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Volkswagen Amarok 2011, Workshop Manual

The Volkswagen Amarok 2011 Workshop Manual is an essential resource for anyone seeking detailed information on maintaining and repairing their vehicle. Designed for professionals and DIY enthusiasts alike, this manual provides comprehensive instructions, diagrams, and troubleshooting tips. Download your free copy today from manualshive.com and unlock the secrets of your Amarok's inner workings.

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1.4

Releasing pressure in high-pressure area   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

2

Fuel pump   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

2.1

Checking fuel pump   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

3

Fuel tank   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

3.1

Assembly overview - fuel tank   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

3.2

Removing and installing fuel tank   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

3.3

Removing and installing fuel delivery unit   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

3.4

Removing and installing fuel gauge sender G    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

3.5

Removing and installing filler neck   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

3.6

Assembly overview - fuel filter with attachments   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

3.7

Removing and installing fuel filter   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

3.8

Removing and installing fuel pump control unit J538    . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

4

Electronic power control (EPC)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

4.1

Assembly overview - accelerator module   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

4.2

Removing and installing accelerator module   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

5

Activated charcoal filter system   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

5.1

Checking fuel tank breather   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

21 - Turbocharging/supercharging   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

1

Charge air system   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

1.1

Safety precautions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

1.2

Rules for cleanliness   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

1.3

Instructions for hose connections with screw-type clips   . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

1.4

Assembly overview - charge air cooling    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

1.5

Removing and installing pressure pipe   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

1.6

Removing and installing charge pressure sender G31    . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

1.7

Removing and installing charge air cooler   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

1.8

Checking charge air system for leaks   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

2

Turbocharger   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

2.1

Assembly overview - turbocharger   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

2.2

Removing and installing turbocharger   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

2.3

Checking vacuum unit for turbocharger   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

24 - Mixture preparation - injection   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

1

Safety precautions and rules for cleanliness   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

1.1

General notes on self-diagnosis   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

2

Injection system   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

2.1

Overview of fitting locations   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

2.2

Assembly overview - air filter   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

2.3

Removing and installing air filter housing   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

2.4

Removing and installing air filter element   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

2.5

Removing and installing air mass meter G70    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

2.6

Assembly overview - intake manifold   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

2.7

Assembly overview - fuel rail   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

2.8

Removing and installing intake manifold   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

2.9

Removing and installing injectors   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

2.10 Renewing Teflon seal on injector   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

2.11 Cleaning injectors   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

2.12 Removing and installing fuel pressure sender -G247-    . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

2.13 Removing and installing throttle valve module J338    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

2.14 Cleaning throttle valve module J338    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

2.15 Assembly overview - high-pressure pump   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

2.16 Removing and installing high-pressure pump   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

2.17 Removing and installing engine control unit   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3

Checking components   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Amarok 2011 ➤

4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011

Contents    

iii

Summary of Contents for Amarok 2011

Page 1: ...enAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Workshop Manual Amarok 2011 4 cylinder injection engine 2 0 l direct injection engine turbocharger Engine ID CFP A Edition 02 2011 Service Service Department Technical Informa...

Page 2: ...Repair Groups Repair Group 00 Technical data 10 Removing and installing engine 13 Crankshaft group 15 Cylinder head valve gear 17 Lubrication 19 Cooling 20 Fuel supply system 21 Turbocharging supercharging 24 Mixture preparation injection 26 Exhaust system 28 Ignition system Technical information should always be available to the foremen and mechanics because their careful and constant adherence t...

Page 3: ...moving and installing needle bearing in from drive plate 32 2 4 Removing and installing sealing flange on gearbox side 33 3 Pistons and conrods 36 3 1 Assembly overview pistons and conrods 36 3 2 Separating new conrod 39 3 3 Piston and cylinder dimensions 39 4 Crankshaft 40 4 1 Assembly overview crankshaft 40 4 2 Allocation of crankshaft bearing shells classification 41 4 3 Crankshaft dimensions 4...

Page 4: ...e oil cooler 129 2 3 Removing and installing oil pressure switch F22 130 2 4 Removing and installing oil supply line to turbocharger 130 2 5 Checking oil pressure 130 19 Cooling 132 1 Cooling system 132 1 1 General notes on cooling system 132 1 2 Draining and filling coolant 133 1 3 Checking cooling system for leaks 136 2 Coolant hose schematic diagram 139 2 1 Coolant hose schematic diagram for ve...

Page 5: ... screw type clips 184 1 4 Assembly overview charge air cooling 184 1 5 Removing and installing pressure pipe 186 1 6 Removing and installing charge pressure sender G31 186 1 7 Removing and installing charge air cooler 186 1 8 Checking charge air system for leaks 189 2 Turbocharger 192 2 1 Assembly overview turbocharger 192 2 2 Removing and installing turbocharger 197 2 3 Checking vacuum unit for t...

Page 6: ...ust system 239 1 1 Removing and installing catalytic converter 240 1 2 Removing and installing exhaust manifold 241 1 3 Removing and installing centre silencer 242 1 4 Removing and installing rear silencer 243 1 5 Checking exhaust system for leaks 243 1 6 Aligning exhaust system free of stress 243 1 7 Installation position and specified torque of the clamp 245 28 Ignition system 247 1 Repairing ig...

Page 7: ...n be found at the joint between engine and gearbox arrow In addition there is a sticker on the toothed belt guard with engine code and serial number The engine code is also included on the vehicle data sticker The engine number consists of up to nine characters alphanu meric The first part maximum 4 characters makes up the engine code and the second part 6 characters the serial number If more than...

Page 8: ...guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 If petrol with a RON rating of less than 95 is used reduced power output and torque must be expected Amarok 2011 4 cylinder injection engine 2 0 l direct injection engine turbocharger Edition 02 201...

Page 9: ...h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 10 Removing and installing engine 1 Removing and installing engine 1 1 Removing engine Special tools and workshop equipment required Lifting tackle 2024 A Support bracket 10 222 A Hook 10 222 A 10 Shackle 10 222 A 12 Adapter 10 222 A 20 qty 2 Amarok 2011 4 cylinder injectio...

