
gh ht
yri by
– Release lever -2- from taper by moving lever up and down then cop Vo
by lksw
remove it. cted agen
Prote AG.
– Move lever -2- together with wiper linkages to side.

frame.


Sharan 1996 ➤
– Insert wiper motor in wiper frame and secure it with the 3 se‐
curing screws.
⇒ page 142 .
Note
♦ New wiper motors are supplied set to the “zero position”.

♦ If the old wiper motor is reinstalled, set wiper motor to park
position before reconnecting the linkages to the motor.

– Pull connector off wiper motor again.
. Volkswage
– Install crank -1- on wiper motor shaft. Ensure wposition
agen
AG
of motorn AG does n
shaft does not change when doing this. Volks ot g
by ua d ran
ise
– Set wiper rods in a straight line uas
tho illustrated.
r tee
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
Distance from lever -1- to stop -2- must be 7 mm (distance -A-).

rrectness of i
– Tighten lever -1- securing nut sufficiently to stop lever turning.

Counterhold on lever with a 30 mm open jaw spanner for this.
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
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Turn lever -1- through approx. 90° using a 30 mm open jaw

spanner.
– Tighten securing nut of lever -1- to torque setting. Counterhold
on lever with a 30 mm open jaw spanner for this.
⇒ page 142 .
Note
Check system runs to park position correctly before installing

wiper frame.
wage es n
– Disconnect connectors for horn and temperature
Vol
ks sensor ot g
by ua
-arrows-. ised ran
or tee
h
The wiring connections to the wiper autmotor are otherwise too short or
ac
ss
for a test run without installing the wiper frame.
ce
e
nl
pt
du
an
itte
y li
WARNING
erm
ab
ility
ot p
♦ Danger from pinching!
wit
, is n
h re
♦ Danger of becoming caught/pinched in the rotating parts
hole
spec
es, in part or in w
♦ Do not hold wiper motor in area of rotating parts when
t to the co
wiper motor is removed.
rrectness of i
– With ignition switched off, reconnect connector to wiper motor.
l purpos
– With the aid of a second person, position wiper system so that

the wiper rods have sufficient clearance.
nform
ercia

m
at
om
– Run wiper motor to park position by switching ignition on and

ion
c
briefly operating wiper switch.

in t
or
his
ate
– Switch ignition off again once wiper motor has reached the
do
priv
park position.
um
for
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
yri by
– Distance from lever -1- to stop -2- must be 4-10 mm (distance cop Vo
by lksw
“A”). cted agen
Prote AG.
If the dimension does not lie within the tolerance, adjust position
of lever -1- again. Repeat test on completion of adjustments.
If dimension lies within tolerance, install wiper frame
⇒ page 105 .

Sharan 1996 ➤

1- Circlip
2- Washer
3- Seal
5- Toggle lever
1.15 Installing windscreen awiper

gen AG system (ve‐
. Volkswagen AG
does
ksw
hicles 11.03 ▸)ed by Vol not
gu
ara
ris nte
Special tools and workshop
au
thequipment
o
required eo
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
1.15.1 Installing wiper frame with linkage and nform

ercia
wiper motor
m
a
com
tion in

r
te o
thi
s
iva
do
r
-1-.
rp
cum
fo
en
g

n
t.
yi Co
op
⇒ page 142 . C py
t. rig
gh ht
yri by
– Clip cable guide back on. op Vo
by c lksw
cted agen
Prote
AG.

wage es n
Sharan 1996 ➤ yV
olks ot g
b ua
Electrical system - riEdition
se
d 12.2008 ran
tee
tho
u or
a ac
1.15.2 ss Installing air ducting trim
ce
le
un
pt
an
d
itte
y li
mm) -arrows-.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
When installing air duct trim, ensure that both sides of the trim lie
mer
under the retaining plate -arrow-.
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.
1.15.3 Installing plenum chamber cover

– Install washer spray jets in plenum chamber cover.
– Secure wiring with retainers -arrows-.
– Reconnect connectors -2-.

Vehicles with heated washer jets only
– Reconnect connector for heated spray jets -1-.
Continuation for all vehicles
Ensure retainers -arrows- are seated securely.

Sharan 1996 ➤
– Install plenum chamber -2-.

– Install rubber seal -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
1.15.4 Installing battery cover
wit
is n
h re
ole,
spec
– Install battery cover and secure with plastic screws -1- and
-2-.
t to the co
– Install engine cover.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r

p
cum
r
fo
en
ng
t.
yi
Co
op py
t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Note
Installation of the wiper arm on the other side of the vehicle is


Sharan 1996 ➤

The measurements for adjusting the park position of the wiper
blades are made at the ends of the wiper blades.
panel grille:
A - 16 mm, tolerance +10 mm
B - 64 mm, tolerance +10 mm
C - 19 mm, tolerance +10 mm
D - 56 mm, tolerance +10 mm
⇒ page 142 .
1.16 Removing and installing wiper rubber

blade
– Press both steel strips together on enclosed side of wiper
blade using suitable pliers and pull them out to side of upper
clip.
– Pull rubber together with astrips
n AGout
. Volkof
swremaining
agen AG
doesclips of wiper
w ge
blade. Vo lks not
g by ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Clip new wiper blade rubber into lower clips of wiper blade.
– Insert both steel strips in the first groove of the wiper blade
rrectness of i
rubber so that the recesses in the strips face the rubber and
l purpos
engage in the rubber lugs of the groove.

– Press both steel strips and rubber together again using suita‐
nform
ercia
ble pliers and place in upper clips so that lugs of clip engage
on both sides in the retaining grooves -arrow- of wiper blade
m
at
rubber.
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
1.17 Removing and installing aerodynamic

wipers
Note
♦ Driver and front passenger side wiper blades must not be in‐
terchanged during installation. AG. Volkswagen AG d
agen oes
ksw
♦ The aerodynamic wiper blades are very flexible. To lift theby V ol not
gu
wiper blades off the windscreen, touch them only in the risearea
d ara
nte
in which the wiper blades are attached to the wipers.utho eo
ra
s a c
s
ce
le
Removing
un
pt
an
d
itte
y li
– Lift up wiper arm.
rm
ab
pe
ility
Grasp wiper blade only in area of mounting to wiper arm. This ot
wit
prevents accidental bending of wiper arm and wiper blade.
, is n
h re
hole
– Fold wiper blade up to stop.
spec
es, in part or in w
– Pull wiper blade off wiper arm -arrow-.
t to the co
Installing
rrectness of i
l purpos
nform
ercia
– Slide wiper blade onto axis of wiper arm -arrows-.

m
a
com
tio
– Fold wiper blade back.
n in
r
te o
thi
– Carefully fold wiper arm back down onto windscreen.
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.
1.18 Checking intermittent wiper regulator -

E38-
VAS 5051A- or successor models ⇒ page 236 .
♦ Body
♦ Multifunction unit
♦ Electrical components, wiper motor
♦ Windscreen intermittent wipe regulator

Sharan 1996 ➤
2 Windscreen washer system
Note
⇒ Self-study programme No. 169 ; The VW Sharan

Fault detection and fault display
The onboard supply control unit has a self-diagnosis function,
which makes fault finding easier.
For fault finding, use vehicle diagnosis, testing and information
system -VAS 5051A- or successor units in “Guided fault finding”
mode.
2.1 Assembly overview - windscreen washer system
1 - Connection piece
❑ Connection to right-
hand windscreen wash‐
er jet
❑ Overview of hose cou‐
plings for washer fluid
lines ⇒ page 140
2 - Windscreen washer system
right washer jets
⇒ page 123
❑ Checking and adjusting
⇒ page 126
3 - Hose
❑ Hose repair olkswage es n
ot g
⇒ page 141 d byV ua
ran
ir se tee
4 - T-piece utho
or
a ac
❑ Distribution of wash wa‐ ss
ce
e
ter line to windscreen

nl
pt
du
an
spray jets
itte
y li
erm
ab
5 - Windscreen washer system

ility
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left washer jets

wit
, is n
h re

hole
⇒ page 123
spec
es, in part or in w
❑ Checking and adjusting

t to the co
⇒ page 126
6 - Angled connection piece
rrectness of i
❑ Connection to wind‐
screen and rear window
l purpos
washer pump -V59-

nf
ercia

rm
m
lines ⇒ page 140

atio
om
n in
c
7 - Windscreen and rear window washer pump -V59-

or
thi
e

t
sd
iva
o
r
rp
cu
8 - Reservoir for windscreen and headlight washer system

o
m
f
en
ng
t.
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Co
Cop py
t. rig
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pyri by
Vo
co
120
by lksw
cted agen
Rep. Gr.92 - Windscreen wash/wipe system Prote AG.
Sharan 1996 ➤
❑ Connection to left-hand windscreen spray jet
❑ Overview of hose couplings for washer fluid lines ⇒ page 140
2.2 Removing and installing reservoir for

windscreen and headlight washer sys‐
tem G. Volkswage
A n AG d
agen oes
Removing ksw not
y Vol gu
db ara
– ise ignition and all
Switchhoroff electrical consumers and eremove
nte
ignition
au key.
t or
ac
ss
– Remove front bumper ⇒ General body repairs, exterior; Rep.
ce
e
nl
pt
du
Gr. 63 ; Front bumper .
an
itte
y li
erm
ab
Only vehicles 06.00 ▸
ility
ot p
wit
– Remove left headlight ⇒ page 146 .
, is n
h re
hole
spec
es, in part or in w
– Pull cover -1- off reservoir for windscreen and headlight wash‐
t to the co
er system.
– Remove cover cap -2- from left headlight, if necessary.
– Remove bolt -3-. rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
o
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f
– Disconnect all connector -1- and open cable guide -2-.

en
ng
t.
yi Co
op py
– If necessary, unclip hoses -3- from reservoir. t. C rig
gh ht
pyri by
– Separate hose connectors -4- at windscreen and rear window
o Vo
by c lksw
cted
washer pump -V59- and headlight washer system pump -
agen
Prote AG.
V11- .
Note
The elbow connections to the windscreen and rear window wash‐

er pump -V59- are colour-coded and must be assigned to the
correct connections on the windscreen and rear window washer
pump -V59- during assembly.
– Drain any escaping fluid in a suitable container.
2. Windscreen washer system 121

Sharan 1996 ➤
– Remove securing bolts -arrows- and remove reservoir.

Installing
following:
⇒ page 142 .
– On completion of installation work, bleed headlight washer
system ⇒ page 139 .
2.3 Removing and installing windscreen

and rear window washer pump -V59-
Removing
ignition key.
– Pull hose connections -4- off windscreen and rear window
washer pump -V59- .
Note
The elbow connections to the windscreen and rear window wash‐

er pump -V59- are colour-coded and must be assigned to the
correct connections on the windscreen and rear window washer
pump -V59- during assembly.

– Disconnect connector -1- on windscreen and rear window AG. Volkswagen AG d
washer pump -V59- . agen oes
olksw not
byV gu
ara
d
– Pull windscreen and rear window washer pump -V59- upwards
orise nte
out of windscreen and headlight washer system reservoir.
aut
h eo
ra
ss c
Installing
ce
e
nl
pt
du
an
itte
y li
following:
erm
ab
ility
ot p

wit
, is n

h re
hole
spec
es, in part or in w

t to the co
washer fluid level sender -G33-

rrectness of i
Note
l purpos
It is possible that the location of the windscreen washer fluid level

nform
ercia
sender -G33- deviates slightly from the illustration, this will de‐
pend on the equipment fitted to the vehicle. The removal proce‐
m
at
om
dure is analogue.
ion
c
in t
or
his
e
Removing
at
do
priv
cum

for
en
g
ignition key.
n
t.
yi Co
Cop py
ht. rig
rig ht
py by
122
co Vo
by lksw
cted
Rep. Gr.92 - Windscreen wash/wipe system
agen
Prote AG.
Sharan 1996 ➤
– Remove front bumper cover ⇒ General body repairs, exterior;

Rep. Gr. 63 ; Front bumper .
AG. Volkswagen
– Unplug connector -1- at windscreen
wage
n
washer fluid level
AG do
es nsender
olks
-G33- . d by V ot g
ua
nt e ra
ris
– Pull windscreen uwasher
tho fluid level sender -G33- -3- out of its ee or
rubber seal -2-.
ss
a ac
ce
le

un
pt
an
d
itte
y li
Installing
erm
ab
ility
ot p
wit
is n
following:
h re
ole,
spec
t to the co
rrectne
washer jets
ss o
cial p
f
2.5.1 Removing and installing windscreen
inform
mer
washer system spray jets (vehicles
atio
m
▸ 05.00)
o
n
c
i
or
n thi
te
Removing
sd
iva
o
pr
cum
r

fo
en
ng
ignition key.
t.
yi Co
Cop py
– Remove bonnet insulation (Qty. 11 clips).
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Pull hose connection -1- off spray jet.

– Disconnect connector -2- for heated washer jet.
– Carefully press out spray jet using a suitable screwdriver
-arrow-.
Installing
following:

Sharan 1996 ➤

06.00 ▸ 10.03)
Removing
Note
For reasons of clarity the windscreen washer system spray jets

are shown removed.

ignition key.
– Pull hose connector off spray jet and, if fitted, disconnect 2-pin
connector.
– Unclip windscreen washer system spray jets by pressing re‐
taining lugs -arrows- together.
AG. Volkswagen AG d
agen oes
olksw not
– Carefully lever middle part -1- of cowl panel grille d by Vupwards gu
ara
-arrows-. horise nte
eo
aut ra
– Renew damage plastic clips as necessary. ss c ce
e
nl
Installing
pt
du
an
itte
y li
erm
ab
following:
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
11.03 ▸)
nform
ercia
Removing
m
at
om
ion
c
in t
r
Note
o
his
ate
do
priv
Heated washer jets must be renewed as a pair, as both a con‐

um
for
nected to one connector.

en
ng
t.
yi Co
Cop py
ht. rig
– Switch off ignition and all electrical consumers and remove rig ht
py by
ignition key.
co Vo
by lksw
cted agen
Prote AG.
– Remove plenum chamber cover ⇒ page 110 .

Sharan 1996 ➤
– Pull off retainers -arrows-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
– Press retaining lugs -arrows- on both sides of washer spray du
an
itte
y li
jet together and push washer spray jet out through retainer.
erm
ab
ility
ot p
Installing
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
o
2.5.4 Removing and installing washer spray
rm
m
atio
jet retainer (vehicles 11.03 ▸)
om
n in
or c
thi
Removing
te
sd
iva
o
r

rp
cu
o
m
f
ignition key.
en
ng
t.
yi Co
op
– Remove washer spray jet ⇒ page 124 .
C py
t. rig
gh ht
yri by
– Remove securing bolts -1-. cop Vo
by lksw
cted agen
Prote AG.
– Remove retainer -2-.
Installing
following:
Note
Note lower guides -arrow- of retainer when installing.


Sharan 1996 ➤
2.6 Checking and adjusting windscreen

washer system spray jets
2.6.1 Checking and adjusting windscreen

▸ 05.00)
Note
If impurities in the washer jet cause an uneven spray field, remove

the washer jet and flush through with water against the spraying
direction. Purging with compressed air against the spraying di‐
rection is then permitted. Do not use objects to clean the washer
jets!
Special tools and workshop equipment required swage

es n
olk ot g
yV
♦ Adjusting tool -T10127- d b ua
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
Note
Never use a needle or similar to adjust the spray jets, as otherwise
nf
ercia
o
water passages in washer spray jets will be damaged!
rm
m
atio
om
n in
c
– Check jet settings and if necessary adjust using adjusting tool

or
thi
-T10127- .
te
sd
iva
o
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cu
– Set right outer washer spray jet to following dimensions:

o
m
f
en
ng
t.
c - 410 mm
yi Co
Cop py
t. rig
d - 620 mm
gh ht
pyri by
Vo
co lksw
by
– Set right inner washer spray jet to following dimensions: Prote
cted AG.
agen
a - 490 mm
b - 200 mm
– Set left inner washer spray jet to following dimensions:
a - 490 mm
b - 200 mm
– Set left outer washer spray jet to following dimensions:
c - 410 mm
d - 620 mm
Tolerance for all spray jets: ± 20 mm

Sharan 1996 ➤

06.00 ▸ 10.03)
Note

jets!
The washer spray jets are preset. However, small differences in

height may be corrected.
– Check that the washer spray jet spray field is set to the centre
of the wiped area and correct washer spray jet field as follows,
AG. Volkswagen AG d
if necessary: lksw
agen oes
n o ot g
yV ua
– Adjust the washer spray jet upwards orisdownwards
ed
b
by hand. ran
r tee
ho
aut or
ac
ss
Note
ce
e
nl
pt
du
an
itte
y li
Never use a needle or similar to adjust the spray jets, as otherwise
erm
ab
water passages in washer spray jets will be damaged!
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
11.03 ▸)
rrectness of i
Note
l purpos

nform
ercia
m
at
om

ion
c
jets!
in t
or
his
ate
do
riv
The washer spray jets are preset. However, small differences in

p
cum
or
height may be corrected.

f
en
ng
t.
yi Co
op
– Check that the washer spray jet spray field is set to the centre C py
t. rig
of the wiped area and correct washer spray jet field as follows,
gh ht
pyri by
if necessary:
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Adjust spray by moving adjuster -1- by hand upwards or down‐

wards.
Note
Do not use tools to adjust the washer spray jets. Adjust washer
spray jets by hand.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
3 Rear window wiper system
Caution
To disconnect and reconnect the battery, the procedure de‐

⇒ page 4 .
n AG. Volkswagen A
3.1 Removing and Volkinstalling
swa
ge
rear window
G do
es n
ot g
wiper rised by ua
ran
te
ho eo
aut ra
ss c
ce
le
3.1.1 Removing wiper arm

un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
Vehicles 06.00 ▸, wiper arms are a mirror image
hole
spec
es, in part or in w
t to the co
– To place wiper motor in its park position, switch rear window
wiper on and off with ignition on.
rrectness of i
– Lift up cover cap -1- of rear window wiper arm.
l purpos
– Loosen but do not completely remove securing nut (13 mm)

-arrow-.
nform
ercia
– Fold up wiper arm -3- and loosen it from taper by rocking it

m
a
com
ti
from side to side.

on in
r
te o
thi
– Remove securing nut -2- and remove wiper arm.