Page 10: ... t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Torque wrench V A G 1331 Torque wrench V A G 1332 Engine and gearbox jack V A G 1383 A Socket set 1 4 22 piece VAS 5528 Workshop hoist VAS 6100 Engine bung set VAS 6122 Amarok 2011 4 cylinder injection engine 2 0 l direct injection engine tu...

Page 11: ... Retainer T10014 High temperature grease G 052 133 A2 Cable ties Square timber 10 x 30 x 10 cm Procedure Note Before carrying out further work remove the battery Check whether a coded radio is fitted Obtain anti theft coding be forehand if necessary The engine is removed upwards The gearbox remains installed All cable ties that are opened or cut through when the engine is removed must be renewed r...

Page 12: ...r fuel hydraulics acti vated charcoal filter system coolant and refrigerant brake fluid and vacuum and electrical wiring in their original po sitions To avoid damage to lines ensure sufficient clearance from all moving or hot components Cut through cable ties carefully and reinstall in the same position Remove bonnet General body repairs exterior Rep gr 55 Bonnet Remove engine guard if fitted Body...

Page 13: ...n connection to release the pressure Wear eye and hand protection when performing any type of repair work on the fuel system Disconnect fuel lines 1 and 2 Disconnect fuel lines 1 from bracket 2 Vehicles with air conditioning system Note To prevent damage to condenser or to refrigerant lines and ho ses ensure that lines and hoses are not stretched kinked or bent To facilitate removing and installin...

Page 14: ... i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew nut 2 of battery positive cable 1 Unhook clips 1 and 3 Uncover cable harness 2 Unscrew shear bolts 1 and remove bow 3 Note Shear bolts must always be renewed Release and pull off connector 2 Unhook clips 2 and 3 Release and pull off connector 1 Open bracket 4 and detach wiring harness Amarok 20...

Page 15: ...G Carefully cut through cable ties arrows Lay wiring harness on engine and secure Release clip 2 disconnect water hose 1 from radiator 3 at bottom right and allow water to drain Disconnect water hoses 2 and 3 from radiator 1 at top left Disconnect water hoses from water pipes Pull line 2 out of brake servo Open clip 1 and remove coolant hose 3 Remove vane pump for power steering with hoses connect...

Page 16: ...a g e n A G To do this release circulating pump V 51 2 from bracket 1 in order to access bolt Remove air filter housing page 207 Unplug all necessary electrical connectors Disconnect all necessary vacuum hoses Remove bolts 1 Detach retaining clips 3 with water hose 4 from cowling 2 Disengage cowling 2 at left and right To do this press re taining lever 1 forwards using a screwdriver and raise cowl...

Page 17: ...racket 10 222 A Secure hook 10 222 A 10 and adapter 10 222 A 20 to support bracket 10 222 A Connect adapter 10 222 A 20 to gearbox transport eye Remove bolts 2 and 3 Only unscrew bolt 1 beneath starter Caution Do not unscrew the two upper bolts 1 Unscrew all connecting bolts for engine gearbox at bottom and in middle The two upper bolts initially remain screwed in Engage lifting tackle 2024 A on w...

Page 18: ...he crankshaft whilst doing this Caution Only a few millimetres of space are available between plenum chamber and radiator lock carrier for removing and installing the engine The engine must therefore be guided carefully when raising and lowering Raise and lower the engine slowly with the assistance of a second mechanic The workshop hoist VAS 6100 must also be guided care fully when raising and low...

Page 19: ...edle bearing arrow in crankshaft If it is damaged or has turned blue it must be renewed page 44 If it is not damaged lightly grease with high temperature grease G 052 133 A2 Slightly grease the journal not the teeth of the gears as well 1 2 Securing engine on engine and gearbox support VAS 6095 Special tools and workshop equipment required Lifting tackle 2024 A Workshop hoist VAS 6100 Engine and g...

Page 20: ... to avoid damage to engine Secure engine to engine and gearbox support VAS 6095 1 3 Notes on installing Special tools and workshop equipment required Vehicle diagnosis testing and information system VAS 5051B Procedure Install in reverse order In the process note the following Caution Only a few millimetres of space are available between plenum chamber and radiator lock carrier for removing and in...

Page 21: ...wering engine make sure that rollers of belt drive and turbocharger do not damage radiator When raising and lowering engine pay attention to lines and hoses to prevent these from being damaged Check whether dowel sleeves for centering engine gearbox are in cylinder block install if necessary gearbox removed Check clutch release bearing for wear and if necessary re place gearbox removed Caution Bri...

Page 22: ...ne guard Install bonnet General body repairs exterior Rep gr 55 Bonnet Fit new screw type clips with barb notes on screw type clips page 184 To prevent the high pressure pump from running while it is empty and to ensure that the engine starts quickly after parts have been renewed it is important to observe the following If components of fuel system between fuel tank and high pres sure pump are rem...

Page 23: ...st subsequently be renewed Engine mounting connection to engine support may only be loosened if engine mounting is to be renewed Secure engine support 1 to crankcase with bolts 3 Always renew bolts 3 and tighten to 50 Nm 180 1 2 turn Right engine mounting to frame Secure engine mounting A to frame with bolts 1 Always renew bolts 1 and tighten to 50 Nm 90 1 4 turn Left engine mounting to frame Secu...

Page 24: ...ine support Bolt new engine mounting 3 to engine support 2 with nut 1 Always renew nut 1 and tighten to 90 Nm 90 1 4 turn Gearbox mounting to gearbox Secure gearbox mounting A to gearbox with bolts 1 Always renew bolts 1 and tighten to 50 Nm 90 1 4 turn Removing and installing gearbox mounting Rep gr 34 Gearbox mounting to gearbox cross member Secure gearbox mounting A to gearbox cross member with...

Page 25: ... belt routing page 21 Caution If a used belt runs in the opposite direction when it is refitted this can cause breakage Before removing mark direction of rotation of poly V belt with chalk or felt tipped pen for re in stallation Removing and installing page 22 When installing make sure it is properly seated on pulleys 2 Guide roller 20 Nm 3 Bolt Renew 150 Nm 90 further Use counterhold T10355 when ...

Page 26: ... spanner to slacken poly V belt Lock with locking tool T40098 Removing and installing page 21 8 Bracket for ancillaries With oil filter and engine oil cooler Removing and installing ancillary bracket page 24 Removing and installing engine oil cooler page 129 9 Alternator Removing and installing Rep gr 27 10 Bolt Specified torque Rep gr 27 11 Bolt Tightening sequence page 21 12 Bolt Specified torqu...

Page 27: ...llaries first tighten bolt 4 Tighten bolts in the sequence 1 5 in 3 stages as follows 1 Tighten bolts hand tight 2 Tighten bolts to 20 Nm 3 Turn bolts 90 further Poly V belt route with air conditioning system 1 Vibration damper 2 Guide roller 3 Poly V belt tensioning element 4 Alternator 5 Vane pump 6 Air conditioner compressor Poly V belt route without air conditioner 1 Vibration damper 2 Guide r...

Page 28: ... this can cause breakage Before removing mark direction of rotation of poly V belt with chalk or felt tipped pen for re installation To slacken poly V belt turn tensioner in direction of arrow Lock tensioner with locking tool T40098 Remove poly V belt from tensioner Remove bolt 1 and take off tensioner for poly V belt from bracket for ancillaries Installing Installation is carried out in the rever...

Page 29: ...en it is refitted this can cause breakage Before removing mark direction of rotation of poly V belt with chalk or felt tipped pen for re installation To slacken poly V belt turn tensioner in direction of arrow Lock tensioner with locking tool T40098 Remove poly V belt Installing Installation is carried out in the reverse order When installing note the following Note Alternator and air conditioner ...

Page 30: ...098 Release tensioner Check that poly V belt is properly seated Start engine and check that poly V belt runs properly 1 4 Removing and installing ancillary brack et Special tools and workshop equipment required Drip tray for workshop hoist VAS 6208 Locking tool T40098 Removing Drain coolant page 133 Caution If a used belt runs in the opposite direction when it is refitted this can cause breakage B...

Page 31: ...ool T40098 Remove poly V belt Remove bolt 1 and take off tensioner for poly V belt from bracket for ancillaries Note Place a cloth underneath bracket for ancillaries to catch any es caping engine oil Detach connector 2 from oil pressure switch F22 1 Unbolt water pipe Item 19 page 141 from bracket for an cillaries Release clip 3 from pressure hose 4 Release hose clip arrow from throttle valve modul...

Page 32: ...onditioner compressor Caution Danger of damage to refrigerant lines and hoses Do NOT stretch kink or bend refrigerant lines and hoses Tie up air conditioner compressor together with refrigerant ho ses to longitudinal member refrigerant hoses remain connec ted Continuation for all vehicles Note Hydraulic lines and vane pump remain connected Unscrew bolts 1 from front through belt pulley unscrew bol...

Page 33: ...the reverse order When installing note the following Specified torques page 19 Note Renew bolts that are tightened with specified further tightening angle Renew O rings and seals Coat O rings 4 with coolant additive coolants Electronic parts catalogue Insert connection 2 into coolant pump housing 3 Push bracket for ancillaries 1 onto connection fit bolts and tighten tightening sequence Install van...

Page 34: ... Turn vibration damper to TDC position arrow using coun terhold T10355 Notch on vibration damper must align with arrow marking on cover for timing chains bottom Remove bolt for vibration damper using counterhold T10355 Caution Risk of damage to engine To avoid disturbing valve timing do not turn crankshaft out of TDC position when vibration damper is removed Installing Specified torque page 19 Ins...

Page 35: ... Sealing flange with oil seal Removing and installing page 33 Renew complete only Do not oil or grease oil seal sealing lip Use support sleeve sup plied when installing Before installing re move oil residue from crankshaft journal using a clean cloth 3 Bolt Tightening sequence page 30 4 Drive plate To loosen securing bolts lock using 3067 Removing and installing page 30 5 Bolt 60 Nm 90 Renew 6 Nee...

Page 36: ...A G Sealing flange at gearbox end tightening sequence Tighten bolts 1 to 8 in the sequence shown 1 Screw in bolts hand tight 2 Tighten bolts to 9 Nm Installing intermediate plate Hook intermediate plate onto sealing flange and slide onto dowel sleeves arrows 2 2 Removing and installing drive plate Special tools and workshop equipment required Counterhold tool VW 558 Depth gauge Hexagon bolt M8 40 ...

Page 37: ... VW 558 in cylinder block and drive plate as shown Installation position of counterhold A to loosen B to tighten Installing drive plate Fit drive plate without washer A first Fit used securing bolts 3 and tighten to 30 Nm Check dimension between drive plate and cylinder block at three points and calculate average Note Measure through hole in drive plate to milled surface of cylinder block When mea...

Page 38: ... m e n t C o p y r i g h t b y V o l k s w a g e n A G If specification is not attained Remove drive plate again and fit shim A Tighten bolts 3 again to 30 Nm Repeat measurement If the specification is not reached re place all securing bolts and tighten Specified torque page 29 2 3 Removing and installing needle bearing in from drive plate Special tools and workshop equipment required Pipe section...

Page 39: ...move needle bearing using pipe section VW 421 and workshop press Thinner of pipe section VW 421 to drive plate Press in needle bearing using pipe section VW 418 A and workshop press as far as stop Installation position closed side of needle bearing to engine Install drive plate page 30 2 4 Removing and installing sealing flange on gearbox side Special tools and workshop equipment required Hand dri...

Page 40: ...lange at gearbox end Installing Specified torques Silicone sealant Electronic parts catalogue Note Observe use by date of silicone sealant The sealing flange must be installed within 5 minutes of ap plying the silicone sealant Remove sealant residues from cylinder block with a flat scra per WARNING Risk of eye injury Wear safety goggles Remove sealant residues from sealing flange e g with rotat in...

Page 41: ...be installed within 5 minutes after ap plying the silicone sealant The bead of sealant must not be thicker than specified other wise excess sealant can enter the sump and obstruct the strainer in the oil intake pipe Fit guide sleeve T20097 onto crankshaft journal Push sealing flange over guide sleeve T20097 onto crank shaft journal and tighten bolts immediately tightening se quence Note After inst...

Page 42: ...allation posi tion The conrod bearing cap only fits in one position and only on the appro priate conrod due to the breaking procedure cracking separating the cap from the conrod Mark with cylinder num ber A Installation position Marking B faces to wards pulley end Separating new conrod page 39 3 Bearing shells Installation position page 38 Do not interchange used bearing shells mark Axial clearanc...