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.
3.1.2 Removing and installing rear window
wiper motor (vehicles ▸ 05.00)
Removing
– Remove wiper arm ⇒ page 129 .
– Remove rear lid trim ⇒ General body repairs, interior; Rep.
Gr. 70 ; Rear lid trim .
– Disconnect connector -1- and pull it out of retainer.
– Unscrew securing screws (10 mm) -2- and carefully pull re‐
tainer with wiper motor out of rear lid.
– Remove wiper motor from retainer after removing the 10 mm
hexagon bolts -3-.
3. Rear window wiper system 129

Sharan 1996 ➤
Installing
following:
– Check seal is seated correctly -arrow- in opening of rear win‐
dow.
⇒ page 142 .
– Install wiper arm ⇒ page 130 .
3.1.3 Removing and installing rear window

wiper motor (vehicles 06.00 ▸)
AG. Volkswagen AG d
agen oes
Removing olksw not
V gu
d by ara
e
– Remove wiper arm ⇒ page 129 . horis nte
eo
aut ra
– Remove rear lid trim ⇒ General body repairs,
ss interior; Rep. c
ce
le
un
pt
an
d
itte
– Disconnect connector -1- on wiper motor.
y li
rm
ab
pe
ility
– Pull hose -2- off washer jet.
ot
wit
, is n
– Remove securing nuts (10 mm) -arrows- and carefully pull out
h re
hole
wiper motor of rear lid.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Installing
nform
ercia
following:
m
a
com
– Check seal is seated correctly -arrow- in opening of rear win‐ tion in

r
dow.
te o
thi
s
iva
do

r
rp
cum
⇒ page 142 .
fo
en
ng
t.
yi Co
– Reconnect battery ⇒ page 4 . t. Cop py
rig
gh ht
– Install wiper arm ⇒ page 130 . pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3.2 Installing wiper arm

– With ignition switched on, switch rear window wiper on and off
to run wiper motor to its rest position.
– Fit wiper arm in approximate park position on wiper arm shaft
and tighten securing nut -arrow- by hand.
– Adjust rear window wiper park position ⇒ page 131 .

Sharan 1996 ➤
3.3 Adjusting rear window wiper park posi‐

tion

Note
Vehicles ▸ 05.00, wiper arms are a mirror image
Distance -a- between wiper blade and lower edge of window

should be 15 mm (measured from lower edge of glass).
– If necessary, adjust rear window wiper park position by moving
wiper arm on shaft.
Removing wiper arm ⇒ page 129 .
⇒ page 142 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Rear window wiper system 131

Sharan 1996 ➤
4 Rear window washer system
Note
⇒ Self-study programme No. 169 ; The VW Sharan AG. Volkswagen AG d

agen oes
Fault detection and fault display olksw not
y V gu
d b ara
ise nte
The onboard supply control unit has a self-diagnosis function,
thor eo
which makes fault finding easier. s au ra
c
s
ce
e
For fault finding, use vehicle diagnosis, test and information sys‐
nl
pt
du
tem -VAS 5051A- in “Guided fault finding” mode.
an
itte
y li
erm
ab
General description
ility
ot p
wit
Vehicles ▸ 05.00: the rear window washer system spray jet is lo‐
, is n
h re
cated above the frame of the rear window, not as illustrated in the
hole
spec
following figures.
es, in part or in w
t to the co
Vehicles 06.00 ▸: the rear window washer system spray jet is lo‐
cated under a cap in the wiper arm shaft.
4.1 Assembly overview - rear window washer system
rrectness of i
l purpos
nform
ercia
❑ Connection to spray jet

for rear window washer
m
at
system
om
ion
c
in t
or
his
e

at
do
riv
lines ⇒ page 140

p
cum
for
en
g
2 - Spray jet for rear window

n
t.
yi Co
washer system t. Cop py
rig
gh
❑ Renewing washer jet
ht
pyri by
Vo
⇒ page 133
co lksw
by
cted agen
Prote
❑ Adjusting washer jet
AG.
⇒ page 134
❑ Point of separation, pas‐
senger compartment
wiring harness to rear lid
wiring harness
lines ⇒ page 140
4 - Hose
❑ Hose repair
⇒ page 141
❑ Point of separation, pas‐
senger compartment
wiring harness
lines ⇒ page 140
❑ Connection to wind‐

Sharan 1996 ➤
screen and rear window washer pump -V59-

7 - Windscreen and rear window washer pump -V59-
4.2 Renewing washer jet
4.2.1 Renewing washer spray jet (vehicles

▸ 05.00)
Removing
ignition key.
– Open the rear lid.
– Unclip upper trim -arrows- on rear lid.
– Pull hose off spray jet. agen
AG. Volkswagen AG d
oes
olksw not
– Close the rear lid. 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
– First push spray jet straight downwards -arrow A- then tilt the
t to the co
jet to rear -arrow B- and out of the fitting hole.
Installing
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
co Vo
by lksw
cted agen
Prote AG.
4. Rear window washer system 133

Sharan 1996 ➤
4.2.2 Renewing washer spray jet (vehicles

06.00 ▸)
Removing
– To place wiper motor in its park position, switch rear window
wiper on and off with ignition on.
n AG. Volkswagen A
– Switch off ignition and all electrical
olks
wconsumers
age and remove
G do
es n
ot g
ignition key. d by V ua
r e an
ris tee
– Lift up cover cap of rear
ut window wiper arm.
ho or
a ac
ss
– Pull washer jet out of wiper arm shaft using suitable pliers
ce
e
nl
-arrow-.
pt
du
an
itte
y li
Installing
erm
ab
ility
ot p
– Push washer jet onto stop in wiper arm shaft with washer jet
wit
, is n
opening facing upwards.
h re
hole
spec
– Adjust spray jet ⇒ page 134 .
es, in part or in w
t to the co
4.3 Adjusting washer jet
rrectness of i
Note
l purpos
♦ Vehicles ▸ 05.00: the rear window washer system spray jet is
nf
ercia
located above the frame of the rear window.
orm
m
atio
♦ Vehicles 06.00 ▸: the rear window washer system spray jet is
om
located under a cap in the wiper arm shaft. n in

or c
thi
e
♦ Renew washer spray jet if spray is irregular or cannot be ad‐

t
sd
iva
justed to centre of wiped area (repair measure).

r
rp
cu
o
m
f
en
ng
♦ Never use a needle or similar object, as otherwise the water

t.
yi Co
op
passage in washer spray jets will be damaged! C py
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.
♦ Adjusting tool -T10127-
– Check spray jet setting.

Spray jet must spray to centre of wiped area.
– If necessary adjust washer spray jet using adjusting tool -
T10127- .

AG. Volkswagen AG d
agen oes
ksw not
by Vol
gu
ara
Sharan 1996 ➤
d
orise nte
eo
th
au ra
ss c
ce
5 Headlight washer system
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐
tions
rrectness of i
⇒ Owner's manual
l purpos
General description
nf
ercia
o
Every time the windscreen washer system is activated the head‐
rm
m
lights are also washed if the windscreen wiper lever on the
atio
m
steering wheel is pulled for at least 1.5 seconds - provided either

o
n in
c
dipped beam or main beam are switched on.

or
thi
te
sd
iva
Following installation work or on initial start-up of the headlight
o
r
rp
cu
washer system, the system must be bled to ensure proper oper‐
o
m
f
en
ng
ation of the pop-up cylinders and washer jets ⇒ page 139 .

t.
yi Co
Cop py
5.1 Assembly overview - headlight washer system
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
❑ Connection to right pop-
up washer jet cylinder
lines ⇒ page 140
2 - Washer spray jet assembly
with right spray jets
washer jet assembly
⇒ page 137
❑ Adjusting spray jets
⇒ page 138
pop-up washer jet cylin‐
der ⇒ page 137
❑ Bleeding headlight
washer system
⇒ page 139
3 - Hose
4 - Washer spray jet assembly
with left spray jets
washer jet assembly
⇒ page 137
❑ Adjusting spray jets
⇒ page 138
pop-up washer jet cylin‐
der ⇒ page 137
❑ Bleeding headlight
washer system
⇒ page 139
5. Headlight washer system 135

Sharan 1996 ➤

6 - Headlight washer system pump -V11-
❑ Connection to headlight washer system pump -V11-
8 - Y-piece
❑ Distribution of washer fluid to spray jets on headlight washer system
❑ Connection to left pop-up washer jet cylinder
Note
♦ Vehicles ▸ 05.00: the washer fluid hoses -item 2- are pushed

onto the pump and pop-up cylinders and secured with hose
clips -item 1-.
♦ Vehicles 06.00 ▸: the washer fluid hoses are secured to the
pump and pop-up cylinders by couplings ⇒ page 140 .
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5.2 Removing and installing headlight

erm
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ility
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washer system pump -V11-

wit
, is n
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Removing
hole
spec
es, in part or in w

t to the co

– Push and hold down securing clip on hose connection and pull
hose connection off headlight washer system pump -V11-
rrectness of i
-7-.
l purpos

nf
– Disconnect connector -1- from headlight washer system pump

ercia
-V11- .
rm
m
atio
m
– Pull headlight washer system pump -V11- upwards out of res‐

o
n in
c
ervoir for windscreen and headlight washer system.

or
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Installing
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following:
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Prote AG.

Sharan 1996 ➤
5.3 Removing and installing pop-up washer

jet cylinder
Removing
ignition key.
– Pull spray jets with cap -1- out of bumper cover onto stop.
– Unclip cap -1- from mounting points -arrows- on washer spray
jet assembly.

– Push and hold down the securing clip -2- and pull the hose
connection -1- away from the pop-up cylinder.
– Remove securing bolts -3-.
Installing
following:
⇒ page 142 .
AG. Volkswagen AG d
agen oes
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5.4 Removing and installing washer jet as‐
d byV
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Removing s
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un
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ignition key.
rm
ab
pe
ility
– Pull washer jet with cover cap -1- onto stop out of bumper
ot
wit
, is n
cover.
h re
hole
– Unclip cap -1- from mounting points -arrows- on washer spray

spec
jet assembly.
es, in part or in w
t to the co
rrectness of i
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5. Headlight washer system
agen
Prote AG.
Sharan 1996 ➤
– Lever locking hook -arrow- up slightly and pull out washer jet
assembly.
Installing
Note
The degree to which the cover cap of the spray jet is pulled down
onto the bumper cover can be adjusted using the clips on the
washer spray jet assembly. If the washer spray jet assembly is
not pulled in far enough, the cover cap will not seat correctly. If
the washer spray jet assembly is pulled in too far, the cover cap
and the bumper cover could be pushed out of shape.
– Push washer spray jet assembly in pop-up cylinder until it en‐

gages.
– Fit cover cap on washer spray jet assembly and allow pop-up
cylinder to retract.
– Check the cover cap is seated correctly on the bumper cover.
– If necessary, adjust seat of cover cap by pushing washer spray
jet assembly in higher or lower position on pop-up cylinder.
– Adjusting headlight washer system jets ⇒ page 138 .
5.5 Adjusting headlight washer system jets

AG. Volkswagen AG d
agen oes
♦ Adjusting tool -3019 A- Volksw not
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5.5.1 Vehicles ▸ 05.00

rrectness of i
l purpos
The following washer spray jet setting figures are for the left
headlight (right headlight is a mirror image):
nf
ercia
– Checking washer spray jet settings

orm
m
atio
a - 30 mm
om
n in
c
b - 80 mm
or
thi
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a
c - 15 mm
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– Adjust spray jet as follows, if necessary:

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Prote AG.

Sharan 1996 ➤
– Pull spray jet -arrow- out to stop and align to respective spray
point with adjusting tool 3019 A.
Note
Renew spray jet if spray is irregular or cannot be adjusted to the

prescribed setting (repair measure).
5.5.2 Vehicles 06.00 ▸

The following washer spray jet setting figures are for the left
headlight (right headlight is a mirror image):
– Checking washer spray jet settings
a - 100 mm
b - 200 mm
c - 75 mm
– Adjust spray jet as follows, if necessary:
– Pull spray jet -arrow- out to stop and align to respective spray
point with adjusting tool 3019 A.
AG. Volkswagen AG d
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olksw not
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Renew spray jet if spray iss irregular or cannot be adjusted to the
s c
prescribed setting (repair measure).
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erm
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ility
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spec
es, in part or in w
5.6 Bleeding headlight washer system

t to the co
To guarantee sound functioning of pop-up cylinders and spray

jets, the headlight washer system must be bled following assem‐
rrectness of i
bly work or when operated for the first time.

l purpos
– Fill reservoir for windscreen and headlight washer system.

– Start engine.
nf
ercia
or
– Switch “ON” the headlight.

m
m
atio
om
– Operate headlight washer system several times (3-5 times, 3

n in
or c
seconds each time).

thi
te
sd
iva
– Repeat this bleeding procedure until the pop-up cylinders and

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washer jets are functioning soundly.

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Prote AG.
5. Headlight washer system 139

Sharan 1996 ➤
6 Washer fluid line hose couplings

6.1 Headlight washer system

Volkswagen AG
link to this workshop manual is not possible at presentw agenfor
AG.tech‐ does
nical reasons. Please select the workshop manual olks “Electrical not
byV gu
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System, General Information” manually inris ELSA.
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tion in
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Prote AG.

Sharan 1996 ➤
7 Hose repair
AG. Volkswagen AG d
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141
co Vo
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7. Hose repair
agen
Prote AG.
Sharan 1996 ➤
8 Specified torques: window wash/

wipe system
8.1 Specified torques for vehicles ▸ 09.98

Wiper motor to wiper frame 10 mm 5 Nm
Motor crank arm to wiper motor shaft 13 mm 20 Nm
Wiper frame to body 13 mm 20 Nm
Windscreen wiper arm nut to wiper motor 15 mm 20 Nm
shaft
Rear wiper arm to rear wiper motor shaft 13 mm 15 Nm
Rear wiper motor to mounting frame 10 mm 7 Nm
AG. Volkswagen AG
Rear wiper motor mounting frame wto
ag rear lid 10 mm
e n does 7 Nm
olks not
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Nut for reservoir for windscreen
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light washer system tothbody
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8.2 Specified torques for vehicles 10.98 ▸ 05.00
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Threaded connections Specified torques wit

, is n
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hole
spec

es, in part or in w
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shaft
rrectness of i
Rear window wiper arm to wiper motor shaft 13 mm 15 Nm

l purpos
Rear wiper motor to mounting frame 10 mm 7 Nm

Rear wiper motor mounting frame to rear lid 10 mm 7 Nm
nform
ercia
Nut for reservoir for windscreen and head‐ 2 Nm

m
at
light washer system to body

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Motor crank arm to wiper motor shaft Prote 13 mm 22 Nm
AG.

shaft
Rear wiper motor to rear lid 10 mm 7 Nm

Sharan 1996 ➤

shaft
AG. Volkswagen AG d
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8.5 Specified torques for vehicles 11.03 ▸ ol not
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Threaded connections auth
Specified torquesra
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shaft
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es, in part or in w
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Prote AG.
8. Specified torques: window wash/wipe system 143

Sharan 1996 ➤
94 – Lights, bulbs, switches - exterior

1 Headlight
Note
♦ If vehicle has a security-coded radio, obtain anti-theft code

before disconnecting battery.
♦ To disconnect and reconnect the battery, the procedure de‐
⇒ page 4 .
1.1 Assembly overview - headlight, vehicles

▸ 05.00
Note
Headlight must be adjusted after any measures which could affect

the headlight setting ⇒ Maintenance ; Booklet 10.1
1 - Securing bolt
❑ 8 Nm
AG. Volkswagen AG d
2 - Retaining clip lksw
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3 - Headlight housing
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❑ Removingaut
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and installing ra
⇒ page
ss
146 c
ce
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un
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4 - Breather
an
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itte
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rm
5 - Cap
ab
pe
ility
❑ Turn to left to release

ot
wit
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6 - Side light bulb holder

hole
spec
7 - Twin filament bulb for main

es, in part or in w
t to the co
and dipped beams

❑ Bulb H4, 12V, 60/55W
❑ Renewing ⇒ page 149
rrectness of i
8 - Side light bulb

l purpos
❑ Bulb 12V/5W
nform
ercia

m
9 - Reflector
a
com
tion in

r
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⇒ page 148
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10 - Seal
rp
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❑ Renew if damaged
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11 - Headlight lens glass
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❑ Removing and installing co Vo
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⇒ page 147
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Prote AG.
144 Rep. Gr.94 - Lights, bulbs, switches - exterior

Sharan 1996 ➤
12 - Securing bolt
13 - Headlight range control
motor
1.2 Assembly overview - headlight, vehicles

06.00 ▸
Note
G. Volkswagen AG d
After any measures which could affect the headlight wsetting,
agen
A
the oes
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headlights must be checked and if necessaryd badjusted
y V gu
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⇒ page 157 . or
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1 - Cap
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2 - Headlight range control mo‐
erm
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tor securing bolts
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spec
4 - Turn signal bulb holder with
es, in part or in w
grip
t to the co
5 - Turn signal bulb -M5- or -
M7-
rrectness of i
❑ Bulb 12V/21W, yellow
glass
l purpos
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6 - Side light bulb -M1- or -M3-
orm
m
❑ Bulb 12V/5W
atio
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7 - Headlight unit
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❑ Adjusting headlights
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⇒ page 157
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8 - Dipped beam bulb -M29- or
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Prote AG.
-M31-
❑ Bulb H7, 12V/55W
9 - Main beam bulb -M30- or -
M32-
❑ Bulb H1, 12V/55W
motor securing flange
motor -V48- or -V49-
1. Headlight 145
Sharan 1996 ➤
1.3 Removing and installing headlight hous‐

ing, vehicles ▸ 05.00
Removing
– Disconnect battery ⇒ page 4
– Remove turn signal ⇒ page 149 .
– Remove radiator grille ⇒ General body repairs, exterior; Rep.
Gr. 66 ; Exterior equipment; Trims; Removing and installing
radiator grille with trim frame .
– Disconnect multi-pin connector for headlight.
– Remove securing bolts -arrows-.
– Pull headlight housing out forwards.
Installing
Installation is carried out in the reverse sequence.
Note
♦ The headlight housing lug -1- must lie against wing.