Page 43: ...raper ring 2 parts Install such that upper steel band ring gap is offset by 120 relative to adjacent compression ring TOP or R marking must face upwards towards piston crown Offset gaps of individual parts of oil scraper ring Checking ring gap page 37 Ring to groove clearance cannot be checked 11 Conrod Renew as set only Mark with cylinder number A Installation position Marking B faces towards pul...

Page 44: ...s and workshop equipment required Inside caliper 50 100 mm Caution The cylinder bore may not be worked on reboring honing grinding may not be carried out using workshop tools This will damage the surface of the cylinder bore Take measurements at 3 positions in both lateral direction A and longitudinal direction B Difference between actual and nominal diameter max 0 08 mm Note Cylinder bores must n...

Page 45: ...od to cylinder Lightly clamp conrod in a vice using aluminium vice jaws as shown in illustration Note Only clamp the conrod lightly in order to avoid damaging it Conrod is clamped below dashed line Unscrew both bolts arrows approx 5 turns Using a plastic hammer carefully knock against conrod bear ing cap in direction of arrow until it is loose 3 3 Piston and cylinder dimensions Caution The cylinde...

Page 46: ...ing shells mark Marking of crankshaft bearing shells classifi cation page 41 3 Crankshaft After removing place it down so that the sender wheel item 5 is not damaged and the crank shaft does not rest on the sender wheel If the crankshaft is re newed the bearing shells must be realloca ted to bearing cap page 41 Axial clearance page 43 Radial clearance page 43 Do not rotate crankshaft when checking...

Page 47: ...tightening sequence Tighten crankshaft bolts in the sequence 1 5 as follows 1 Bolts 1 10 and arrows hand tighten 2 Bolts 1 10 pre tighten to 65 Nm 3 Bolts 1 10 turn 90 further with fixed wrench 4 Pre tighten bolts arrows to 20 Nm 5 Turn bolts arrows 90 further using a fixed wrench 4 2 Allocation of crankshaft bearing shells classification Bearing shells of the correct thickness are allocated to th...

Page 48: ...n the sump sealing surface or in the front end gearbox side of the cylinder block Identification on cylinder block is allocated to upper bearing shell bearing shell for cylinder block Note letters and identify colour code to be installed based on table Marking on bearing shell for bearing cap Identification on crankshaft is allocated to lower bearing shell bearing shell for bearing cap Note letter...

Page 49: ...crankshaft Special tools and workshop equipment required Universal dial gauge bracket VW 387 Dial gauge VAS 6079 Procedure Screw dial gauge VAS 6079 with universal dial gauge holder VW 387 onto cylinder block and set against crank web Press crankshaft against dial gauge by hand and set gauge to 0 Push crankshaft away from dial gauge and read off value Axial clearance New 0 07 0 23 mm Wear limit 0 ...

Page 50: ...ponding to the width of the bearing on the bearing journal or in the bearing shells Plastigage must rest in middle of bearing shell Fit main bearing caps and tighten to 60 Nm without rotating crankshaft Remove main bearing cap again Compare width of Plastigage with the measurement scale Radial clearance New 0 017 0 037 mm Wear limit 0 15 mm 4 6 Pulling needle bearing out of and driving into cranks...

Page 51: ...o p y r i g h t b y V o l k s w a g e n A G Pull needle bearing out using commercially available internal puller e g KUKKO 21 2 and KUKKO 22 1 A Installing Note The lettering on the needle bearing must be visible when installed Drive in needle bearing using drift VW 207 C or centring mandrel 3176 Drive needle bearing in carefully Constantly measure insertion depth when driving in Renew bearing if ...

Page 52: ...stic protectors fitted to protect the open valves must only be removed immediately before fitting the cylinder head When fitting a new cylinder head or cylinder head gasket drain off all the old coolant and refill with new coolant 1 Cylinder head gasket Renew Observe installation po sition Part number to cylinder head 2 Bolt 25 Nm 3 Transport lug 4 Bolt Tighten in 2 stages 1 Tighten to 8 Nm 2 Use ...

Page 53: ...e cover panel 9 Cap With seal 10 O ring Renew Lubricate with engine oil 11 Plug 12 To intake manifold 13 Heat shield 14 Bolt 20 Nm 15 Bolt 20 Nm 16 To intake manifold turbocharger 17 Breather pipe 18 O ring No replacement part available 19 Seal No replacement part available 20 Bolt Tightening sequence page 48 21 Crankcase breather 22 Seal No replacement part available 23 Seal Renew if damaged 24 V...

Page 54: ...ghtening torque Note Bolts are self tapping When renewing cylinder head only genuine bolts may be used since cylinder head is supplied without thread to attach crankcase breather system Threads may not be tapped with a thread tap Tighten bolts for crankcase breather in the sequence 1 10 to 11 Nm Checking cylinder head for distortion Use straight edge and feeler gauge to measure cylinder head for d...

Page 55: ... guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Removal tool T10352 and removal tool T10352 1 Counterhold tool T10355 Locking pin T40011 Assembly pin T40196 Amarok 2011 4 cylinder injection engine 2 0 l direct injection engine turbocharger Edition...

Page 56: ... intake and exhaust system with suitable plugs for example from engine bung set VAS 6122 WARNING Hot steam hot coolant can escape risk of scalding The cooling system is under pressure when the engine is hot Cover filler cap on expansion tank with a cloth and open carefully to dissipate pressure Remove engine guard if fitted Body front Rep gr 50 Engine guard Drain coolant page 133 Remove catalytic ...

Page 57: ...o p y r i g h t b y V o l k s w a g e n A G Release and remove clip 2 for fuel return line 1 Release clip 2 for fuel pressurisation line 3 and detach from high pressure pump 1 Disconnect electrical connectors 1 and 3 from air filter hous ing Release air intake hose 3 from air filter housing 1 Pull off vacuum hose 2 Unscrew securing bolt for air filter housing in area of coolant expansion tank With...

Page 58: ...module J338 Unscrew bolt 1 from pressure pipe 2 and remove pressure pipe 2 Unplug following electrical connectors 2 From knock sensor 1 G61 and lay to one side 3 From variable intake manifold valve N316 fuel pressure sender G247 and Hall sender G40 4 From injectors 5 From throttle valve module J338 6 From intake air temperature sender G42 Unplug electrical connections 1 and 2 and lay wiring to one...

Page 59: ...c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove intake manifold support remove securing nut 1 and bolt 2 Disconnect coolant hose arrow Release connectors arrows and simultaneously detach all connectors from ignition coils Remove ignition coils using puller T40039 Unscrew spark plugs using spark plug socket and extension 3122 B ...

Page 60: ... e n t C o p y r i g h t b y V o l k s w a g e n A G Disconnect crankcase breather hose 1 Unscrew bolts arrows remove crankcase breather system and detach from hose 2 for crankcase breather system in direction of arrow Unscrew bolts 1 and 2 and lay oil supply line to one side Unscrew bolt 3 and lay coolant line to one side Detach connector 2 from oil pressure switch F22 1 Unplug electrical connect...

Page 61: ... c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew bolts arrows and remove support for turbocharger Unscrew bolts arrows on oil return line Unscrew nuts arrows and remove catalytic converter page 240 Detach connector from inlet camshaft control valve 1 N205 1 Unscrew bolts arrows and remove inlet camshaft control valve 1 N205 Am...

Page 62: ... g e n A G Unscrew bolts 1 to 5 and detach top cover for timing chain Turn vibration damper to TDC position arrow using coun terhold T10355 Notch on vibration damper must align with arrow marking on bottom cover for timing chains Markings 1 on camshafts must face upwards Caution The timing valve has a left hand thread Depending on model remove regulating valve using removal tool T10352 or removal ...

Page 63: ...to TDC position arrow using coun terhold T10355 Notch on vibration damper must align with arrow marking on cover for timing chains bottom Use a waterproof pen to mark drive chain chain sprockets arrows Remove sealing plug arrow Insert scriber or suitable screwdriver in hole of chain tensioner in direction of arrow 1 and lift locking element for chain ten sioner Turn crankshaft in opposite directio...

Page 64: ...h t b y V o l k s w a g e n A G Remove bolt 1 and guide tensioning rail 2 downwards Use screwdriver to release catch and press off top guide rail 3 forwards Remove camshaft timing chain from camshaft sprockets Caution Avoid damage to valves and piston crowns Do not turn the crankshaft after the camshaft timing chain has been removed from the cylinder head Turn sealing plugs arrows 90 anti clockwis...

Page 65: ...ge to sealing surfaces Carefully remove sealant residue from cylinder head and cylinder block Ensure that no long scores or scratches are made on the surfaces Avoid damage to cylinder block No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block Ensure that cylinder head gasket seals properly Carefully remove remains of emery and abrasives D...

Page 66: ...ng a new cylinder head or cylinder head gasket the engine oil and coolant must be changed Position cylinder head gasket Note centring pins in cylinder block arrows Check installation position of cylinder head gasket The part number should be legible from the inlet side WARNING When turning crankshaft make sure that no components are damaged by timing chain If crankshaft is turned in the meantime p...

Page 67: ...n the drive chain sprocket markings must align arrows Use spanner to turn inlet camshaft in direction of arrow and fit timing chain Attach bearing saddle and screw in bolts arrows hand tight Remove locking pin T40011 Tighten bolts arrows for bearing saddle Install regulating valve Insert bolts 1 2 Tighten bolts for cylinder head in sequence 1 and 2 in 3 stages in total page 46 Perform further asse...

Page 68: ... h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 3 Checking compression Special tools and workshop equipment required Spark plug socket and extension 3122 B Puller T40039 Compression tester V A G 1763 Test procedure Note Engine oil temperature min 30 C Battery voltage at least 12 7 V Amarok 2011 4 cylinder injection en...

Page 69: ...n tester V A G 1763 and adapter V A G 1763 6 Note Using compression tester Operating instructions Operate starter until tester shows no further pressure in crease Compression pressures New bar pressure Wear limit bar bar pressure Difference between cylinders bar pres sure 11 0 14 0 7 0 max 3 0 Install ignition coils with final output stages Rep gr 28 Note Faults will have been stored in the memory...

Page 70: ...u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unbolt earth cable 1 and remove bolt Remove vacuum hose 3 from vacuum pump 2 Unscrew bolts arrows and remove vacuum pump Note The vacuum pump must not be dismantled Installing Specified torques page 46 Perform assembly in reverse order of removal When doing this observe the following Clean sealing surfaces Place gasket on vacuum pump insert 2...

Page 71: ...O ring Renew Lubricate before instal ling 2 Dipstick guide tube 3 Bolt 9 Nm 4 Bolt 9 Nm 5 Inlet camshaft control valve 1 N205 Removing and installing page 66 6 Seal Lubricate before instal ling Renew if damaged 7 Bolt Tightening sequence page 66 8 Timing chain cover top Removing and installing page 66 9 Seal Renew if damaged 10 O ring Renew Lubricate before instal ling 11 Dowel pins For centring c...

Page 72: ...bolts to 9 Nm Timing chain cover bottom tightening sequence Tighten bolts 1 to 15 in two stages in the sequence shown 1 Tighten bolts to 8 Nm 2 Turn bolts 45 further 2 2 Removing and installing inlet camshaft control valve 1 N205 Removing Detach connector from inlet camshaft control valve 1 N205 1 Unscrew bolts arrows and remove inlet camshaft control valve 1 N205 Installing Installation is carrie...

Page 73: ...05 1 Unscrew bolts arrows and remove inlet camshaft control valve 1 N205 Unscrew bolts 1 to 5 and detach top cover for timing chain Installing Installation is carried out in the reverse order When installing note the following Specified torque 2 1 Assembly overview timing chain cover page 65 Note Renew O ring Lubricate seal and O ring with engine oil Install timing chain cover top tightening seque...

Page 74: ...s w a g e n A G Counterhold tool T10355 Thrust piece T10368 Removing Caution If a used belt runs in the opposite direction when it is refitted this can cause breakage Before removing mark direction of rotation of poly V belt with chalk or felt tipped pen for re installation To slacken poly V belt turn tensioner in direction of arrow Lock tensioner with locking tool T40098 Remove bolt 1 and take of...