♦ Tighten securing bolts -arrows- to 8 Nm.
– Checking headlight settings ⇒ Maintenance ; Booklet 10.1
1.4 Removing and installing headlight hous‐

ing, vehicles 06.00 ▸
Headlight can be removed without removing bumper.
olkswagen AG
en AG. V
To prevent damage to paintwork, we recommend othat lksw the bumper
ag does
not
is covered over in the area of the headlight. ed by V gu
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Removing utho eo
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ss
– Disconnect battery ⇒ page 4
ce
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un
pt
an
d
– Remove upper securing bolts for headlight and one bolt for the
itte
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radiator grille -arrows-.

erm
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ility
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Sharan 1996 ➤
– Push radiator grille to side and loosen lower securing bolt (dowagen AG. Volkswagen AG does
not remove completely). olks not
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es, in part or in w
t to the co
– Loosen outer lower securing bolt for headlight (do not remove
completely).
rrectness of i
– Pull headlight housing out forwards, tilt headlight upwards
l purpos
slightly when doing this.
nf
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– Disconnect multi-pin connector for headlight -arrow-.
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Installing
co Vo
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Prote AG.
– Loosen lower securing bolts as far as possible (do not remove
completely).
– Guide headlight into position, ensuring that the lower securing

lugs on the headlight are positioned correctly on the lower se‐
curing bolts -arrow-.
– Reconnect headlight multi-pin connector.
– Screw upper securing bolts in loosely.
– Align headlight to body contours and tighten all 4 securing
bolts.
– Tighten radiator grille upper bolt(s).
– Check headlight settings and adjust if necessary
⇒ page 157 .
1.5 Removing and installing headlight lens

glass, vehicles ▸ 05.00
Removing
1. Headlight 147
Sharan 1996 ➤
– Lever off retaining clips -arrows-.

– Remove headlight lens glass and rubber seal.
Installing
1.6 Removing and installing reflector, vehi‐

cles ▸ 05.00
Removing
– Remove headlight lens glass ⇒ page 147 .
Note
Do not touch reflector with bare hands. Always use a clean clove olkswage es n
ot g
or fabric gloves when removing and installing. ed
by
V ua
ran
ris tee
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– Unclip reflector from inner adjustment spindle -arrowssA-.
a ac
ce
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– Push reflector outwards slightly and unclip reflector from outer

un
pt
an
d
adjustment spindle -arrow B-.

itte
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erm
ab
– Remove headlight bulbs ⇒ page 149 .
ility
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Installing
h re
ole,
– Install headlight bulbs ⇒ page 149 .
spec
t to the co
rrectne
– Clip reflector into adjustment spindles.

ss o
cial p
– Remainder of installation is carried out in the reverse se‐

inform
quence.
mer
atio
m
– Check headlight settings ⇒ Maintenance ; Booklet 10.1 .

o
n
c
i
or
n thi
te
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Sharan 1996 ➤
1.7 Removing and installing front turn sig‐

nals, vehicles ▸ 05.00
Removing
– Remove securing bolt -arrow-.
– Pull turn signal out forwards.
– Disconnect connector.
Installing
– Reconnect connector.
– Slide turn signal into the aperture in the wing.
Note
The lugs on the turn signal must locate in the guides -arrows- of
the headlight housing.
– Install securing bolt.

Specified torque: 4 Nm.
AG. Volkswagen AG d
agen oes
olksw not
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1.8 Replacing headlight bulbs, vehicles
d ara
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ss aut
▸ 05.00 ra
c
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nl
1- Spring retaining clip

pt
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2- Connector
erm
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ility
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3- Side light bulb with holder

wit
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4- Twin-filament bulb
hole
spec
5- Locating lugs
es, in part or in w
t to the co
Note
rrectness of i
Do not touch bulb glass when fitting a new bulb. Fingers leave
l purpos
traces of grease on the glass, which evaporate when the bulb is

switched on and cause the glass to cloud over.
nf
ercia
orm
m
atio
1.8.1 Replacing side light bulb

om
n in
or c
thi
– Release sealing cap on rear of headlight housing (turn to left)

te
sd
a
and remove.
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– Pull holder -3- with bulb on connector out from reflector.

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ng
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– After changing bulb, push bulb with holder into reflector to
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1.8.2 Replacing twin-filament bulb
agen
Prote AG.
– Release sealing cap on rear of headlight housing (turn to left)

and remove.
1. Headlight 149
Sharan 1996 ➤
– Pull connector -2- off twin-filament bulb.

– Unclip spring retaining clip -1- from retaining lugs -5- and
swing clip downwards.
– Pull twin-filament bulb -4- out of reflector.
– Insert new bulb so that the lugs on the disc plate align with the
recesses in the reflector.
– After installing a new twin-filament bulb check headlight set‐
tings ⇒ Maintenance ; Booklet 10.1 .
1.8.3 Replacing turn signal bulb

– Turn coupling opposite to -direction of arrow- and pull out of
housing.
– Remove bulb from holder.
Note n AG. Volkswagen AG do

lkswage es n
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yV
Do not touch bulb glass when fitting a new bulb. Fingers
ir se
dleave
b ua
ran
traces of grease on the glass, which evaporate when th the bulb is
o tee
or
switched on and cause the glass to cloud over. ss au ac
ce
e
nl
pt
du
When installing, turn coupling until it engages (in direction of ar‐
an
itte
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row).
erm
ab
ility
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1.9 Replacing headlight bulbs, vehicles
, is n
h re
06.00 ▸
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos

nform
ercia
1.9.1 Renewing dipped beam bulb

m
at
om
io
– Release spring clip -arrow- and take off sealing cap.

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c
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or
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ate
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Prote AG.

Sharan 1996 ➤
AG. Volkswagen AG d
– Pull connector -arrow- off bulb. agen oes
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– Push spring retainer over locking lugs and release. orise nte
th eo
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– Pull bulb out of reflector. ss a c
ce
le
– Do not touch bulb glass when installing.
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
– Reconnect connectors.
h re
hole
spec
– Fit sealing cap.
es, in part or in w
t to the co
⇒ page 157 .
– Check function of headlight after installing a new bulb.
rrectness of i
l purpos
1.9.2 Renewing main beam bulb

– Pull connector -arrow- off bulb.
nform
mercia
– Push spring retainer over locking lugs and release.
a
com
tion in
– Pull bulb out of reflector.
r
te o
thi
s
iva
– Do not touch bulb glass when installing.
do
r
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t.
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by
– Fit sealing cap. Prote
cted AG.
agen

⇒ page 157 .
1.9.3 Removing and installing side light bulb

– Slide open cover -arrow- in wheel housing.
– Unscrew holder for side light bulb -arrow- and remove bulb.
Do not forget to close cover.
⇒ page 157 .
1. Headlight 151
Sharan 1996 ➤
1.9.4 Removing and installing front turn signal

bulb
AG. Volkswagen AG d
– Slide open cover -arrow- in wheel housing. lksw
agen oes
not
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un
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an
d
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Unscrew turn signal bulb holder on grip -arrow- and remove
bulb.
rrectne
ss o
cial p
f in
Note
form
mer
atio
m
When installing, ensure that the bulb holder engages correctly

o
n
c
when inserting into bulb housing.
i
or
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te
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r
Do not forget to close cover.

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1.10 Removing and installing headlight range
p by
co Vo
by lksw
cted
control motor, vehicles ▸ 05.00
agen
Prote AG.
Removing
– Remove headlight bulbs ⇒ page 149 .
– Remove headlight lens glass ⇒ page 147 .
– Remove reflector ⇒ page 148 .
– Remove securing bolts -1-.
– Disconnect multi-pin connector for headlight.

Sharan 1996 ➤
– Unclip connector -2- on headlight housing and press contacts

5, 6 and 7 out of connector.
Installing
– Press contacts 5, 6 and 7 into connector and reconnect con‐
nector to headlight housing.
Pin assignment ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
quence.
– Checking headlight settings ⇒ Maintenance ; Booklet 10.1

control motor, vehicles 06.00 ▸
Note
♦ The control motor can only be removed and installed when the
headlight housing has been removed.
♦ If control motors are removed and installed or renewed, al‐
ways carry out the headlight basic setting with a beam setting
appliance. Inclination dimension is embossed on headlight
housing.
Removing
– Remove headlight ⇒ page 146 .
AG. Volkswagen AG d
– Release spring clip -arrow- and take off sealing cap. agen oes
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pt
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itte
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ility
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, is n
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spec
es, in part or in w
t to the co
– Unscrew both securing bolts -arrows- on outside of housing.
rrectness of i
– Pull adjustment shaft ball head out of mounting on reflector.

l purpos
– Remove headlight range control motor and disconnect con‐

nector on control motor.
nform
ercia
Installing
m
at
om
ion
c
in t
or
– Guide adjustment shaft of control motor into ball head mount‐

his
te
ing -arrow-, hold reflector base plate up through opening in

a
do
riv
headlight for this.

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Prote AG.
1. Headlight 153
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
– Disconnect headlight range control motor connector -6-. olksw not
byV gu
ara
ed
– Fit sealing cap. horis nte
eo
aut ra
– Install headlight ⇒ page 146 . ss c
ce
e
nl
pt
du
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itte
⇒ page 157 .
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erm
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ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
1.12 Converting headlights for use when driv‐
rrectness of i
ing on the left or right (vehicles 06.00 ▸)
l purpos
nf
Note
ercia
orm
m
atio
♦ The main headlight conversion set consists of two pieces of
om
n in
film.
or c
thi
te
♦ The film sets used to convert from driving on left to driving on
sd
iva
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r
right and for converting from driving on right to driving on left

rp
cu
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m
are different. Observe part number.
f
en
ng
t.
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op
♦ Clean main headlight lens before converting.
C py
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1.12.1 Conversion from driving on right to driv‐ cted agen
Prote AG.
ing on left
(For vehicles from countries who drive on the right with left-hand
drive)
Film conversion set for converting normal Sharan headlights from
driving on right to driving on left (shown without protective backing
paper).
– For right headlight use film with lettering “rechter
Scheinwerfer” (right headlight) and for left headlight use film
with lettering “linker Scheinwerfer” (left headlight).
– Remove protective paper from application film.
– Align application film on headlight so that the film edge with

the lettering “Unterkante Scheinwerfer” (lower edge of head‐
light) is positioned on the lower edge of the headlight reflector
-arrows-.

Sharan 1996 ➤
– In addition, align application film on headlight so that the bow

shaped edge of the film is positioned on the first marker line
of the headlight lens glass -arrows-.
– Remove application film from left headlight. The adhesive

masking film cut-out -1- remains on headlight.
AG. Volkswagen AG d
agen oes
olksw not
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– Remove application film from right headlight.
rise
d b
The adhesive ara
nte
masking film cut-out -1- remains on utho headlight. eo
ra
s a c
s
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le
un
pt
Note
an
d
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ab
Any adhesive material remaining on headlight plastic cover after
ility
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removing the film, should be removed with an alcohol or alcohol

wit
is n
and water based cleanser. For example a cloth soaked with iso‐
h re
ole,
propyl alcohol.
spec
t to the co
rrectne
1.12.2 Conversion from driving on left to driving

on right
ss o
cial p
(For vehicles from countries who drive on the left with right-hand
inform
drive)
mer
atio
m
Film conversion set for converting normal Sharan headlights from

o
n
c
driving on left to driving on right (shown without protective backing

i
or
n thi
paper).
te
sd
iva
o
pr
– For right headlight use film with lettering “rechter

um
r
fo
Scheinwerfer” (right headlight) and for left headlight use film

en
ng
t.
yi
with lettering “linker Scheinwerfer” (left headlight).
Co
Cop py
t. rig
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– Remove protective paper from application film. yri
p by
co Vo
by lksw
cted agen
Prote AG.
1. Headlight 155
Sharan 1996 ➤
– Align application film on headlight so that the film edge with

the lettering “Unterkante Scheinwerfer” (lower edge of head‐
light) is positioned on the lower edge of the headlight reflector
-arrows-.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
– In addition, align application film on headlight so that the bow
ab
ility
shaped edge of the film is positioned on the first marker line
ot p
wit
of the headlight lens glass -arrows-.
, 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
– Remove application film from left headlight. The adhesive
atio
m

o
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.
– Remove application film from right headlight. The adhesive

Note
Any adhesive material remaining on headlight plastic cover after

removing the film, should be removed with an alcohol or alcohol
and water based cleanser. For example a cloth soaked with iso‐
propyl alcohol.

Sharan 1996 ➤
1.13 Adjusting headlight
Note
♦ Use a headlight adjusting unit when adjusting headlights

⇒ Maintenance ; Booklet 10.1 .
♦ Adjusting the headlights adjusts the main beam at the same
time.
Left headlight (adjustment screws for right headlight are a mirror

image):
1- Lateral adjustment
2- Height adjustment
lkswage es n
Vo ot g
Adjusting beam laterally or vertically, adjust respective knurleded
by ua
ran
thumb wheel using a cross-point screwdriver. horis tee
ut or
a ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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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
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t.
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Cop py
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cted agen
Prote AG.
1. Headlight 157
Sharan 1996 ➤
2 Headlights with gas discharge bulbs,

vehicles
Vol
06.00
ksw
agen
▸
AG. Volkswagen AG d
oes
not
y gu
db ara
rise nte
tho
WARNING eo
s au ra
c
s
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Warning high voltage!

nl
pt
du
an
itte
y li
Before working on headlights with gas discharge bulbs, always
erm
ab
switch off the headlights and remove the ignition key.
ility
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wit
Then switch dipped beam on and off again. This will eliminate
, is n
h re
any possible residual voltage.
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ It is essential to first remove the complete headlight to remove
l purpos
or install the dipped beam gas discharge bulb and the main
beam H7 bulb.
nform
ercia
♦ The side light bulb and the turn signal bulb can be replaced
m
with the headlight installed.

at
om
ion
c
♦ The headlight range control with gas discharge bulbs is equip‐

in t
or
ped with self-diagnosis.

his
ate
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priv
cum
or

f
en
ng
t.
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system -VAS 5051A- or successor units in “guided fault finding”
Co
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2.1 Components and senders of headlights with gas discharge bulbs

o Vo
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
1 - Front axle vehicle level

sender -G78-
⇒ page 166
2 - Rear axle vehicle level
sender -G76-
⇒ page 167
3 - Warning lamp in dash panel
insert
4 - Headlight range control mo‐
tor -V48- or -V49-
⇒ page 153
5 - Headlight housing sealing
cap
6 - Left gas discharge bulb and
headlight range control control
unit -J567- or right -J568- AG. Volkswagen AG d
agen
❑ Left side control unit is Volksw
oes
not
gu
the “master control unit” d by ara
rise nte
❑ Right side control unit is utho eo
ra
the “slave control unit” ss a c
ce
le

un
pt
an
⇒ page 165
d
itte
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ab
7 - Gas discharge lamp control
pe
ility
unit -J343- or -J344-
ot
wit
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❑ Each headlight has a
hole
dedicated starter mod‐
spec
ule
es, in part or in w
t to the co
❑ Starter module cannot
be replaced separately,
complete headlight
rrectness of i
housing must be re‐
placed ⇒ page 146
l purpos
8 - Turn signal bulb holder with grip
nform
ercia
9 - Turn signal bulb -M5- or -M7-

m
a
❑ Halogen bulb 12V/21W, yellow glass
com
tion in

r
te o
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11 - Side light bulb -M1- or -M3-

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❑ Bulb 12V/5W t. Cop py
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12 - Headlight housing cted agen
Prote AG.
13 - Gas discharge bulb -L13- or -L14-
❑ Type DS2, 35W
❑ Operating voltage 80V...117V
14 - Main beam bulb -M30- or -M32-
❑ Bulb H7, 12V/55W
2. Headlights with gas discharge bulbs, vehicles 06.00 ▸ 159

Sharan 1996 ➤
2.2 Removing and installing headlight with

gas discharge bulb
WARNING

Note
Headlight can be removed without removing bumper.

lkswage es n
o ot g
byV ua
Caution
ir se
d ran
tee
tho
u or
a a
♦ We recommend that the bumper is covered over in the c
ss
ce
le
area of the headlight to prevent damage to paintwork.

un
pt
an
d
itte
♦ If a headlight with automatic range control is removed, the

y li
rm
ab
basic setting of the headlight must always be performed

pe
ility
when reinstalling ⇒ page 171 .

ot
wit
, is n
h re
hole
spec

es, in part or in w
t to the co
♦ Insert tool -T10113-

rrectness of i
l purpos
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mercia
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com
tion in
r
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thi
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Removing C py
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ignition key. Switch then dipped beam on and off. This will cted agen
Prote AG.
eliminate any possible residual voltage.
– Removing and installing turn signal bulb ⇒ page 152 .
– Removing and installing side light bulb ⇒ page 151 .

Sharan 1996 ➤
– Remove upper securing bolts for headlight and one bolt for the
radiator grille -arrows-.
– Carefully push the radiator grille to side and loosen the lower
securing bolt using socket -T10113- . Do not remove bolt com‐
pletely.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
– Loosen the lower securing bolt on the outer side of the head‐
ot
wit
light using socket -T10113- . Do not remove bolt completely.
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
We recommend that the bumper is covered over in the area of
the headlight to prevent damage to paintwork.
rrectness of i
l purpos
– Pull headlight out forwards, tilt headlight upwards slightly

when doing this.
nform
mercia
a
com
tio
– Disconnect multi-pin connector -arrow- on headlight.

n in
r
te o
thi
s
iva
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r
rp
Note
cum
fo
en
ng
t.
yi Co
Two multi-pin connectors are located on the left headlight and one Cop py
.
multi-pin connector is located on the right headlight.
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pyri by
Vo
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cted agen
Installing Prote AG.
Caution
If a headlight with automatic range control is removed, the ba‐

sic setting of the headlight must always be performed when
reinstalling ⇒ page 171 .
– Loosen lower securing bolts as far as possible (do not remove

completely).

Sharan 1996 ➤
– Guide in headlight. Ensure that the lower securing lugs

-arrow- on the headlight are positioned correctly under the
lower securing bolts.
– Reconnect multi-pin connector to headlight.
Note
Do not forget that the left headlight has two multi-pin connectors.
The signals from the vehicle level senders are transmitted via the
second multi-pin connector
– Fit upper securing bolts loosely.

– Align headlight housing to body contours and tighten the 4
bolts.
– Tighten radiator grille upper bolt(s)
– Adjust headlight with gas discharge bulb ⇒ page 171 .
2.3 Renewing bulbs for gas discharge head‐

lights
2.3.1 Renewing dipped beam gas discharge

bulb
WARNING

Then switch dipped beam on and off again. This will eliminate agen
AG. Volkswagen AG d
oes
any possible residual voltage. yV
olksw not
gu b ara
ed nte
oris e
th or
au
Removing ss
ac
ce
e
nl

pt
du
an
ignition key.
itte
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erm
ab

ility
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wit
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– Remove bolt -arrow- and remove sealing cap.

h re
hole
spec
es, in part or in w
Note
t to the co
The sealing cover is secured with one or two screws, depending

rrectness of i
on the manufacturer of the headlight.