Page 75: ...tion damper must align with arrow marking on bottom cover for timing chains Remove bolt for vibration damper using counterhold T10355 Remove vibration damper Note Always use thrust piece T10368 when fitting bolt for vibration damper to avoid damaging splines Screw bolt for vibration damper and thrust piece T10368 back in Caution Risk of damage to engine To avoid disturbing valve timing do not turn...

Page 76: ...fter applying the silicone sealant Renew bolts that are tightened with specified further tightening angle Gaskets oil seals and self locking nuts must be renewed Spray sealing surface with sealant remover and leave to act Remove sealant residues from cylinder block with a flat scra per WARNING Risk of eye injury Wear safety goggles Mask oil seal on both sides with adhesive tape to make sure the se...

Page 77: ...rface of cover as illustrated Thickness of sealant bead 2 3 mm Note The cover must be installed within 5 minutes after applying the silicone sealant The bead of sealant must not be thicker than specified other wise excess sealant can enter the sump and obstruct the strainer in the oil intake pipe Install cover immediately and tighten bolts tightening se quence Fig Timing chain cover bottom tighten...

Page 78: ...not guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Locking tool T40098 Counterhold tool T10355 Thrust piece T10368 Thrust piece T10354 Amarok 2011 4 cylinder injection engine 2 0 l direct injection engine turbocharger Edition 02 2011 72 Rep gr 15 ...

Page 79: ...direction of rotation of poly V belt with chalk or felt tipped pen for re installation To slacken poly V belt turn tensioner in direction of arrow Lock tensioner with locking tool T40098 Remove poly V belt from pulley on vibration damper Caution Risk of damage to engine To avoid disturbing valve timing do not turn crankshaft out of TDC position when vibration damper is removed Remove engine guard ...

Page 80: ...10368 in its place Pull out oil seal using puller hooks T20143 2 Installing Specified torques page 65 Clean contact surface and sealing surface Unscrew thrust piece T10368 Use thrust piece T10354 and bolt for vibration damper to pull in oil seal arrow onto stop Note Renew bolt for vibration damper Renew O ring Further assembly is basically the reverse of the dismantling se quence In the process no...

Page 81: ...sioner Is spring loaded Before removing lock in place using locking pin T40011 3 Tensioning rail for timing chain 4 Guide pins 20 Nm 5 Bolt 9 Nm 6 Regulating valve Left hand thread 35 Nm Depending on model remove using removal tool T10352 or remov al tool T10352 1 7 Bolt Renew 20 Nm 90 further 8 Washer 9 Bearing saddle 10 Guide rail for camshaft tim ing chain 11 Camshaft housing 12 Camshaft timing...

Page 82: ... n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Crankshaft chain sprocket installation position The two sections arrows must be aligned 2 7 Removing and installing camshaft tim ing chain Special tools and workshop equipment required Locking tool T40098 Counterhold tool T10355 Removal tool T10352 and removal tool T10352 1 Amarok 2011 4 cy...

Page 83: ... m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Locking pin T40011 Removing Remove timing chain cover top page 67 Caution The timing valve has a left hand thread Depending on model remove regulating valve using removal tool T10352 or removal tool T10352 1 in direction of arrow Remove bolts arrows and detach bearing saddle Remove engine guard if fitted Body fr...

Page 84: ...ng on bottom cover for timing chains Markings 1 on camshafts must face upwards Remove lower timing chain cover page 67 Press oil pump chain tensioner in direction of arrow and lock in place using locking pin T40011 Remove oil pump chain tensioner 1 Remove oil pump chain Insert scriber or suitable screwdriver in hole of chain tensioner in direction of arrow 1 and lift locking element for chain ten ...

Page 85: ...ve timing chain Installing Specified torque 2 6 Camshaft timing chain exploded view page 75 Note Following procedure must be carried out in a single operation This requires a 2nd mechanic Timing chain links with coloured markings must be positioned at markings on chain sprockets Continue to hold wrench until tensioning rail is installed Fit timing chain onto exhaust camshaft Fit timing chain onto ...

Page 86: ...ll timing chain cover top page 67 Install tensioner for poly V belt page 21 Install poly V belt page 22 Fit engine guard if available Body front Rep gr 50 En gine guard 2 8 Assembly overview balancer shaft timing chain 1 Bolt Renew 9 Nm 2 Balancer shaft Exhaust side Must always be re newed if removed Lubricate bearing with engine oil Renewing page 87 3 Tube for balancer shaft Installation position...

Page 87: ...Item 9 page 80 will need to be renewed Tightening sequence page 82 13 Guide rail For timing chain 14 Guide pins 20 Nm 15 Tensioning plate For timing chain 16 Guide pins 20 Nm 17 Timing chain Removing page 82 18 Chain sprocket Installation position page 76 19 Guide rail For balancer shaft timing chain 20 Guide pins 20 Nm Tube for balancer shaft installation position Lug on tube for balancer shaft m...

Page 88: ...bricant that wears off after a short period and thus the tooth backlash is automatically set With new bolt tighten as follows 1 Tighten with torque wrench initially to 10 Nm 2 Turn intermediate shaft sprocket There must be no play in intermediate shaft sprocket otherwise loosen bolt and tighten again 3 Tighten with torque wrench to 25 Nm 4 Use fixed wrench to turn 90 further 2 9 Removing and insta...

Page 89: ...emove timing chain Installing Specified torque 2 8 Assembly overview balancer shaft timing chain page 80 Turn intermediate shaft sprocket balancer shaft to markings arrows Note Timing chain links with coloured markings must be positioned at markings on chain sprockets Fit timing chain The timing chain links with coloured markings must be positioned at the markings on the chain sprockets Fit guide ...

Page 90: ... For illustration purposes the markings on intermediate shaft sprocket balancer shaft are shown with the chain removed Further assembly is basically the reverse of the dismantling se quence In the process note the following Install camshaft timing chain page 76 Install timing chain cover bottom page 67 Install timing chain cover top page 67 Install tensioner for poly V belt page 21 Install poly V ...