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
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pyri by
Vo
o
by c lksw
cted
162
agen
Prote AG.
Rep. Gr.94 - Lights, bulbs, switches - exterior
wage es n
yV
olks ot g Sharan 1996 ➤
b ua
ir se
d ran
tee Electrical system - Edition 12.2008
tho
u or
a ac
– Release connector
ss by turning connector 90° to left
-rotary arrow- and pull off.
ce
e
nl
pt
du
an
itte
– Turn gas discharge bulb retaining ring to left and remove it
y li
erm
ab
ility
ot p
WARNING
wit
, is n
h re
hole
spec
♦ Within the bulb glass of gas discharge bulbs, pressures
es, in part or in w
can range from between 7 bar (cold) and 100 bar (hot).
t to the co
Temperatures can reach up to 700 degrees Celsius on the
glass bulb.
rrectness of i
♦ Should the glass bulb explode, there is a risk of injury from
burning.
l purpos
♦ Always wear eye protection and gloves when removing

and installing gas discharge bulbs!
nform
mercia
at
om
io
– Carefully pull out gas discharge bulb.
n
c
in t
or
his
e
Installing
at
do
priv
cum
for
Caution
en
ng
t.
yi Co
Cop py
. rig
♦ Do not touch bulb glass when fitting gas discharge bulb.
t
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Fingers leave traces of grease on the glass, which evap‐ cop Vo
by lksw
orate when the bulb is switched on and cause the glass to
cted agen
Prote AG.
cloud over.
♦ Take great care when handling the gas discharge bulb
(ensure the bulb is not stressed mechanically). The bulb
glass is extremely fragile and has a high internal pressure.
WARNING
Avoid looking directly into the collimated beam as the UV rays

from the gas discharge bulb are about 2.5 times greater than
normal halogen bulbs.
– Insert the new bulb such that the locking lugs on the disc plate
are positioned in recess on the reflector.
– Fit the two slots -arrow- of the retaining ring -1- over the lo‐
cating lugs -2- on the gas discharge bulb -3- and secure by
turning clockwise.
– After installing a new gas discharge bulb check function of
headlight.
2.3.2 Renewing main beam bulb

Removing

Sharan 1996 ➤
– Remove screw -arrow- and remove sealing cover.
Note

– Pull connector -arrow- off bulb.

– Push spring retainer over locking lugs and release.
– Pull bulb out of reflector.
Installing
Caution
traces of grease on the glass, which evaporate when the bulb
is switched on and cause the glass to cloud over.
Note agen
AG. Volkswagen AG d
oes
olksw not
y V gu
b
Insert new bulb so that the lugs
rise on the disc plate align with the
d ara
nte
recesses in the reflector. utho eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
– Install sealing cover.

erm
ab
ility
ot p
– Always check function of headlight after installing a bulb.

wit
is n

h re
ole,
spec
2.3.3 Renewing side light bulb

t to the co
Removing
rrectne

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

AG. Volkswagen AG d
agen oes
Volksw not
gu
Sharan 1996 ➤
y
rise
d b
Electrical
ara
nte system - Edition 12.2008
tho eo
au r ac
– Unscrew holder for side
ss light bulb -arrow- and remove bulb.
ce
e
nl
Installing
pt
du
an
itte
y li
erm
ab
following:
ility
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wit
, is n
– Secure sealing cap.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
2.3.4 Renewing front turn signal bulb
nform
ercia
Removing
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew turn signal bulb holder on grip -arrow- and remove

bulb.
Installing
following:
Note
When installing, ensure that the bulb holder engages correctly

when inserting into bulb housing.
– Secure sealing cap.

2.4 Removing and installing control unit for

gas discharge lamp bulb and headlight
range control
WARNING


Sharan 1996 ➤
Removing
ignition key.
– Remove the 3 securing bolts -arrows- for control unit.
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
– Remove control unit.
ot
wit
, is n
h re
Installing
hole
spec
es, in part or in w
t to the co
Caution
rrectness of i
l purpos
nform
ercia

m
a
com
tion in
2.5 Removing and installing front left vehicle
r
te o
thi
level sender -G78- on front axle
s
iva
do
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rp
cum
fo
en
ng
t.
Caution
yi Co
Cop py
t. rig
gh ht
yri
If the vehicle level sender is removed, after reinstallation the p by
o Vo
by c
basic setting of the headlight must be performed and the head‐
lksw
cted agen
Prote
light must be set using a headlight setting unit ⇒ page 171 .
AG.
The front left vehicle level sender -G78- is secured on the anti-roll
bar under the noise insulation tray.
The sender is not adjustable, a default setting is predetermined
during construction.
Removing
– Remove noise insulation tray.

Sharan 1996 ➤

– Remove sender.
– Pull off connector for voltage supply.
Installing
– Adjusting headlights with gas discharge bulb ⇒ page 171 .
2.6 Removing agen and installingdoerear

s no left vehicle
AG. Volkswa
gen AG
olksw
level sender -G76- on rear axle
y V t gu
edb ara
i
rs n tee
ho
aut or
ac
ss Caution
ce
e
nl
pt
du
an
If the vehicle level sender is removed, after reinstallation the
itte
y li
erm
basic setting of the headlight must be performed and the head‐
ab
ility
light must be set using a headlight setting unit ⇒ page 171 .
ot p
wit
, is n
h re
hole
spec
The rear left vehicle level sender -G76- is secured on the right
es, in part or in w
side of the rear axle. t to the co

The sender is not adjustable, a default setting is predetermined
during construction.
rrectness of i
Removing
l purpos

nf
ercia
– Remove sender.
orm
m
– Pull off connector for voltage supply.

atio
om
n in
c
Installing
or
thi
te
sd
a

iv
o
r
rp
cu
o

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

control motor
Note
The control motor can only be removed and installed when the
headlight housing has been removed.
Caution
If control motors are removed and installed or renewed, after

reinstallation the basic setting of the headlight must be carried
out ⇒ page 171 .

Sharan 1996 ➤
Removing
ignition key.
AG. Volkswagen AG d
– Remove bolt -arrow- and remove sealing cap. lksw
agen oes
not
Vo gu
by ara
d
rise nte
o eo
Note auth
ra
ss c
ce
le
un
pt
an
d
itte
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ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew both securing bolts -arrows- on outside of housing.
rrectness of i
– Pull adjustment shaft ball head out of mounting on reflector.
l purpos
– Remove headlight range control motor and disconnect con‐

nector on control motor.
nform
ercia
Installing
m
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
– Guide adjustment shaft of control motor into ball head mount‐
t. rig
gh ht
yri by
ing -arrow-, hold reflector base plate up through opening in cop Vo
by lksw
headlight for this. cted agen
Prote AG.
– Disconnect headlight range control motor connector -6-.

– Fit sealing cap.
– Install headlight ⇒ page 160 .
2.8 Adapting components, headlights with

gas discharge bulbs

Sharan 1996 ➤

5051A-
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
♦ Body
rrectness of i
l purpos

nform
ercia
♦ Automatic headlight range control

m
♦ Code automatic vertical headlight aim control functions

com
tion in
r
te o
2.9 Converting headlights for use when driv‐

thi
s
iva
do
ing on the left or right

r
rp
cum
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The gas discharge lamp headlights have a setting mechanism

t.
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which prevents dazzling of oncoming traffic in countries who drive C py
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on the left.
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Prote AG.
Note
Depending on manufacturer, either a lever must be repositioned

or using an Allen key a sleeve turned.

Sharan 1996 ➤
Converting
WARNING
Avoid looking directly into the collimated beam as the UV rays

from the gas discharge bulb are about 2.5 times greater than
that of conventional halogen bulbs.
Caution


– Remove bolt -arrow- and remove sealing cap.
Note

Vehicles with a lever
– Move lever -arrow- to respective position.

Lever down - driving on right.
Lever up - driving on left. AG. Volkswagen AG d
agen oes
lksw not
Vehicles with a hexagon socket sleeve by
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ility
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– Carefully turn hexagon socket -arrow- to respective position.

hole
spec
es, in part or in w
Turn hexagon socket anti-clockwise for driving on the right.

t to the co
Turn hexagon socket clockwise for driving on the left.

– Adjust headlight ⇒ page 171 .
rrectness of i
l purpos
nform
mercia
at
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ion
c
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Rep. Gr.94 - Lights, bulbs, switches - exterior
AG.
Sharan 1996 ➤
AG. Volkswagen AG d
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2.10 Adjusting headlights with gas discharge d by
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Adjusting headlights with gas discharge bulb ⇒ Maintenance ; s
ce
le
Booklet 10.1 .
un
pt
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d
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pe
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
3 Fog light
3.1 Removing and installing front fog light,

vehicles ▸ 05.00
Removing
ignition key.
– Remove bumper ⇒ General body repairs, exterior; Rep. Gr.
63 ; Front bumper .
– Pull fog light out to rear.
Installing
– Check fog light settings ⇒ Maintenance ; Booklet 10.1 .
3.2 Removing and installing front fog light,

vehicles 06.00 ▸
Removing AG. Volkswagen AG d
agen oes
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– Switch off ignition and all electrical consumersseand remove
d b ara
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ignition key. hori
eo
aut ra
c
– Unclip air inlet grille in lower part of bumper.
ss
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nl
pt
du

an
itte
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erm
ab
– Pull fog light out to rear.

ility
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Installing
wit
, is n
h re
hole

spec
es, in part or in w
– Check fog light settings ⇒ Maintenance ; Booklet 10.1 .

t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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ng
t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.

Sharan 1996 ➤
3.3 Replacing front fog light bulb, vehicles

▸ 05.00
– Release spring retaining clip -1- from retaining lugs and swing
out.
– Remove housing cover -2-.
– Disconnect earth connector -3- and connector -4-.

. Volkswagen AG
– Release spring clip -2- andkswing
swa out.
gen AG does
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– Pull bulb -1- out of housing.by ara
ed nte
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ss
Note
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nl
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hole
– Insert new bulb so that the recess in the bulb holder aligns with
spec
es, in part or in w
guide lug of housing. t to the co

quence.
rrectness of i
– After installing a new bulb check fog light settings ⇒ Mainte‐

nance ; Booklet 10.1 .
l purpos
3.4 Replacing front fog light bulb, vehicles

nf
ercia
or
06.00 ▸
m
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– Unscrew sealing cover for fog light.

or
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– Pull off connector.

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– Release spring retaining clip -arrow- from retaining lugs and

f
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t.
swing out.
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– Pull bulb out of housing.
gh ht
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Prote AG.
Note
– Insert new bulb so that the recess in the bulb holder aligns with
guide lug of housing.
quence.
– After installing a new bulb check fog light settings ⇒ Mainte‐
nance ; Booklet 10.1 .
3. Fog light 173

Sharan 1996 ➤
4 Side mounted repeater turn signals
4.1 Removing and installing side mounted

repeater turn signal
Removing
Note
Extreme caution must be exercised when removing the side

mounted repeater turn signal as removing is only possible in one
direction ,and when installed it is not possible to recognise on
which side of the turn signal the spring clip or the mounting is
located. When using force to remove the light on the spring clip
side there is a great danger that the turn signal or the vehicle
paintwork surface will be damaged.

ignition key.
– Press turn signal with a suitable tool on the mounting side
-1- carefully in direction of arrow against the force of the spring
clip -2- on the opposite side, and remove (protect paintwork
surface with adhesive tape first if necessary).
– Pull rubber holder with push-fit bulb off bulb housing.
– Pull push-fit bulb (12 V/5 W) out of socket (do not turn).
Installing
– Fit rubber holder with push-fit bulb onto bulb housing.
– Insert turn signal in wing. n AG. Volkswagen AG do
lkswage es n
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– After installing a new bulb check function of turn signals. d byV ua
ran
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ility
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spec
es, in part or in w
t to the co
rrectness of i
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nf
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m
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Cop py
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Vo
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by
cted agen
Prote AG.

Sharan 1996 ➤
5 Removing and installing turn signal

bulb in exterior mirror
Note
♦ Vehicles with a turn signal repeater in the exterior mirror do

not have a turn signal repeater in the wing.
♦ Long-lasting light emitting diodes (LEDs), rather than conven‐
tional bulbs, are installed in the mirror housing repeater turn
signals.
♦ In the event of damage, the entire turn signal must be re‐
newed.
Removing
ignition key.
– Remove driver side exterior mirror turn signal -L131- unit or
front passenger side exterior mirror turn signal -L132- unit ⇒
General body repairs, exterior; Rep. Gr. 66 ; Rear view mirror;
Removing and installing mirror housing with turn signal .
Installing
– Install driver side exterior mirror turn signal -L131- unit or front
passenger side exterior mirror turn signal -L132- unit ⇒ Gen‐
eral body repairs, exterior; Rep. Gr. 66 ; Rear view mirror;
Removing and installing mirror housing with turn signal .
AG. Volkswagen AG d
agen oes
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un
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spec
t to the co
rrectness o
cial p
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mer
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Prote AG.
5. Removing and installing turn signal bulb in exterior mirror 175

Sharan 1996 ➤
6 Rear lights
6.1 Assembly overview - rear light in side panel, vehicles ▸ 05.00
1 - Seal
2 - Rear light bulb
❑ 12 V/5 W
3 - Turn signal bulb
AG. Volkswagen AG d
❑ 12 V/21 W agen oes
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d b ara
4 - Bulb holder orise nte
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❑ Removing and installing s au ra
c
⇒ page 181 s
ce
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nl
pt
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5 - Twin-filament bulb for brake
an
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and rear light
erm
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ility
❑ 12V, 21W/5W
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6 - M5 hexagon nut
h re
hole
spec
❑ 6 Nm
es, in part or in w
t to the co
7 - Housing
⇒ page 178
rrectness of i
l purpos
nform
mercia
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ion
c
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AG. Volkswagen AG d
agen oes
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Vol not
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d ara
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h eo
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6.2 s
Assembly overview - rear light in side panel, vehicles 06.00 ▸ 10.03
ce
le
un
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ab
1 - Housing
pe
ility
ot
wit
, is n
⇒ page 179
h re
hole
spec
2 - Seal
es, in part or in w
t to the co
3 - M5 hexagon nuts
rrectness of i
❑ Qty. 3
l purpos
4 - Bulb holder
⇒ page 181
nform
ercia
5 - Brake light bulb

m
a
com
tio
❑ 12 V/21 W
n in
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❑ 12 V/21 W
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7 - Rear light bulb

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❑ 12 V/5 W
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8 - Plastic clip by c lksw
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Prote AG.
9 - Securing bolt
6. Rear lights 177

Sharan 1996 ➤
6.3 Assembly overview - rear light in side panel, vehicles 11.03 ▸
1 - Bulb holder
⇒ page 182
❑ 12 V/21 W
3 - M5 hexagon nuts
4 - Seal
5 - Housing
⇒ page 180
6 - Securing bolt
7 - Plastic clip
8 - Brake and rear light bulb
❑ 12V, 21W/5W
AG. Volkswagen AG d
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6.4 Removing and installing rear light, vehi‐

spec
es, in part or in w
cles ▸ 05.00
t to the co
Removing
rrectness of i

ignition key.
l purpos
– Remove rear side trim panel ⇒ General body repairs, interior;

Rep. Gr. 70 ; Pillars and side trim panel .
nf
ercia
or
– Remove bulb holder ⇒ page 181 .

m
m
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om
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Prote AG.

Sharan 1996 ➤
– Remove securing nuts -arrow- (Qty. 3) and remove rear light

housing.
Installing

cles 06.00 ▸ 10.03
Removing
ignition key.
– Remove cover in luggage compartment trim.
– Unclip interior light in luggage compartment trim.
– Remove securing nuts -arrows- (Qty. 3).
AG. Volkswagen AG d
agen oes
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d by ara
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un
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pe
ility
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wit
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– Unclip trim below rear light in vicinity of -arrows-, then pull out
hole
spec
to rear.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
s
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Cop py
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Prote AG.
6. Rear lights 179

Sharan 1996 ➤
– Remove screw in rear light and remove plastic clip located on

side of light -arrows-.
– Remove rear light.
Installing

cles 11.03 ▸
Removing
ignition key.
Removing and installing right rear light
– Unclip interior light in luggage compartment trim.
– Remove securing nuts -arrows- for rear light -1-.
AG. Volkswagen AG d
agen oes
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V gu
d by ara
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– Unclip trim under rear light ho-arrow
ris
A-. nte
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– Pull trim off to rear -arrow
ss B-. c
ce
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un
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rm
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pe
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove rear light -1- securing screw -2- and remove plastic
l purpos
clip -3- from side of light.

nform
mercia
a
com
tion in
r
te o
thi
s
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Cop py
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Vo
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by c lksw
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Prote AG.

Sharan 1996 ➤
– Tilt top of rear light -1- to rear -movement arrow-.

– Pull securing tab -2- to rear -arrow- and take rear light -1- out
upwards.
Installing
6.7 Removing and installing rear light bulb

holder, vehicles ▸ 05.00
Removing
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ignition key. swa
gen AG does
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– Remove rear side trim panel ⇒ General body repairs,
ise
d binterior; ara
nte
Rep. Gr. 70 ; Pillars and side trim panel . thor eo
au ra
c
– Disconnect connector. ss
ce
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nl
pt
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– Release locking device -arrows- (turn) and remove bulb hold‐
an
itte
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er.
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ility
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Installing
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia

m
holder, vehicles 06.00 ▸ 10.03

at
om
ion
c
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or
Removing
his
ate
do
riv

p
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or
ignition key.
f
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t.
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– Remove cover in luggage compartment trim. Cop py
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– Release retaining lugs -arrows- and take out bulb holder. p by
co Vo
by lksw
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– Pull off connector. Prote AG.
Installing
6. Rear lights 181

Sharan 1996 ➤

holder, vehicles 11.03 ▸
Removing
ignition key.
– Release retaining lugs -2- and take out bulb holder -1-.
Installing
6.10 Assembly overview - rear light in rear lid, vehicles ▸ 05.00
1 - Rubber washer
2 - Stud
❑ 6 Nm
3 - M5 hexagon nut with wash‐
er
AG. Volkswagen AG d
agen
❑ 6 Nm Volksw
oes
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4 - Rubber grommet
or
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5 - Bulb holder
ss
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nl
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⇒ page 184
an
itte
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6 - Reversing light bulb

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❑ 12 V/21 W
wit
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7 - Seal
hole
spec
es, in part or in w
t to the co
8 - Housing
rrectness of i
⇒ page 185
l purpos
9 - Number plate light -X- bulb

holder
nform

mercia
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ion
c
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Prote AG.

Sharan 1996 ➤
⇒ page 191
10 - Number plate light -X- bulb
❑ 12 V/5 W
11 - Cover
12 - Securing bolt
13 - Rear fog light bulb
❑ 12 V/21 W
❑ 12 V/21 W
6.11 Assembly overview - rear light in rear lid, vehicles 11.03 ▸
1 - Left bulb holder

⇒ page 184
2 - Hexagon nut for securing
bolt ⇒ Item 13 (page 184) .
❑ 3 Nm
3 - Right bulb holder
⇒ page 184
❑ 12 V/21 W
❑ To change a bulb, re‐
move right rear light
bulb holder
⇒ Item 3 (page 183) and AG. Volkswagen AG d
reinstall after changing agen oes
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5 - Rubber pad utho eo
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❑ Renew if damaged ss
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un
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6 - Rear lights in rear lid

an
d
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⇒ page 187
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❑ Dismantling
h re
⇒ page 188
hole
spec
es, in part or in w
7 - Rubber seal
t to the co
8 - Number plate light -X- fes‐
rrectness of i
toon bulb
l purpos
❑ 12 V/5 W
9 - Number plate light -X-
nform
ercia

⇒ page 191
m
a
com
tion in
10 - Securing bolts
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11 - Rubber pad
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agen 6. Rear lights
Sharan 1996 ➤
12 - Rear fog light bulb

❑ 12 V/21 W
❑ To change a bulb, remove left rear light bulb holder ⇒ Item 1 (page 183) and reinstall after changing bulb
13 - Securing bolt
14 - Rubber pad

holder in rear lid, vehicles ▸ 05.00
Removing
ignition key.
– Remove cover for rear light.
– Disconnect connectors -1- and -2-.
– Unclip bulb holder and remove.
Installing
AG. Volkswagen AG d
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olksw not
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holder in rear lid, vehicles 06.00 ▸ 10.03
ed
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Removing ss c
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nl
pt

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ignition key.
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erm
ab
ility
– Remove cover in rear lid trim.

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, is n
– Release retaining lug -arrow- and take out bulb holder.

h re
hole
spec

es, in part or in w
t to the co
The reversing light and rear fog light are installed on the left side.
♦ Upper bulb for reversing light, 12V/21W
rrectness of i
♦ Lower bulb for rear fog light, 12V/21W

l purpos
The reversing light is installed on the right side.

♦ Upper bulb for reversing light, 12V/21W
nf
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orm
Installing
m
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holder in rear lid, vehicles 11.03 ▸

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Removing
ht ht
rig by
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by
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Prote
ignition key.
AG.

Sharan 1996 ➤
– Remove cover for rear light.

– Disconnect connector -1-.
– Unclip -arrow- bulb holder and remove.

Installing
G. Volkswage nA n AG d
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Volks not
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ility
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6.15 Removing and installing rear light in rear

hole
spec
lid, vehicles ▸ 05.00

es, in part or in w
t to the co
Removing
rrectness of i
ignition key.
l purpos

Gr. 70 ; Trim .
nform
ercia
– Pull connector -1- off bulb holder.

m
at
om
– Remove securing nuts -arrows-.

on
c
in t
or
– Close rear lid and remove rear light.

his
ate
do
riv
Installing
p
cum
for
en
ng

t.
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Cop py
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Prote AG.

lid, vehicles 06.00 ▸ 10.03
The rear light in the rear lid consists of the left and right rear lights
and a middle section with the number plate lights -X- . It installed
as a single unit and must be remove as a complete item to remove
a rear light.
Removing
ignition key.
6. Rear lights 185

Sharan 1996 ➤

Gr. 70 ; Trim .
– Pull connector -arrow- off both bulb holders.
AG. Volkswagen AG d
agen oes
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ara
ed
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aut ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
– Remove the 4 securing nuts -arrows- on each rear light.
spec
es, in part or in w
– Unscrew number plate lights -X- and remove ⇒ page 190 .
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
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thi
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sd
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– Remove securing nut -arrow- from middle section.
o
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cu
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f
en
ng
– Carefully close rear lid and remove complete rear light unit.
t.
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Installing
. C rig
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Install in reverse order of removal. by c lksw
cted agen
Prote AG.

Sharan 1996 ➤

lid, vehicles 11.03 ▸
Assembly overview
1 – 11 - Hexagon nuts (specified torque: 3 Nm)
12 - Securing bolt with pop rivet nut (Qty. 2).
13 - Number plate
AG. Volkswagen AG d
14 - Securing screws (Qty. 3) agen oes
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15 - Rear light/luminous oband
ris
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ce
le
Note
un
pt
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Note when installing the luminous band -15- that the hexagon
rm
ab
pe
ility
nuts for items -1 to 11- are tightened in sequence as numbered
ot
and to a specified torque of 3 Nm.
wit
, is n
h re
hole
spec
Removing
es, in part or in w
t to the co
ignition key.
rrectness of i
Gr. 70 ; Trim .
l purpos
Only one side is described in the figures, but remove both sides.
nform
ercia
– Pull connectors -1- off bulb holders.

m
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tion in
r
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fo
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ng
t.
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.
– Remove securing nuts -arrows- on each rear light.
6. Rear lights 187

Sharan 1996 ➤
– Additionally remove securing nut -arrow- in in middle of rear

lid in vicinity of luminous band.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut
– Also remove securing nuts -4- andss -8- in vicinity of luminous
a ra
c
band.
ce
e
nl
pt
du
an
– Carefully close rear lid and remove complete rear light unit.
itte
y li
erm
ab
Installing
ility
ot p
wit
, is n
h re
ing:
hole
spec
– Tighten hexagon nuts for items -1 to 11- in sequence as num‐
es, in part or in w
t to the co
bered in figure and to a torque setting of 3 Nm.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
6.18 Dismantling rear light in rear lid, vehicles

p
cum
for
▸ 10.03
en
ng
t.
yi Co
Cop py
. rig
Removing
ht ht
rig by
copy Vo
– Remove rear lights in rear lid ⇒ page 185 .
by lksw
cted agen
Prote AG.
– Unscrew securing bolts -arrows- and remove rear light.
Installing
6.19 Dismantling rear light in rear lid, vehicles

11.03 ▸
Removing
– Remove rear lights in rear lid ⇒ page 187 .

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
– Unclip -arrow- rear light from luminous band.
an
d
itte
y li
erm
– Open out rear light -arrow A- and remove it from the guides on
ab
ility
the side -arrow B-.
ot p
wit
is n
Installing
h re
ole,
spec
ing:
t to the co
Specified torque: 3 Nm
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Rear lights 189

Sharan 1996 ➤
7 Number plate light -X-
7.1 Removing and installing number plate

light -X- , vehicles ▸ 05.00 olkswage es n
ot
yV gu
db ara
Removing ir se nte
ho eo
ut
– Switch off ignition and all electrical consumers
ss
a and remove ra
c
ignition key.
ce
e
nl
pt
du
an
– Remove rear lid rear light ⇒ page 185 .
itte
y li
erm
ab
– Disconnect connectors on bulb holders.
ility
ot p
wit
, is n
– Remove securing screws -arrows- for number plate light -X- .
h re
hole
– Unclip electrical wiring on rear light unit.
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
– Pull out number plate light -X- -arrow-.
thi
te
sd
iva
o
Installing
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.
7.2 Replacing number plate light -X- bulb,

vehicles ▸ 05.00
– Remove securing bolts -arrows- for number plate light -X- .
– Remove cover for number light plate -X- .

AG. Volkswagen AG d
agen oes
olksw nSharan
ot g 1996 ➤
byV ua
rised
Electrical system - Edition ran 12.2008
tee
tho or
au ac
– Pull out glass base bulb (12V/5W), do nots turn.
s
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Push in new bulb, fit cover and tighten securing screws.
rrectness of i
l purpos
nf
light -X- , vehicles ▸ 06.00
ercia
orm
m
atio
om
n in
ignition key.
or c
thi
te
Removing
sd
iva
o
r
rp
cu
– Remove cross-head screws -arrows- for appropriate number
o
m
f
en
ng
plate light -X- .

t.
yi Co
Cop py
.
– Remove lens with bulb.
ht rig
rig ht
py by
co Vo
– Take out bulb (12V/5W).
by lksw
cted agen
Prote AG.
Installing

light -X- , vehicles 11.03 ▸
Removing
ignition key.
– Remove cross-head screws -arrows- for appropriate number
plate light -X- .
– Remove number plate light -X- , consists of lens with festoon
bulb.
7. Number plate light X 191

Sharan 1996 ➤
– Release connector -arrows-.

Installing
7.5 Replacing number plate light -X- bulb,

vehicles 11.03 ▸
– Remove number plate light -X- ⇒ page 191 .
– Press contact plate -1- of light in -direction of arrow- and re‐
move bulb -2- from holder.
– Replace festoon bulb (12V/5W)
AG. Volkswagen AG d
Note lksw
agen oes
not
o
byV gu
ara
d
Do not touch bulb glass whenhfitting a new bulb. Fingers leave
ise nte
or eo
traces of grease on the glass,aut which evaporate when the bulb is ra
c
ss ce
e
nl
pt
du
an
itte
Installing
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
n AG. Volkswagen AG
8 Additional
yV
olks
wage brake light
does
not
g
b ua
ed ra
The additional
ho
ris brake light is located on the rear window.
nte
e
t or
au ac
8.1 ss Removing and installing additional
ce
le
brake light bulb holder, vehicles ▸ 05.00

un
pt
an
d
itte
y li
erm
ab
Removing
ility
ot p
wit
is n
h re
ignition key.
ole,
spec
– Pull off connector, press back retaining spring -arrows- and

take out bulb holder.
t to the co
Installing
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
8.1.1 Changing bulbs

r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note
p by
co Vo
by lksw
cted agen
Prote AG.
– The bulbs (12 V/5 W) -2- are a push fit. They can be pulled out
of and pushed into the bulb holder -1-.
8. Additional brake light 193

Sharan 1996 ➤
8.2 Removing and installing additional

brake light housing, vehicles ▸ 05.00
Removing
– Press back retaining springs -arrows- and take housing with
lens off rear window.
AG. Volkswagen AG d
Installing agen oes
olksw not
byV gu
ara
Installation is carriedrisout in the reverse sequence.
ed
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
8.3 Removing and installing additional
t to the co
brake light bulb holder, vehicles 06.00 ▸
Removing
rrectness of i
l purpos
ignition key.
– Remove upper and lower rear lid trim ⇒ General body repairs,
nform
ercia
interior; Rep. Gr. 70 ; Rear lid trim .

m
at
om

on
c
in t
or

his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
8.3.1 Removing and installing bulb holder, ve‐

hicles 06.00 ▸
Removing
– Unclip bulb housing on both sides -arrow-.

Sharan 1996 ➤
– Unclip bulb housing at top and bottom -arrows-.
Note
On the bulb holder there is a circuit board with 18 gsoldered

en AG. V LEDs
olkswagen AG
which are covered by a plastic strip. Changing olksan
wa individual LED does
not
is not possible, the bulb holder must beerenewed
db
y V
complete in ca‐ gu
ara
ses of repair. thoris nte
e or
au ac
ss
Installing
ce
le
un
pt
an
d

itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
8. Additional brake light 195

Sharan 1996 ➤
9 Steering column switch

AG. Volkswagen AG d
Note agen oes
olksw not
byV gu
ara
ed
♦ For further information concerning workthoon steering column ⇒
ris nte
eo
Running gear, axles, steering; Rep. Gr.
s au 48 ; Steering: Airbag, ra
c
steering wheel, steering column. s
ce
e
nl
pt
♦ Instructions for working on vehicles fitted with an airbag ⇒ du
an
itte
y li
General body repairs, interior; Rep. Gr. 69 ; Passenger pro‐
erm
ab
tection; Airbag.
ility
ot p
wit
, is n
h re
9.1 Assembly overview - steering wheel, vehicles ▸ 05.00
hole
spec
es, in part or in w
t to the co
1 - Steering wheel
rrectness of i
⇒ page 196
l purpos
2 - Connector
3 - Airbag unit
nform
ercia
4 - Hexagon bolt
m
at
om
❑ Must always be re‐
ion
c
placed
in t
or
his
e
❑ 40 Nm
at
do
priv
cum
5 - Torx screw -T30-
for
en
ng
t.
❑ Must always be re‐
yi Co
op
placed
C py
ht. rig
rig ht
❑ 8 Nm
py by
co Vo
by lksw
cted agen
6 - Trim - lower part
Prote AG.
7 - Foam tube
8 - Connector
9 - Coil connector with slip ring
⇒ page 197
9.2 Removing and installing steering wheel,

vehicles ▸ 05.00
– Remove driver side airbag unit ⇒ General body repairs, inte‐
rior; Rep. Gr. 69 ; Airbag .

Sharan 1996 ➤
WARNING
Safety precautions when working on airbag.
– Remove lower part of steering column switch trim

⇒ Item 6 (page 196) .
– Pull foam tube ⇒ Item 7 (page 196) off connector
⇒ Item 8 (page 196) and separate connection.
– Remove hexagon bolt ⇒ Item 4 (page 196) and pull steering
wheel off steering column (hexagon bolt 40 Nm).
Coil connector with slip ring ⇒ Item 9 (page 196) remains on
steering wheel
9.3 Removing and installing coil connector

with slip ring, vehicles ▸ 05.00
Note
♦ If the vehicle has a security-coded radio, obtain the anti-theft

code from customer before disconnecting the battery.
⇒ page 4 .
. Volkswagen AG
gen AG does
– Remove driver side airbag unit ⇒ General bodyVrepairs,
olks
wa inte‐ not
rior; Rep. Gr. 69 ; Airbag . ed by gu
ara
nte
is
or eo
– Disconnect single connector for horn. auth ra
ss c
– Remove cross-head screws -1- and pull coil connector with
ce
le
un
pt
slip ring -2- off steering wheel.
an
d
itte
y li
erm
ab
ility
ot p
Note
wit
is n
h re
ole,
♦ Removal and installation of the coil connector with slip ring spec
must be undertaken in the central position (wheels straight t to the co

ahead).
♦ A new coil connector with slip ring is secured in the central
position by a cable tie.
rrectness o
9.4 Removing and installing steering col‐

cial p
f inform
umn switch and steering lock housing

mer
atio
with ignition switch, vehicles ▸ 05.00

om
n
c
i
or
n thi
te
sd
va
Note
i
o
pr
cum
r
fo
en
ng
t.
yi
Co
op py
code from customer before disconnecting the battery. t. C rig
gh ht
pyri by
o Vo
by c lksw
cted
agen
Prote AG.
⇒ page 4 .
9. Steering column switch 197

Sharan 1996 ➤
♦ Multi-purpose tool -VW 771-
♦ M10 threaded rod x 50 mm

Removing
– Remove trim below steering column switch.
– Remove trim over steering column switch -arrows-.
– Pull connector off steering lock housing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove bolt -arrow- for steering column switch. nform

ercia
– Pull connectors off steering column switch.

m
a
com
– Remove steering column switch.

ion in
r
te o
– Pull immobilizer reader coil -D2- off steering lock housing.

thi
s
iva
do
– Pull steering column as far as possible out of column tube.

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

Sharan 1996 ➤
– Remove bearing ring -2-.

1- M10 threaded rod, approx. 50 mm long.
2- Manufacture locally if necessary, e.g. use a M10 bolt and
cut head off.
– Remove multi-purpose tool -VW 771- from steering column.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
– Drive off steering lock housing.

un
pt
an
d
itte
y li
Installing
erm
ab
ility
ot p
– Fit steering lock housing on column tube.
wit
is n
h re
– Fit bearing ring onto steering column.
ole,
spec
t to the co
rrectness o
cial p
f i
– Pull steering column as far as possible out of column tube and
nform
hold in place.
mer
atio
m
1- Press bearing ring against ball bearing in steering lock hous‐

o
n
c
ing when pulling out steering column.
i
or
n thi
te
sd
a
2- M10 threaded rod, approx. 50 mm long.

iv
o
pr
cum
r
fo
– Remove multi-purpose tool -VW 771- .

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
9.5 Removing and installing steering col‐

umn switch, vehicles 06.00 ▸
Note

⇒ page 4 .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Sharan 1996 ➤ thor eo
u ra
ss a c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
Removing
mer
atio
m

o
n
c
i
or
n thi
te
sd
a
– Remove multi-point socket head bolt -2-.

iv
o
pr
cum
r
fo
– Position steering wheel -1- in central position (wheels straight
en
ng
t.
ahead).
yi Co
Cop py
t. rig
– Pull steering wheel -1- off steering column.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove bolts -1-, -2- and -3-.

– Remove lower part of steering column switch trim.
– Remove upper part of steering column switch trim -1-.

Sharan 1996 ➤
– Disconnect connector -1-.

– Release retainers -arrows- and pull coil connector with slip ring
off steering column switch.
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
– Remove steering column switch clamping bolt -arrow- and re‐
move steering column switch.
rrectness of i
Installing
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
If steering column switch was removed, distance -a- between Cop py
steering wheel and coil connector housing must be reset.
t. rig
gh ht
pyri by
Vo
co
1- Steering wheel
by lksw
cted agen
Prote AG.
2- Coil connector housing
3- Clamping bolt for steering column switch
a - Approx. 2.5 mm
– Install steering column switch.
– Fit steering wheel so that the mark -arrow A- on steering wheel

aligns with mark -arrow B- on steering column.
– Install multi-point socket head bolt and tighten.
– Position steering column switch so that it is horizontal.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Sharan 1996ho➤ ris nte
eo
t
Electrical ssystem - Edition 12.2008
au ra
c
s
ce
e
nl
pt
– Set gap -a- to approx. 2.5 mm.
du
an
itte
y li
– Tighten clamping bolt -3-.
erm
ab
ility
ot p
– Remove steering wheel again.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
– Install upper part of steering column switch trim -1-.
ercia
orm
m
– Install lower part of steering column switch trim.
atio
om
n in
c
– Install height and reach adjustment handle, if necessary.

or
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.
– Install screws -1-, -2- and -3-.

– Install steering wheel.
– Check head of multi-point socket head bolt.
A multi-point socket head bolt which already has five punch marks
on head must be renewed!
– Coat multi-point socket head bolt with locking fluid.
– Install multi-point socket head bolt and tighten.
Specified torque: 50 Nm
– Drive a punch mark into head of multi-point socket head bolt.
– Install driver side airbag unit ⇒ General body repairs, interior;
Rep. Gr. 69 ; Airbag .
9.6 Removing and installing signal horn ac‐

tivation, vehicles 06.00 ▸
Note

⇒ page 4 .
Removing
– Remove driver side airbag ⇒ General body repairs, interior;
Rep. Gr. 69 ; Airbag .

Sharan 1996 ➤
– Remove securing screws -arrows- on contact plate.