Page 91: ...y V o l k s w a g e n A G Puller T10055 Removing Note The balancer shaft for the inlet camshaft must always be renewed after removing Remove toothed belt for coolant pump page 146 Remove timing chain cover top page 67 Remove engine guard if fitted Body front Rep gr 50 Engine guard Remove lower timing chain cover page 67 Remove camshaft timing chain page 76 Remove balancer shaft timing chain page 8...

Page 92: ...nd force out bal ancer shaft in direction of arrow Installing Note Due to the small amount of play between the balancer shaft and cylinder block the balancer shaft may need to be installed chilled Check whether the balancer shaft can be fitted into the cylinder block without exerting force If this is not the case the balancer shaft must be chilled before installing Specified torque 2 8 Assembly ov...

Page 93: ...the tooth backlash Mark faces of gear teeth of intermediate shaft sprocket with paint arrows Insert intermediate shaft sprocket marking on balancer shaft must be positioned between markings on faces of gear teeth Tighten bolt 1 for intermediate shaft sprocket tightening se quence page 82 Check markings on intermediate shaft sprocket balancer shaft arrow Assembly is performed analogously in the rev...

Page 94: ... t C o p y r i g h t b y V o l k s w a g e n A G Puller T10394 Puller T10055 Removing Note The balancer shaft for the inlet camshaft must always be renewed after removing Remove timing chain cover top page 67 Remove engine guard if fitted Body front Rep gr 50 Engine guard Remove lower timing chain cover page 67 Remove camshaft timing chain page 76 Remove balancer shaft timing chain page 82 Unscrew...

Page 95: ... bal ancer shaft Installing Note Due to the small amount of play between the balancer shaft and cylinder block the balancer shaft may need to be installed chilled Check whether the balancer shaft can be fitted into the cylinder block without exerting force If this is not the case the balancer shaft must be chilled before installing Specified torque 2 8 Assembly overview balancer shaft timing chain...

Page 96: ...shaft module page 82 Install camshaft timing chain page 76 Install timing chain cover bottom page 67 Install timing chain cover top page 67 Install tensioner for poly V belt page 21 Install poly V belt page 22 Fit engine guard if available Body front Rep gr 50 En gine guard 2 12 Checking valve timing Remove timing chain cover top page 67 Note Use a ratchet spanner with a 24 mm socket to turn the v...

Page 97: ... s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G If the specified value is achieved measure the distance be tween the marking on the inlet camshaft B and the marking on the exhaust camshaft C Specification 124 126 mm Note Offset of one tooth means a deviation of approx 6 mm from the specified value If an offset is found the timing chain must be...

Page 98: ...linder head 3 Valve guide Check page 112 4 Valve stem seal Renew with cylinder head fitted page 109 with cylin der head removed page 109 5 Valve spring 6 Valve spring plate 7 Valve cotters 8 Hydraulic compensation el ement Do not interchange Oil contact surface 9 Exhaust camshaft Removing and installing page 94 Check radial clearance with Plastigage roller rocker fingers re moved Radial clearance ...

Page 99: ...l clearance 0 024 0 066 mm Runout max 0 04 mm 15 Cap Renew Remove with cylinder head cover installed pierce on one side of cover with an awl and pry out 16 Inlet valve Do not rework Only lapping in is permitted Valve dimensions page 94 Checking valve guides page 112 Cylinder head cover release Undo and remove cylinder head cover in the sequence 1 6 Tightening sequence for cylinder head cover Renew...

Page 100: ...i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Valve dimensions Note Inlet and exhaust valves must not be reworked Only lapping in is permitted Dimension Inlet valve Exhaust valve a mm 33 85 0 10 28 0 0 1 b mm 5 98 0 01 5 96 0 01 c mm 104 0 0 2 101 9 0 2 α 45 45 3 2 Removing and installing camshafts Special tools and workshop equipment required Puller T40039 Removal tool T10352 ...

Page 101: ...VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Locking pin T40011 Thrust piece T10174 Assembly pin T40196 Spacers T40191 Amarok 2011 4 cylinder injection engine 2 0 l direct injection engine turbocharger Edition 02 2011 3 Valve...

Page 102: ...e integrated into cylinder head and cyl inder head cover Camshaft timing chain must be relieved of tension before you remove cylinder head cover Renew sealing cap if cylinder head cover has been detached Fit cable tie in same place when installing Disconnect electrical connectors 1 and 3 from air filter hous ing Release clip 4 and detach hose Release air intake hose 3 from air filter housing 1 Pul...

Page 103: ... C o p y r i g h t b y V o l k s w a g e n A G Remove ignition coils using puller T40039 Disconnect crankcase breather hose 1 Unscrew bolts arrows remove crankcase breather system and detach from hose 2 for crankcase breather system in direction of arrow Disconnect line arrows Detach and remove electrical connector 1 from Hall sender G40 Detach connector from inlet camshaft control valve 1 N205 1 ...

Page 104: ...A G Unscrew bolts 1 to 5 and detach top cover for timing chain Caution The timing valve has a left hand thread Remove regulating valve using removal tool T10352 1 in di rection of arrow Remove bolts arrows and detach bearing saddle Remove engine guard if fitted Body front Rep gr 50 Engine guard Turn vibration damper to TDC position arrow using coun terhold T10355 Notch on vibration damper must ali...

Page 105: ...a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Use a waterproof pen to mark drive chain at marks on chain sprockets arrows Remove sealing plug arrow Insert scriber or suitable screwdriver in hole of chain tensioner in direction of arrow 1 and lift locking element for chain ten sioner Turn crankshaft in opposite direction to normal rotation arrow 2 and lock in p...

Page 106: ... k s w a g e n A G Note Inlet camshaft will move in direction of engine rotation Remove bolt 1 and guide tensioning rail 2 downwards Use screwdriver to release catch and press off top guide rail 3 forwards Remove camshaft timing chain from camshaft sprockets Caution Avoid damage to valves and piston crowns Do not turn the crankshaft after the camshaft timing chain has been removed from the cylinde...

Page 107: ...on system and bearings Cover open parts of engine Installing Specified torques page 92 Note Sealing surfaces must be free of oil and grease Pistons must not be positioned at TDC Ensure that all roller rocker fingers are properly seated on valve stem ends Remove sealant remaining on cylinder head with flat scraper WARNING Risk of eye injury Wear safety goggles Caution Danger of soiling lubrication ...