– Pull off connector and remove contact plate.
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
Note
, is n
h re
hole
spec
Ensure that the contact surfaces of the contact plate as well as
es, in part or in w
the contact pin in steering wheel -arrows- are metallically clean
t to the co
before reinstalling.
rrectness of i
Installing
l purpos
nf
ercia
orm
m
atio
m
9.7 Pin assignment for steering column

o
n in
or c
switch, vehicles 06.00 ▸ thi

te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
9.7.1 Switch for windscreen wash and wipe
yi Co
Cop py
.
system and multifunction indicator
ht rig
rig ht
py by
co Vo
by lksw
6-pin connector -A-
cted agen
Prote AG.
1- MFI call-up button - right

2- MFI call-up button - left
3- MFI call-up button - terminal 31
4- MFI save switch - reset
5- Windscreen wiper intermittent wipe regulator - to automatic
intermittent wash/wipe relay
6- Windscreen wiper intermittent wipe regulator - terminal 31
8-pin connector -B-

1- Windscreen wiper switch - terminal 53
2- Windscreen wiper switch - terminal 31
3- Windscreen wiper switch - terminal 53e
4- Windscreen wiper switch - terminal 53c
5- Windscreen wiper switch - rear window wiper
6- Windscreen wiper switch - terminal 53b
7- Windscreen wiper switch - intermittent operation
8- Windscreen wiper switch - terminal 53a

Sharan 1996 ➤
9.7.2 Switch for turn signals, main and dipped

beam, headlight flasher and parking
light
12-pin connector -C-
1- Switch for dip beam and headlight flasher - terminal 30
AG. Volkswagen AG d
3- Turn signal switch - terminal L agen oes
olksw not
y V gu
b ara
4- Parking light switch - terminal P rise
d
nte
tho eo
u
5- Turn signal switch - terminal
ss a 49a ra
c
ce
e
6- Horn plate - terminal 71

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
8- Switch for dip beam/headlight flasher - terminal 56b
wit
, is n
h re
9- Parking light switch - terminal PL
hole
spec
10 - Parking light switch - terminal PR
es, in part or in w
t to the co
11 - Turn signal switch - terminal R
12 - Switch for dip beam/headlight flasher - terminal 56a
rrectness of i
l purpos
9.7.3 Switch for cruise control system

10-pin connector -D-
nf
ercia
or
1- Not assigned
m
m
atio
om
2- CCS switch - on / off

n in
or c
thi
e
3- CCS button -set / delay

t
sd
iva
o
r
rp
cu
4- CCS switch - reset / resume saved speed / accelerate

o
m
f
en
ng
t.
yi
5- CCS switch - reset / resume saved speed / accelerate
Co
Cop py
t. rig
gh
6- CCS switch - on / off
ht
pyri by
Vo
co lksw
by
cted
7- Cruise control system switch
agen
Prote AG.
8- Not assigned
9- Not assigned
10 - Not assigned

Sharan 1996 ➤
10 Ignition/starter switch and lockswage

n cylin‐
AG. Volkswagen AG d
oes
der olk not
byV gu
ara
ed
ris nte
utho eo
ra
a c
ss
10.1 Removing and installing lock cylinder,
ce
le
un
pt
vehicles ▸ 05.00
an
d
itte
y li
rm
ab
pe
Positions for key in lock cylinder:
ility
ot
wit
, is n
1- Position “Stop”
h re
hole
spec
2- Position “Drive”
es, in part or in w
t to the co
3- Position “Start”
Removing
rrectness of i
ignition key.
l purpos
– Remove trim below steering column switch.
nform
ercia
– Insert ignition key in lock cylinder and turn to position “Drive”.

m
a
com
t
– Insert a piece of steel wire (approx. ∅ 1.2 mm) in drilling next
ion in
to ignition key -arrow-.
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
10. Ignition/starter switch and lock cylinder 205

Sharan 1996 ➤ agen
AG. Volkswagen AG d
oes
ksw not
Electrical system - Edition 12.2008 by Vol
gu
a
ed ran
oris tee
– Release lock cylinder securing lever
au using steel wire -arrow-
th or
ac
and remove lock cylinder from steering
ss lock housing.
ce
e
nl
pt
1- Lock cylinder
du
an
itte
y li
erm
2- Steel wire (approx. ∅ 1.2 mm)
ab
ility
ot p
3- Securing lever
wit
, is n
h re
Installing
hole
spec
es, in part or in w
t to the co
– Release securing lever using a piece of steel wire (approx. ∅
1.2 mm) and insert lock cylinder in steering lock housing.
rrectness of i
l purpos
Note
nf
ercia
If necessary, turn lock cylinder in steering lock housing to correct
or
installation position.
m
m
atio
om
n in
c
– Pull piece of steel wire out of lock cylinder and check that lock
or
thi
e
cylinder is sitting properly in steering lock housing.

t
sd
iva
o
r
rp
cu
– Install trim under steering column switch.
o
m
f
en
ng
t.
yi Co
op
10.2 Removing and installing lock cylinder,
C py
t. rig
gh ht
yri by
vehicles 06.00 ▸ cop Vo
by lksw
cted agen
Prote AG.
Note

♦ When the battery is reconnected, check operation of electrical
equipment (radio, clock, convenience electronics and so on)
according to the workshop manual and/or the owner's manual.
Removing
ignition key.
– Remove steering column switch ⇒ page 196 .
– Remove trim under steering column.
– Carefully pull immobilizer reader coil connector -arrow- off im‐
mobilizer control unit (located behind dash panel insert).
Note
The immobilizer reader coil is secured to the lock cylinder and

cannot be changed individually.

Positions for key in lock cylinder:
1- Position “Stop”
2- Position “Drive”
3- Position “Start”

Sharan 1996 ➤
– Insert a piece of steel wire (approx. ∅ 1.2 mm) in drilling next

to ignition key -arrow-.
To ensure the steel wire is inserted straight into drilling, it may
become necessary to dismantle ignition key and insert key into
lock cylinder without key head.
– Dismantling ignition key ⇒ General body repairs, exterior;
Rep. Gr. 57 ; Central locking .
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
– Release lock cylinder securing lever using steel wire -arrow-
wit
, is n
and remove lock cylinder from steering lock housing.
h re
hole
spec
1- Lock cylinder
es, in part or in w
t to the co
2- Steel wire (approx. ∅ 1.2 mm)
3- Securing lever
rrectness of i
Installing
l purpos

– Release securing lever using a piece of steel wire (approx. ∅
nf
ercia
o
1.2 mm) and insert lock cylinder in steering lock housing.
rm
m
atio
om
n in
or c
Note
thi
te
sd
iva
o
r
rp
cu
When installing lock cylinder, ensure that connection for immo‐
o
m
f
en
bilizer reader coil is in guide of steering lock housing.
ng
t.
yi Co
Cop py
ht. rig
– Pull piece of steel wire out of lock cylinder and check that lock rig ht
py by
Vo
cylinder is sitting properly in steering lock housing.
co lksw
by
cted agen
Prote AG.
– Reconnect immobilizer reader coil connector -arrow- to im‐

mobilizer control unit.
– Install trim under steering column.
– Install steering column switch and steering wheel
⇒ page 196 .
10. Ignition/starter switch and lock cylinder 207

Sharan 1996 ➤
10.3 Removing and installing ignition switch,

vehicles 06.00 ▸
Note

Removing
ignition key.
– Remove steering column switch ⇒ page 196 .
– Pull multi-pin connector off ignition switch -arrow-.
– Remove anti-tamper paint from securing screws -A-.
– Loosen the two securing screws -A- slightly and pull ignition
switch out from steering lock housing in -direction of arrow-.
AG. Volkswagen AG d
Installing agen oes
olksw not
y V gu
b ara
– Push ignition switch into steering lock housing. rise
d
nte
tho eo
au ra
ss c
ce
Note
le
un
pt
an
d
itte
y li
When installing the ignition/starter switch ensure that the ignition/
erm
ab
starter switch and the lock cylinder are in the same position, e.g.
ility
ot p
“ignition on”.
wit
is n
h re
ole,
spec
– Tighten securing screws and reinstate anti-tamper paint coat‐
ing.
t to the co
– Connect multi-pin connector to ignition switch.
– Install steering column switch and steering wheel rrectne
⇒ page 196 .
ss o
10.4 Pin assignment for ignition/starter

cial p
f inform
switch
mer
atio
m
8-pin connector
o
n
c
i
or
n thi
1- Terminal 50, (not assigned)

te
sd
iva
o
pr
2- Terminal 75
um
r
fo
en
ng
t.
3- Terminal 30
yi Co
Cop py
t. rig
4- Terminal P
gh ht
pyri by
Vo
co lksw
by
5- Terminal 50b Prote
cted AG.
agen
6- Terminal 15
7- Terminal 30
8- Terminal 86s

Sharan 1996 ➤
11 Parking aid, vehicles 06.00 ▸

AG. Volkswagen AG d
agen oes
Note olksw not
y V gu
d b ara
rise nte
o
♦ When faced with complaints, it is absolutely
auth necessary to un‐ eo
ra
derstand the function and operationsof the parking aid system.
s c
ce
le
un
pt
♦ Additional information ⇒ Operating instructions
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
11.1 General description
es, in part or in w
t to the co
The parking aid system assists the driver when parking by acous‐
tically indicating the distance to an obstacle from the front or rear
of the vehicle.
rrectness of i
The parking aid system consists of:
l purpos
♦ the parking aid control unit
nform
ercia
♦ the senders in the front bumper

m
a
com
♦ the senders in the rear bumper
tion in
r
te o
♦ the front and rear warning buzzers
thi
s
iva
do
♦ the parking aid switch
r
rp
cum
fo
en
g

n
t.
yi Co
Cop py
t. rig
The parking aid system is equipped with self-diagnosis, which is
gh ht
pyri by
designed to simplify fault finding.
co Vo
by lksw
cted agen
Prote AG.
For fault finding, use vehicle diagnosis, test and information sys‐
tem -VAS 5051 A- in “Guided fault finding” mode.
11.2 Assembly overview - parking aid
11. Parking aid, vehicles 06.00 ▸ 209

Sharan 1996 ➤
1 - Parking aid senders

❑ On right in front bumper
-G252-
❑ On centre right in front
bumper -G253-
❑ On centre left in front
bumper -G254-
❑ On left in front bumper -
G255-
⇒ page 211
2 - Parking aid button -E266-
⇒ page 224
3 - Parking aid senders
❑ On right in rear bumper
-G206-
❑ On centre right in rear
bumper -G205- AG. Volkswagen AG d
agen oes
❑ On centre left in rear olksw not
yV gu
bumper -G204- ised b ara
nte
or
❑ On left in rear bumper - auth eo
ra
G203- ss c
ce
e
nl
pt
du
an
⇒ page 211
itte
y li
erm
ab
4 - Rear parking aid warning
ility
ot p
buzzer -H15-
wit
, is n
h re
❑ Next to left rear light
hole
❑ Removing and installing spec

es, in part or in w
⇒ page 212
t to the co
5 - Front parking aid warning

buzzer -H22-
rrectness of i

l purpos
⇒ page 212
❑ Under driver seat
nf
ercia
6 - Parking aid control unit

orm
m
atio
❑ Under driver seat

om
n in
c

or
thi
te
sd
iva
o
r
rp
cu
o
m
f
11.3 Removing and installing parking aid

en
ng
t.
yi Co
op
control unit
C py
t. rig
gh ht
pyri by
Vo
Removing
o
by c lksw
cted agen
Prote AG.
ignition key.
– Pull driver seat forwards as far as possible.
– Remove cover in floor under driver seat.

Sharan 1996 ➤
– Release connectors -arrows- and pull off.

– Remove assembly plate with control unit and warning buzzer.
– To remove control unit, remove securing screws on underside
of assembly plate.
Installing
AG. Volkswagen AG d
agen oes
Installation is carried out in the reverse
Vol
kswsequence. not
gu
y
db ara
rise nte
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
11.4 Removing and installing front parking
pe
ility
ot
aid sender
wit
, is n
h re
hole
Removing
spec
es, in part or in w

ignition key. t to the co

rrectness of i
Gr. 63 .
l purpos
– Push back both securing tabs on sender -arrows-.

– Press out sender inwards from outside of bumper.
nform
ercia

m
a
com
tio
Installing
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
o
by c lksw
cted agen
Prote AG.
11.5 Removing and installing rear parking aid

sender
Note
There is no requirement to remove the rear bumper.
Removing
ignition key.
11. Parking aid, vehicles 06.00 ▸ 211

Sharan 1996 ➤
– Push back both securing tabs on sender -arrows-.

– Press out sender inwards from outside of bumper.
Installing
11.6 Removing and installing rear parking aid

warning buzzer
Removing
ignition key.
– Remove left rear light cover in luggage compartment.
. Volkswagen AG
ksw
agen
AG does
not
Vol gu
– Pull off connector. by ara
ed nte
oris eo
th
Installing au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
11.7 Removing and installing front parking

rrectness of i
aid warning buzzer

l purpos
Removing
nform
ercia
ignition key.
m
a
com
– Pull driver seat forwards as far as possible.

ion in
r
te o
– Remove cover in floor under driver seat.

thi
s
iva
do

r
rp
cum
fo
en
g

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

Sharan 1996 ➤
96 – Lights, bulbs, switches - interior

1 Immobilizer
Note

General description
Up to 08.97: a first generation immobilizer is installed in the Shar‐
an.
Communications between the immobilizer control unit and the
engine control unit take place on the W-wire.
From 09.97 to 05.00 second generation immobilizer is installed in
Sharan.
Communications between the immobilizer control unit and the
engine control unit take place on the W-wire.
From 06.00 a third generation immobilizer is installed in the Shar‐
an, one of two versions is installed depending on the type of
engine.
On one version the immobilizer control unit and engine control
unit communicate via data-bus, on the other version this commu‐
nication is via W-wire.
The immobilizer consist of:
♦ An immobilizer control unit.
♦ An adapted (matched) engine control unit. wagen AG. Volkswagen AG doe
olks s no
yV t gu
♦ A reader coil on ignition lock. edb ara
ris nte
♦ adapted (matched) ignition keys ho eo
aut with electronic components ra
(transponder and response reader
ss memory), c
ce
e
nl
pt
♦ and the immobilizer warning lamp -K117- .

du
an
itte
y li

erm
ab
ility
ot p
The immobilizer is equipped with self-diagnosis, which makes

wit
, is n
fault finding easier.

h re
hole
spec
Vehicles up to 05.00: for fault finding, use the “self-diagnosis” and

es, in part or in w
the vehicle diagnosis, test and information system -VAS 5051A-

t to the co
in “Guided fault finding” mode.

Vehicles from 06.00: for fault finding, use vehicle diagnosis, test
rrectness of i
and information system -VAS 5051A- in “Guided fault finding”

mode.
l purpos
1.1 Assembly overview - immobilizer

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Immobilizer 213
Sharan 1996 ➤
1 - Immobilizer control unit -

J362-
⇒ page 215
2 - Immobilizer reader coil -
D2- , fitted on steering lock
housing
⇒ page 215
3 - Transponder (response-
reader memory) integrated in
ignition key
4 - Engine control unit
❑ For vehicles with a pet‐
rol engine
❑ For vehicles with a die‐
sel engine control unit
with fuel shut-of valve,
on diesel injection pump
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
1.2 Removing and installing immobilizer

control unit -J362-
nform
ercia
Removing
m
at
om
ion
c

in t
or
ignition key.
his
ate
do
riv
The immobilizer control unit -J362- is located on the left behind

p
cum
or
the dash panel, under the engine control unit retaining plate.
f
en
ng
t.
yi Co
op
– Pull connectors -arrows- off immobilizer control unit.
C py
t. rig
gh ht
yri by
– Remove Torx bolts -1- and -2- for securing immobilizer control cop Vo
by lksw
unit and remove control unit.
cted agen
Prote AG.
Installing
214 Rep. Gr.96 - Lights, bulbs, switches - interior

Sharan 1996 ➤
1.3 Removing and installing immobilizer swagen AG. Volkswagen AG does

k
reader coil -D2-
not
Vol gu
by ara
ed nte
ris
Removing ho eo
aut ra
ss c
ce
e
nl
pt
ignition key.
du
an
itte
y li
– Remove lower trim of steering column switch ⇒ General body
erm
ab
ility
repairs, interior; Rep. Gr. 70 ; Dash panel .
ot p
wit
, is n
– Unclip wiring from reader coil to immobilizer control unit.
h re
hole
spec
– Pull connector off immobilizer control unit.
es, in part or in w
t to the co
– Pull reader coil -arrow- off steering lock housing.
Installing
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
1.4 Ignition key
Co
Cop py
ht. rig
rig ht
Vehicles to 04.00 py by
co Vo
by lksw
cted agen
– Removing and installing the battery and remote container for Prote AG.
the ignition key with remote control ⇒ General body repairs,
exterior; Rep. Gr. 57 ; Central locking; Removing and instal‐
ling battery for key with remote control > 04.01 .
Vehicles from 05.00
– Removing and installing the battery and remote container for
the ignition key with remote control ⇒ General body repairs,
exterior; Rep. Gr. 57 ; Central locking; Removing and instal‐
ling battery for key with remote control (folding) 05.01 > .
1.4.1 Ignition key - variable code transponder

The variable code transponder in the ignition key cannot be re‐
placed.
The ignition key must always be replaced if the variable code
transponder is defective.
Note
♦ If an ignition key is replaced or a further ignition key is required,

the new ignition key must always be adapted to the immobil‐
izer ⇒ page 216 .
♦ If the radio container (transmission unit for remote controlled
central locking) of the ignition key is also replaced, it must be
adapted to the convenience system ⇒ page 216 .
1. Immobilizer 215
Sharan 1996 ➤
1.4.2 Adapting ignition keys to the immobilizer

Vehicles to 05.00
– Adapting ignition keys ⇒ Electrical system, self-diagnosis;
Rep. Gr. 01 ; Guided functions for immobilizer; Vehicles up to
05.00; Adapting ignition keys .
Vehicles from 06.00
– Adapting ignition keys ⇒ Electrical system, self-diagnosis;
Rep. Gr. 01 ; Guided fault finding / Guided functions for im‐
mobilizer; Vehicles from 06.00; Adapting ignition keys .
1.4.3 Adapting ignition keys to the conven‐

ience system
Vehicles to 04.00
– Adapting ignition key to convenience system ⇒ General body
repairs, exterior; Rep. Gr. 57 ; Central locking; Adapting (syn‐
chronising) key with remote control > 04.01 .
Vehicles from 05.00
– Adapting ignition key to convenience system ⇒ General body
repairs, exterior; Rep. Gr. 57 ; Central locking; Adapting key
with remote control 05.01 > .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
2 Voltage converter
The fitting location of the voltage converter is on the left, behind
the dash panel insert, under the engine control unit bracket. The
voltage converter is only installed on vehicles with radio naviga‐
tion system with black-and-white display (7Q5).
2.1 Removing and installing voltage con‐

verter
2.1.1 Removing
ignition key.
– Remove dash panel insert ⇒ page 68 .
– Release both bolts -1- and disconnect connector.
– Remove voltage converter.
2.1.2 Installing
Installation is carried out in the reverse sequence of removal.
Note
If necessary, recode radio unit and reset clock.
2.2 Pin assignment of voltage converter

32-pin connector
1 - Input, terminal 30
AG. Volkswagen AG d
agen
2 - Input, terminal 30 Volksw
oes
not
gu
by ara
d
3 - Input, terminal 31 orise nte
eo
th
u ra
4 - Input, terminal 15 ss a c
ce
e
nl
5 - Output, terminal 30 (rod aerial)

pt
du
an
itte
y li

erm
ab
ility
ot p
wit
, is n
h re
8 - Input CU (start)
hole
spec
es, in part or in w
t to the co
10 - Input, terminal X
rrectness of i
12 - Output, terminal X (rod aerial)

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Voltage converter 217

Sharan 1996 ➤
3 Anti-theft alarm (ATA)
Note
♦ Vehicles 09.07 ▸, central locking control unit and anti-theft

alarm system control unit are integrated in the multifunction
unit (electronic central electrics).
♦ For fault finding, use vehicle diagnosis, testing and information
system -VAS 5051A- or successor units in “Guided fault find‐
ing” mode.
♦ Respective current flow diagram is located in binder Current
flow diagrams, Electrical fault finding and Fitting locations.
AG. Volkswagen AG d
agen oes
lksw not
1 - Rear lid central locking d by Vo gu
ara
switch -F218- orise nte
th eo
❑ Removing and installing s au ra
c
⇒ page 222 s
ce
e
nl
pt
du
♦ Rear lid release switch -
an
itte
y li
E165-
erm
ab
ility
ot p
wit
⇒ page 222
, is n
h re
hole
2 - Rear door contact switch -
spec
F160-
es, in part or in w
t to the co
⇒ page 223
rrectness of i
3 - Left ultrasonic sensor for
anti-theft alarm system -G170-
l purpos
and right ultrasonic sensor for

removing and installing anti-
nf
ercia
theft alarm system

rm
m
⇒ page 221
atio
om
n in
c
4 - Warning lamp for immobil‐

or
thi
e
izer -K117-
t
sd
iva
o
r

rp
cu
o
⇒ page 219
f
en
ng
t.
yi Co
op
5 - Door contact switch -F2- C py
t. rig
gh ht
yri
❑ Removing and installing p by
co Vo
⇒ page 229
by lksw
cted agen
Prote AG.
6 - Driver side central locking
switch -F59- and front passen‐
ger side central locking switch
-F114-
⇒ page 221
7 - Central locking and anti-
theft alarm system control unit
-J379-
❑ Vehicles 09.97 ▸, integrated in multifunction unit.
8 - Engine compartment light switch -F214-

Sharan 1996 ➤
9 - Alarm horn -H12- for anti-theft alarm system, vehicles 05.00 ▸

10 - Alarm horn -H12- for anti-theft alarm system, vehicles ▸ 04.00
3.1 Removing and installing central locking

and anti-theft alarm system control unit
-J379-
Note
Vehicles 09.07 ▸, central locking control unit and anti-theft alarm

system control unit are integrated in the multi-function unit (elec‐
tronic central electrics)
AG. Volkswagen AG d
agen
Removing o lksw
oes
not
byV gu
a
d
– Switch off ignitionorand
ise all electrical consumers and removerante
eo
ignition key. auth ra
ss c
– Slide driver seat forwards.
ce
le
un
pt
an
d
– Remove cover under driver seat.

itte
y li
erm
ab
– Remove plastic nuts on central locking and anti-theft alarm
ility
ot p
system control unit -J379- -arrows-

wit
is n
h re
ole,
– Disconnect the three connectors on control unit. spec

– Take control unit out upwards.

t to the co
Installing
rrectness o
cial p
f inform
mer
atio
m
3.2 Removing and installing immobilizer

o
n
c
i
or
warning lamp -K117-

thi
te
sd
iva
o
pr
Removing
um
r
fo
en
ng
t.
yi
Co
op py
ignition key.
. C rig
ht ht
rig by
py
– Remove door trim ⇒ General body repairs, interior; Rep. Gr.
co Vo
by lksw
cted
70 ; Door trims.
agen
Prote AG.
3. Anti-theft alarm (ATA) 219

Sharan 1996 ➤
– Release lower part of warning lamp from fasteners and pull

off. Pull upper part out of door trim.
Installing
3.3 Removing and installing alarm horn -

H12- for anti-theft alarm system . Volkswag
AG en AG
agen does
The alarm horn is located behind the engine yon
Vol the bulkhead in
ksw not
gu
the engine compartment. ise
d b ara
nte
r
ho eo
♦ Vehicles ▸ 05.00, on right of bulkhead.
sa
ut ra
c
s
♦ Vehicles 06.00 ▸, centre on bulkhead.
ce
e
nl
pt
du
an
itte
Removing
y li
erm
ab
ility
ot p
ignition key.
wit
, is n
h re
hole
– Remove trim under plenum chamber cover.

spec
es, in part or in w
♦ Vehicles ▸ 09.98 ⇒ page 78 t to the co
♦ Vehicles 10.98 ▸ 05.00 ⇒ page 84

rrectness of i
♦ Vehicles 06.00 ▸ ⇒ page 92

– Release and disconnect connector on signal horn.
l purpos
– Remove securing bolt -arrow-.

nform
ercia
Installing
m
at
om
ion
c
following:
in t
or
his
ate

do
priv
⇒ page 235 .
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
3.4 Removing and installing left ultrasonic

sensor for anti-theft alarm system -
G170- and right ultrasonic sensor for
Removing
ignition key.
– Remove upper B-pillar trim ⇒ General body repairs, interior;
Rep. Gr. 70 .
– Release connector.
– Press locking tabs -arrow- and pull ultrasonic sensor upwards
out of B-pillar trim.
Installing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
– Slide ultrasonic sensor into guides in B-pillar trim until it en‐
hole
spec
gages.
es, in part or in w
t to the co
– Install upper B-pillar trim ⇒ General body repairs, interior;
Rep. Gr. 70 .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
3.5 Removing and installing driver side cen‐

s
iva
do
r
rp
cum
tral locking switch -F59- and front pas‐

fo
en
ng
t.
yi
senger side central locking switch -
Co
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F114- rig ht
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Note
♦ The driver side central locking switch -F59- is installed in the

driver door and the front passenger side central locking switch
-F114- is installed in the front passenger door.
♦ The procedures are similar for the left and right sides.
Removing
ignition key.
– Remove front door trim ⇒ General body repairs, interior; Rep.
Gr. 70 ; Door trims .

Sharan 1996 ➤
– Remove front door lock ⇒ General body repairs, exterior; Rep.

Gr. 57 ; Front door, Removing and installing door lock .
– Unclip central locking/anti-theft alarm system switch -arrow-
from lock housing by pressing fasteners on back of switch
together.
Installing
3.6 Removing and installing central locking/

anti-theft alarm system switch -F218- in n AG. Volkswagen AG do
wage
rear lid yV
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Removing thoris nte
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au ac
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ignition key.
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erm
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ility
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wit
– Disconnect switch connector.
is n
h re
ole,
– Remove lock cylinder ⇒ General body repairs, exterior; Rep.
spec
Gr. 55 ; Rear lid; Removing and installing lock cylinder .
t to the co
– Lever off retaining plate for contact switch -1-.
– Take contact switch -2- off lock cylinder housing -3-.
rrectne
Installing
s
s o
cial p
f inform
mer
Note
atio
om
n
c
i
or
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♦ Ensure contact switch wiring is routed correctly on rear lid!
thi
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♦ Install lock cylinder securing clip on handle recess before in‐

i
o
pr
cum
stalling assembled lock cylinder. Then press lock cylinder

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fo
en
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through securing clip unit lock cylinder engages audibly.

t.
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Cop py
♦ Check installation position of contact switch by operating lock
t. rig
gh ht
yri
cylinder, before reinstalling the rear lid lock.
p by
co Vo
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Prote AG.
3.7 Removing and installing rear lid release

switch -E165-
Removing
ignition key.

Sharan 1996 ➤
– Lever off retaining plate for contact switch -3-.

– Take contact switch -2- off lock cylinder housing -1-.
Installing
3.8 Removing and installing engine com‐

partment light switch -F214-
The engine compartment light switch -F214- is located on the left
of the engine compartment near the bonnet hinge.
Removing
ignition key.
– Remove rubber boot.
– Carefully lever contact switch out -arrow-.
– Release connector.
Installing
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Install in reverse order of removal.kswagen AG does
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Note tho eo
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The function of the switch can only be guaranteed when the

nl
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switch is installed correctly. Check installation position after com‐

itte
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pleting repairs, if necessary.

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3.9 Removing and installing door contact

hole
spec
switch rear (rear lid) -F160-

es, in part or in w
t to the co
Note
rrectness of i
The door contact switch rear (rear lid) -F160- is integrated in the
l purpos
rear lid lock module.

nform
ercia
Removing
m
at
om

ion
c
ignition key.
in t
or
his
ate

do
priv

um
for
en
ng
t.
– Remove rear lid lock cylinder ⇒ General body repairs, exterior;
yi Co
op
Rep. Gr. 55 ; Rear lid; Removing and installing lock cylinder .
C py
t. rig
gh ht
yri by
Installing
op Vo
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cted agen
Prote AG.

Sharan 1996 ➤
4 Interior lightskswand
agen switchesAG does
AG. Volkswagen
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4.1 Removing
ss
and installing light switch
au ra
c
ce
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nl
pt
du
an
itte
4.1.1 Vehicles ▸ 05.00
y li
erm
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ility
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Removing
wit
, is n
h re
hole
spec
ignition key.
es, in part or in w
t to the co
– Remove left vent ⇒ Heating and air conditioning system; Rep.
Gr. 80 ; Repairing heating .
– Grasp through vent opening and locate fastener on top left of
rrectness of i
light switch.
l purpos
nform
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at
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ion
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or
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ate
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t.
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– Press fastener -arrow- on light switch back and release light co Vo
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cted
switch.
agen
Prote AG.
– Pull light switch out of dash panel.

Installing
– Insert light switch in dash panel and engage.
– Install left vent ⇒ Heating and air conditioning system; Rep.
Gr. 80 ; Repairing heating .
4.1.2 Vehicles 06.00 ▸

Removing
ignition key.
Carry out following procedures:
– Turn rotary knob part of light switch to “0”.
– Press rotary part of light switch firmly inwards -1- and turn
slightly to right -2-.
– Hold grip in this position and pull light switch out of dash panel
using grip -3-.
Installing

Sharan 1996 ➤
– Hold light switch and press rotary part of light switch firmly in‐
wards -1- and turn slightly to right -2-
– Hold grip in this position and insert light switch in dash panel en AG. Volkswagen AG
-3-. olks
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– Turn rotary knob part to “0” position, release and locate
ris
ed switch. nte
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s au ra
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nl
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, is n
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hole
spec
es, in part or in w
control adjuster -E102-
t to the co
rrectness of i
4.2.1 Vehicles ▸ 05.00
l purpos
Removing
nform
ercia
ignition key.
m
at
om
– Remove light switch ⇒ page 224 .
ion
c
in t
or
– Press locating lugs on sides of headlight range control regu‐
his
ate
lator inwards, so that the locating lugs disengage.
do
priv
cum
or
– Pull headlight range control regulator to rear out of front plate

f
en
ng
t.
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of light switch.
Co
Cop py
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– Pull off connector. rig ht
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Installing cted agen
Prote AG.
– Insert headlight range control regulator in guide on light switch
and press into front plate.
– Press locating lugs outwards until lugs locate.
– Insert light switch in dash panel and engage.
4.2.2 Vehicles 06.00 ▸

Removing
ignition key.
– Remove light switch ⇒ page 224 .
– Unclip dash panel end cover -arrows-
– Grasp through the side opening and press fasteners together
on sides of headlight range control regulator, then push switch
out of dash panel.
Installing
– Insert headlight range control regulator in guide on mounting
frame and press in.
– Install dash panel end cover.
– Install light switch switch ⇒ page 224 .
4. Interior lights and switches 225

. Volkswagen AG
Sharan 1996 ➤ wage
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Electrical systemd-byEdition 12.2008
V gu
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4.3 Removing
ss and installing switches in au ra
c
centre of dash panel
ce
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nl
pt
du
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itte
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ab
ility
4.3.1 Vehicles ▸ 05.00
ot p
wit
, is n
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Removing and installing
hole
spec
es, in part or in w
♦ Heated rear window switch
t to the co
♦ Heated windscreen switch
♦ Power window switch
rrectness of i
♦ Heated seat regulator
l purpos
♦ Switches for other optional equipment
nform
ercia
is the same for all switches and is described for only one switch.
m
at
Removing
om
ion
c
in t
r

o
his
e
ignition key.
at
do
priv
cum
– Remove switch trim in centre of dash panel. ⇒ General body
for
en
g
repairs, interior; Rep. Gr. 70 ; Dash panel

n
t.
yi Co
Cop py
– Press switch to side, by hand, until the switch is released from ht. rig
rig ht
the switch frame.
py by
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– Pull switch out of dash panel.
Prote AG.

Installing
– Push switch into switch trim in dash panel and engage.
– Install trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Dash
panel .
4.3.2 Vehicles 06.00 ▸

Removing and installing
♦ Heated rear window switch
♦ Heated windscreen switch
♦ Heated seat regulator
♦ Hazard warning light switch
♦ Switches for other optional equipment
is the same for all switches and is described for only one switch.
Removing
ignition key.
– Protect dash panel around cover with adhesive tape if neces‐
sary.
– Carefully lever switch housing (on sides) out of switch trim us‐
ing a flat blade screwdriver.
Installing

Sharan 1996 ➤
4.4 Removing and installing interior light
Note
♦ Only the lens of the interior light need be removed to replace

a bulb.
. Volkswagen AG
gen AG
♦ The interior light must be removedkswto replace a bulb in the front
a oes d
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Vol
passenger reading light. ed
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Removing au ra
c
ss
ce
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nl
– Carefully lever interior light out of roof trim using a flat-blade
pt
du
an
screwdriver -arrow A-.
itte
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ab
– Release connections and pull off.
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Installing
h re
hole
spec
es, in part or in w
t to the co
– Insert interior light in roof trim and engage.
rrectness of i
l purpos
4.4.1 Replacing front interior light bulb -W1-
nform
mercia
at
– Carefully lever lens off interior light and remove -arrow B-.
om
ion
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ate
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for
en
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– Replace bulb 12V/10W festoon bulb -arrow-.

– Insert lens again and engage.
Note
Removal, installation and replacing bulb for rear interior light -

W43- is performed in the same manner.
Replacing bulb in rear interior light W43 ⇒ page 227 .
4.4.2 Replacing rear interior light bulb -W43-
Note
Removal, installation and replacing bulb for rear interior light -

W43- is performed in the same manner.

Sharan 1996 ➤ . Volkswagen AG
gen AG does
Electrical system - Edition 12.2008 Volkswa not
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4.4.3 Replacing front passenger reading light
r
tho eo
au ra
bulb -W13- ss c
ce
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un
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an
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– Remove interior light.
itte
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rm
ab
– Release holder of glass base bulb by turning to left and pull
pe
ility
out of interior light. ot
wit
, is n
h re
– Pull out glass base bulb (12V/5W) out of holder (do not turn)
hole
spec
and replace bulb.
es, in part or in w
t to the co
– Insert holder of glass base bulb in interior light and secure by
turning to right.
rrectness of i
l purpos
nform
mercia
a
com
t
4.5 Removing and installing sliding sunroof
ion in
r
switch -E8-
te o
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s
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Removing
rp
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fo
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t.
– Switch off ignition and all electrical consumers and remove op
yi Co
ignition key.
C py
t. rig
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– Remove interior light ⇒ page 227 .
op Vo
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cted agen
Prote AG.
– Pull off connector to interior light.
– Release fasteners on both sides of sliding sunroof switch
-arrows- and take switch out of interior light.
Installing
– Insert switch in interior light and engage fasteners on sides.
– Reconnect connector and install interior light.
4.6 Removing and installing glove compart‐

ment light -W6-
4.6.1 Vehicles ▸ 05.00

Removing
– Insert flat-blade screwdriver behind top of lens and carefully
lever light out.
– Pull out lens with bulb holder and microswitch.
Installing
– Insert lens with bulb holder and microswitch in glove compart‐
ment and engage.
After working on the glove compartment light, a functional check
of the switch must be carried out. With the lid closed the lamp
must not light!

Sharan 1996 ➤
Note
Removal, installation and replacing bulb is performed in the same

manner on the footwell lights and luggage compartment lights.
4.6.2 Vehicles 06.00 ▸

Removing
– Insert flat-blade screwdriver behind side of lens and carefully
lever light out.
– Pull out lens with bulb holder.
Installing
– Insert lens with bulb holder in storage compartment and en‐
gage.
Note
Removal, installation and replacing bulb is performed in the same

manner on the footwell lights and luggage compartment lights.
4.7 Removing and installing door contact

switch
Removing and installing the
♦ Driver door contact switch -F2- .agen AG. Volkswagen AG d
w oes
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♦ Front passenger door contact
db
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ara
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♦ Rear left door contact
ut switch -F10- .
ho eo
ra
a c
ss
♦ Rear right door contact switch -F11-
ce
e
nl
pt
du
an
Is performed in the same way for all switches and is described

itte
y li
only for the front passenger door contact switch -F3- .

erm
ab
ility
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Removing
wit
, is n
h re
– Pull off rubber seal -arrow-.

hole
spec
– Carefully release spring tension of door contact switch with a

es, in part or in w
t to the co
flat-blade screwdriver and pull switch out forwards.

rrectness of i
Installing
l purpos

nform
mercia
at
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ion
c
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or
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ate
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for
en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
Electrical system - Edition 12.2008 AG. Volkswagen AG d
agen oes
olksw not
V gu
4.8 Removing and installing power window orised by ara
nte
switch and mirror adjustment switch in h eo
aut ra
s c
doors
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
4.8.1 Vehicles ▸ 05.00
ility
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ The removal and installation sequence for the front doors is
as follows.
rrectness of i
♦ The door trim panel must be removed to remove and install
switches in rear doors ⇒ General body repairs, interior; Rep.
l purpos
Gr. 70 ; Door trims .
nf
ercia
Removing
orm
m
atio
m

o
n in
c
ignition key.
or
thi
te
sd
– Position screwdriver on lower part of switch frame and care‐
iva
o
r
fully lever switch frame out.

rp
cu
o
m
f
en
ng
– Press fasteners on switch together and release.

t.
yi Co
Cop py
t. rig
– Pull off connector. opyri
gh by
Vo
ht
by c lksw
Installing Prote
cted AG.
agen
– Insert switch in cut-out of frame.
– Clip switch frame in door trim.
4.8.2 Vehicles 06.00 ▸

The removal and installation sequence is performed in the same
way for all switches and is described only for the driver door power
window switch.
Removing power window switch:
ignition key.
– Position screwdriver on lower edge of door interior handle re‐
cess and carefully lever door handle recess out
-direction of arrow-.
– Position screwdriver on lower part of switch frame and care‐
fully lever switch frame out.
Installing power window switch:
Removing mirror adjustment switch:
ignition key.

Sharan 1996 ➤
– Take out mirror adjustment switch -arrow- forwards.

AG. Volkswagen AG d
Installing mirror adjustment switch: ksw
agen oes
not
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Install in reverse order of removal. ised b ara
nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
5 Horn and dual tone horn -H1-

The dual tone horn -H1- comprises two individual fanfare horns
with different pitches. The treble horn -H2- and the bass horn -
H7- are activated together via the signal horn activation and the
dual tone horn relay -J4- . They are installed together on a bracket
which is located on the right of the vehicle behind the front bumper
cover.
5.1 Removing and installing treble horn -H2-

and bass horn -H7-
5.1.1 Removing and installing treble horn -H2-

The treble horn -H2- is located behind the front bumper on the
outer side of the right longitudinal member.
Removing
– Switch off ignition and all electrical consumers.
– Take treble horn -H2- -3- off bracket, as far as the connected
cables will allow. gen AG
. Volkswagen AG
a does
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au ra
c
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ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Release and disconnect the connector -1- and remove treble

es, in part or in w
horn -2- from vehicle.

t to the co
Installing
– Install in the reverse order of removal. When doing this, note
rrectness of i
the following:
l purpos
Note
nform
mercia
When installing, position the signal horn so it is not in contact with

at
om
io
adjacent components.
n
c
in t
or
his
ate

do
priv
⇒ page 235 .
um
for
en
ng
t.
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op
5.1.2 Removing and installing the bass horn -
C py
t. rig
gh ht
yri by
H7-
op Vo
by c lksw
cted agen
Prote AG.
The bass horn -H7- is located behind the front bumper on the
outer side of the right longitudinal member.
Removing
– Switch off ignition and all electrical consumers.

Sharan 1996 ➤

– Take bass horn -H7- -2- off bracket, as far as the connected
cables will allow.
– Release and disconnect n AGthe

. Voconnector
lkswagen AG -1- and remove bass
wage
horn -2- from Vvehicle.
does
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by ua
ed ran
Installing oris tee
th or
au a
– Install
ss in the reverse order of removal. When doing this,c note
the following:
ce
le
un
pt
an
d
itte
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rm
ab
Note
pe
ility
ot
wit
, is n
When installing, position the signal horn so it is not in contact with

h re
hole
adjacent components.
spec
es, in part or in w
t to the co
⇒ page 235 .
rrectness of i
5.2 Removing and installing dual tone horn

l purpos
relay -J4-
nform
ercia
Removing
m
The dual tone horn relay -J4- is located above the relay carrier
com
tio
behind the multifunction unit.

n in
r
te o
thi
– Open the cover -1- to gain access to the relay.

s
iva
do
r
rp
cum
fo
en
ng
t.
Note
yi Co
Cop py
ht. rig
rig ht
Relay carrier assignment ⇒ Current flow diagrams, Electrical fault
py by
co Vo
finding and Fitting locations
by lksw
cted agen
Prote AG.
Installing
5. Horn and dual tone horn H1 233

Sharan 1996 ➤
6 Taxi equipment
Since November 2002 the Sharan is also available with Taxi
equipment. The complete taxi equipment is retrofitted by the
Service Division. Refer to the Service division for enquires refer‐
ence the removal and installation of Taxi equipment.
AG. Volkswagen AG d
agen oes
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byV gu
ara
ed
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aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
7 Specified torques: lights, bulbs,

switches - interior
7.1 Specified torque: dual tone horn

Treble tone horn -H2-
Bracket securing bolts to longitudinal mem‐ M8 20 Nm
ber
Bass tone horn -H7-

Bracket securing bolts to longitudinal mem‐ M8 20 Nm
ber
7.2 Specified torque: alarm horn -H12-

Horn securing bolt to M8 20 Nm
bracket on bulkhead
AG. Volkswagen AG d
agen oes
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h
aut ra
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nl
pt
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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f
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ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
7. Specified torques: lights, bulbs, switches - interior 235

Sharan 1996 ➤
97 – Wiring
1 Vehicle diagnosis, test and informa‐
tion systems
1.1 Connecting vehicle diagnosis, testing

and information system -VAS 5051A-
and successor units
link to this workshop manual is not possible at present for tech‐ n AG. Volkswagen A
nical reasons. Please select the workshop manual “Electrical olks
wage
G do
es n
ot g
System, General Information” manually in ELSA. db
y V ua
r e an
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
236 Rep. Gr.97 - Wiring

Sharan 1996 ➤
2 Relay carrier ▸ 08.97
Caution

served ⇒ page 4 .
2.1 Removing and installing relay carrier
Note
The relay carrier with fuse holder is located behind a cover for the
relay carrier on the driver side.
Removing
– Open cover -1- for relay carrier and unclip it from the dash
panel trim.
AG. Volkswagen AG d
agen oes
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d b ara
rise nte
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au ra
ss c
ce
le
un
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an
d
itte
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erm
ab
ility
ot p
– Pull out lower cover -1- for relay carrier.

wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
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ng
t.
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Cop py
t. rig
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pyri by
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co lksw
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cted agen
Prote AG.
2. Relay carrier ▸ 08.97 237

Sharan 1996 ➤
– Release securing clips -1- from pins -3- on left and right of relay
carrier and swing them upwards.
– Press left retaining arm -2- outwards, until the locking device
on the relay carrier is pulled out of the hole -4- of the retaining
arm.
– Swing relay carrier towards rear of vehicle, to ensure sufficient
clearance for removal of additional relay carrier above the re‐
lay carrier. Then unhook relay carrier. gen AG
. Volkswagen AG
wa does
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Installing byV gu
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au ra
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pt
When installing, ensure the relay carrier locking device engages
an
d
itte
in the hole -4- of the retaining arm. The securing clips -1- engage
y li
erm
ab
on the pins -3-.
ility
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Installation of the relay carrier cover is carried out in the reverse
is n
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sequence.
ole,
spec
t to the co
rrectness o
cial p
f in
2.2 Removing and installing multi-pin con‐
form
mer
nector on back of relay carrier
atio
om
n
c
i
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Note
iv
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Multi-pin connector pin assignment ⇒ Current flow diagrams,

t.
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Electrical fault finding and Fitting locations C py
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Removing
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– Pull locking slide -1- on back of relay carrier out of housing to
stop (approx. 5 mm) -arrow-.

Sharan 1996 ➤
– Press locking lug -arrow- on multi-pin connector and pull multi-

pin connector out of relay carrier.
Installing
Note
♦ When installing, insert multi-pin connector so that the locking

pins -2- face towards the locking slide -1-.
♦ To lock locking slide, all multi-pin connectors must be installed
and each locking lug -3- must be fitted.
– Insert multi-pin connector into respective slot so that locking

pin -2- is inserted into cut-out -4-
ageand
n AG.press
Volkswinwards
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does
ing lug -3- engages. yV
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– Press locking slideho-1-
ris to stop -arrow-. tee
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ate
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2. Relay carrier ▸ 08.97 239

Sharan 1996 ➤
3 Multifunction unit (electronic central

electrics) 09.97 ▸
Caution

served ⇒ page 4 .
Note
The multifunction unit with relay carriers and fuse holder is located
behind the cover on the driver side.

The multifunction unit is equipped with self-diagnosis, which
system -VAS 5051- or successor units in “guided fault finding”
mode.
Note
Multifunction unit self-diagnosis is initiated with address word “09

- Electronic central electrics”.
3.1 Removing and installingagen

AG. Vomultifunction
lkswagen AG
does
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unit with relay
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3.1.1 Removing and installing multifunction
ce
le
un
pt
unit, vehicles ▸ 05.00

an
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ab
Removing
ility
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wit
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h re
ole,
– Open cover -1- for relay carrier and unclip it from the dash
spec
panel trim.
t to the co
rrectness o
cial p
f inform
mer
atio
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c
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Sharan 1996 ➤
– Pull out lower cover -1- for relay carrier.
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spec
es, in part or in w
t to the co
rrectness of i
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– Remove cover -1- (located under dash panel).
nf
ercia
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– Pull door seal -3- off in vicinity of dash panel.

– Prise out clip -2-.
– Remove cover on driver side -1- and disconnect connector for
footwell light.
– Release locking devices of multi-pin connectors to multifunc‐
tion unit and disconnect connectors..
– Remove cross-head screw -1- above multifunction unit.
3. Multifunction unit (electronic central electrics) 09.97 ▸ 241

Sharan 1996 ➤
– Release securing clips -1- from pins -3- on left and right of
multifunction unit and swing them upwards.
– Unhook multifunction unit from retaining arms -2-.
Installing
AG. Volkswagen AG d
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3.1.2 Removing and installing upper relay car‐ author eo
ra
rier of multifunction unit, vehicles ss c
ce
e
nl
▸ 05.00
pt
du
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itte
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ab
Removing
ility
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– Press retaining lugs -arrows- outwards and take upper relay
wit
, is n
h re
carrier out forwards.
hole
spec
es, in part or in w
t to the co
Note
If the relay carrier is to be removed completely, the relay sockets
rrectness of i
must be removed ⇒ page 247 .
l purpos
Installing
nf
ercia
orm
m
atio
om
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c
3.1.3 Removing and installing lower relay car‐

or
thi
te
sd
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rier of multifunction unit, vehicles

iv
o
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rp
cu
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▸ 05.00
m
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en
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t.
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op py
Removing t. C rig
gh ht
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– Remove upper relay carrier ⇒ page 242 .
co Vo
by lksw
cted agen
Prote AG.
– Remove multifunction unit ⇒ page 243 .
If the relay carrier is to be removed completely, perform subse‐
quent procedures:
– Remove relay sockets and fuse sockets from lower relay car‐
rier.
– Remove fuse holder ⇒ page 243 .
– Remove lower relay carrier.
Installing

Sharan 1996 ➤
3.1.4 Disconnecting multifunction unit from re‐AG. Volkswagen AG d

tainer, vehicles ▸ 05.00 yV
olksw
agen oes
not
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ed ran
– Unscrew cross-head screws -arrows- andhtake
ris multifunction tee
unit out downwards. t o or
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ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
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ole,
spec
t to the co
rrectne
3.1.5 Removing and installing fuse holder, ve‐
s
hicles ▸ 05.00
s o
cial p
f in
Removing
form
mer
atio
– Press locking lugs -arrows- upwards.
om
n
c
i
– Press fuse holder downwards and out of lower relay carrier.
or
n thi
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sd
a
Installing
iv
o
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.
3.1.6 Removing and installing upper relay car‐

06.00 ▸
Removing
Note
Before using leverage tools, mask area on dash panel using ad‐
hesive tape.
– Carefully unclip cover -1- from dash panel -arrows A-.

– Open cover -2- and unclip it from dash panel trim -arrows B-.
– Unclip side cover -3- from dash panel -arrows C-.

Sharan 1996 ➤
– Remove Torx bolts -1-.
– Unclip diagnosis connection -2- from lower dash panel trim by

pressing fasteners together.
– Remove Torx bolts -1-.
– Unclip lower dash panel trim -arrows- and remove it.
– Remove Torx bolt -arrow- above multifunction unit.
AG. Volkswagen AG d
agen oes
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ce
le
– Separate connectors -arrows-.

un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
244
by lksw
cted agen
Prote
Rep. Gr.97 - Wiring
AG.
Sharan 1996 ➤
– Release securing clips -1- from pins -3- on left and right of
multifunction unit and swing them upwards.
– Press retaining arm -2- apart lightly, to release pin -4-.
– Swing multifunction unit forwards.
lkswage es n
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byV ua
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ir se tee
tho
u or
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ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
– Unclip wiring guide -1- -arrows-.
wit
is n
h re
– Unhook multifunction unit from retaining arms.
ole,
spec
t to the co
WARNING
Ensure the relays and control units do not make contact when
rrectne
unhooking the multifunction unit. If a relay or control unit is
struck/makes contact, check contacts and socket to ensure
they are not damaged.
ss o
cial p
f inform
mer
atio
om
n
c
– Cut through cable tie -2- and remove it.
i
or
n thi
te
sd
a
– Pull relay -1- out of relay carrier.

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.
– Cut through cable tie -arrow- and remove it.

Sharan 1996 ➤
– Press retaining lugs -arrows- outwards and take upper relay

carrier out forwards.
Note
If the relay carrier is to be removed completely, the relay sockets

must be removed ⇒ page 247 .
Installing
3.1.7 Removing and installing multifunction

unit, vehicles 06.00 ▸ agen
AG. Volkswagen AG d
oes
olksw not
Removing d by
V gu
ara
ise nte
r
– Remove upper relay carrier ⇒ page 243 . aut
ho eo
ra
ss c
– Unscrew cross-head screws -arrows- and take multifunction
ce
e
nl
unit out downwards.
pt
du
an
itte
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Installing
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
3.1.8 Removing and installing lower relay car‐
nf
ercia
orm
m
atio
06.00 ▸
om
n in
or c
Removing
thi
te
sd
iva
o
r

rp
cu
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en
ng
If the relay carrier is to be removed completely, perform subse‐

t.
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op
quent procedures: C py
t. rig
gh ht
yri by
– Remove relay sockets and fuse sockets from lower relay car‐ op Vo
by c lksw
rier. cted agen
Prote AG.
– Remove fuse holder ⇒ page 243 .

– Remove lower relay carrier.
Installing
3.1.9 Removing and installing fuse holder, ve‐

hicles 06.00 ▸
Removing

Sharan 1996 ➤
– Press locking lugs -arrows- upwards.

– Press fuse holder downwards and out of lower relay carrier.
Installing
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agen oes
olksw not
yV gu
db ara
rise nte
tho eo
au ra
c
ss
ce
e
nl
pt
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an
itte
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erm
ab
ility
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3.1.10 Removing and installing relay sockets
wit
, is n
from relay carrier, all vehicles
h re
hole
spec
es, in part or in w
Removing
t to the co
– Pull relay or control unit out of relay socket.
– Press locking lugs -arrows- outwards.
rrectness of i
– Press relay socket out to rear.
l purpos
Installing
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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en
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t.
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Cop py
t. rig
gh ht
yri
3.2 Multifunction unit control unit -J501-
p by
o Vo
by c lksw
cted agen
Prote AG.
The multifunction unit control unit -J501- is equipped with self-
diagnosis, which is designed to simplify fault finding.
To localise faults, refer to chapter “Vehicle diagnosis, test and
information system” and use function “Guided fault finding”
⇒ page 236 .
3.2.1 Renewing multifunction unit control unit

-J501-
♦ Body
♦ Multifunction unit functions
♦ Renewing multifunction unit control unit

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o ot g
Sharan 1996 ➤ byV ua
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ir se
Electrical system - Edition 12.2008th o tee
or
au ac
ss
3.2.2 Reading control unit version, multifunc‐
ce
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un
pt
an
d
tion unit control unit -J501-
itte
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rm
ab
pe
ility
ot
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Body
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nform
ercia
m
a
com
tio
n in
r
te o
thi
♦ Reading control unit version
s
iva
do
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rp
c
3.2.3 Adaptation of ignition keys with radio re‐
um
fo
en
ng
t.
mote control
yi Co
Cop py
t. rig
gh ht
yri
– Connect vehicle diagnosis, test and information system -VAS p by
co Vo
5051A- to ⇒ page 236 .
by lksw
cted agen
Prote AG.
♦ Body
♦ Adaptation of ignition keys with radio remote control

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
ksw
4 Wiring harness and connector re‐
d by Vol not
gu
ara
ise
pairs
r nte
tho eo
au ra
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ce
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un
pt
an
d

itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Wiring harness and connector repairs 249

Sharan 1996 ➤
5 Renewal of aerial wiring

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o ot g
byV ua
d ran
ir se tee
tho
u or
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ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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Service

Service Department. Technical Information

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Copyright © 2015 Volkswagen AG, Wolfsburg 00056605520

27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 Removing and installing battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5.1 Removing and installing battery in engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . 9

8.3 Vehicles 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

9.2 Checking poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

9.3 Checking alternator C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

9.8 Alternator for 4-cylinder diesel engine ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

11.4 Activating and deactivating cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . 62

92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

2.5 Removing and installing windscreen washer jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

3 Rear window wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

3.1 Removing and installing rear window wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

3.2 Installing wiper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

3.3 Adjusting rear window wiper park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

4 Rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

4.3 Adjusting washer jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

5 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

5.1 Assembly overview - headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

5.3 Removing and installing pop-up washer jet cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

5.4 Removing and installing washer jet assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

5.5 Adjusting headlight washer system jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

5.6 Bleeding headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

6 Washer fluid line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

8 Specified torques: window wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

3 Fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

3.4 Replacing front fog light bulb, vehicles 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

5 Removing and installing turn signal bulb in exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . 175

6.4 Removing and installing rear light, vehicles ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

6.6 Removing and installing rear light, vehicles 11.03 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

10.3 Removing and installing ignition switch, vehicles 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . 208

10.4 Pin assignment for ignition/starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

11.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

11.2 Assembly overview - parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . h re

11.4 Removing and installing front parking aid sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

11.5 Removing and installing rear parking aid sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

1.1 Assembly overview - immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

1.2 Removing and installing immobilizer control unit J362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

1.3 Removing and installing immobilizer reader coil D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

1.4 Ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

2 Voltage converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

2.1 Removing and installing voltage converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

7.2 Specified torque: alarm horn H12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

1 Vehicle diagnosis, test and information systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

4 Wiring harness and connector repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

5 Renewal of aerial wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

27 – Starter, current supply, CCS

Danger of injury! Observe warning notices and safety regula‐

the workshop manual “Electrical System, General Information”. A

1.2 Types of battery

nical reasons. Please select the workshop manual “Electrical

System, General Information” manually in ELSA. at

1.3 Warning notices and safety regulations

the workshop manual “Electrical System, General Information”. A

link to this workshop manual is not possible at present for tech‐