Page 108: ...e n t C o p y r i g h t b y V o l k s w a g e n A G WARNING Risk of eye injury Wear safety goggles Lock camshaft with spacers T40191 as shown if necessary slide forked sleeves into correct position Note If available use 2nd set of spacers T40191 or reuse T40191 1 Insert camshafts in cylinder head markings arrows must be positioned as shown Check alignment arrows of camshafts Cut off nozzle on tube...

Page 109: ...ead of sealant must not be thicker than specified other wise excess sealant can enter the sump and obstruct the strainer in the oil intake pipe Observe expiry date of sealing compound Sealant Electronic parts catalogue Fit cylinder head cover onto cylinder head Renew bolts for cylinder head cover Tighten bolts in several stages tightening sequence page 92 Note Take care to keep cylinder head cover...

Page 110: ...sprocket markings must align arrows Use spanner to turn inlet camshaft in direction of arrow and fit timing chain Attach bearing saddle and screw in bolts arrows hand tight Remove locking pin T40011 Tighten bolts arrows for bearing saddle Install regulating valve Turn crankshaft 4 times in direction of engine s rotation Install timing chain cover top page 65 Install vacuum pump Rep gr 47 Installin...

Page 111: ...pment required Spark plug socket and ex tension 3122 B Valve stem seal puller 3364 Valve stem seal fitting tool 3365 Adapter T40012 Torque wrench V A G 1331 Dismantling and assem bling device for valve cot ters VAS 5161 Guide plate for 2 0 l and 3 0 l FSI engine VAS 5161 19B Removing valve stem oil seals Remove camshafts page 94 Mark allocation of roller rocker fingers and hydraulic compen sation ...

Page 112: ...61 3 and a plastic hammer For inlet side Screw retainer VAS 5161 6 with guide fork VAS 5161 5 into centre thread of guide plate for 2 0 ltr and 3 0 ltr FSI engine VAS 5161 19B Insert assembly cartridge VAS 5161 8 into guide plate for 2 0 ltr and 3 0 ltr FSI engine VAS 5161 19B Attach pressure fork VAS 5161 2 to retainer VAS 5161 6 For exhaust side Screw retainer VAS 5161 6 with guide fork VAS 5161...

Page 113: ...knock out pin arrow with a punch and re move the impact extractor attachment Place lower part of valve stem seal puller 3364 onto valve stem seal Insert punch 1 into bore in lower part of puller Place installation lever on puller and pull out valve stem seal arrow Installing valve stem seals To prevent damage to new valve stem seals B attach plastic sleeve A to valve stem Lubricate sealing lip of ...

Page 114: ...allation cartridge they must first be inserted into the insertion device VAS 5161 18 Press assembly cartridge VAS 5161 8 onto insertion device from above and pick up valve cotters Press installation cartridge VAS 5161 8 down with pressure fork VAS 5161 2 and turn installation cartridge knurled screw back and forth whilst pulling upwards Relieve pressure fork VAS 5161 2 whilst pulling on knurled sc...

Page 115: ...3365 Dismantling and assem bling device for valve cot ters VAS 5161 Guide plate for 2 0 l and 3 0 l FSI engine VAS 5161 19B Engine and gearbox sup port VAS 6095 Cylinder head tensioning device VAS 6419 Procedure Remove camshafts page 94 Mark allocation of roller rocker fingers and hydraulic compen sation elements for reinstallation Remove roller rocker fingers together with hydraulic compen sation...

Page 116: ...nto guide plate and use a plastic hammer to knock loose the firmly seated valve cotters For inlet side Screw retainer VAS 5161 6 with guide fork VAS 5161 5 into centre thread of guide plate for 2 0 ltr and 3 0 ltr FSI engine VAS 5161 19B Insert assembly cartridge VAS 5161 8 into guide plate for 2 0 ltr and 3 0 ltr FSI engine VAS 5161 19B Attach pressure fork VAS 5161 2 to retainer VAS 5161 6 For e...

Page 117: ...using valve stem seal puller 3364 Installing valve stem seals Caution Risk of damage when installing valve stem seals Place plastic sleeve A enclosed with new valve stem seals B onto valve stem Lightly oil sealing lip of valve stem seal Push valve stem oil seal onto plastic sleeve Carefully press valve stem oil seal onto valve guide using valve stem seal fitting tool 3365 Remove plastic sleeve Ins...

Page 118: ... assembly cartridge VAS 5161 8 onto insertion device from above and pick up valve cotters Press installation cartridge VAS 5161 8 down with pressure fork VAS 5161 2 and turn installation cartridge knurled screw back and forth whilst pulling upwards Relieve pressure fork VAS 5161 2 whilst pulling on knurled screw Remove removal and installation device for valve cotters VAS 5161 Further assembly is ...

Page 119: ... flush with guide On account of differing stem diameters only use inlet valve in inlet guide and exhaust valve in exhaust guide Determine rock Wear limit Inlet valve guide Exhaust valve guide 0 80 mm 0 80 mm Note If the wear limit is exceeded repeat the measurement with new valves If the wear limit is exceeded again renew the cyl inder head If the valve is to be renewed as part of a repair use a n...

Page 120: ... n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Test procedure Take measurements with retaining frame removed Fit camshaft to be tested in retaining frame Attach dial gauge VAS 6079 with universal dial gauge holder VW 387 to cylinder head Press camshaft against dial gauge by hand Set dial gauge to 0 Press camshaft away from dial gauge and read off value Axial clearance...

Page 121: ...x mark danger of damage to catalytic converter Caution If large quantities of metal chips and abraded material are found during engine repair this may indicate that the crank shaft bearings or conrod bearings are damaged To avoid any subsequent damage the following work must be carried out following the repair Thoroughly clean oil passages Renew oil spray jets Renew engine oil cooler Renew oil fil...

Page 122: ... a Oil is not to be topped up b Oil can be topped up c Oil must be topped up Note The oil level must not be above the max marking arrow 1 nor below the min marking arrow 2 1 3 Assembly overview sump oil pump 1 Bolt Renew Tightening sequence page 117 2 Lower part of sump Removing and installing page 120 3 Baffle plate Renew 4 Suction line Clean strainer if soiled 5 Bolt 9 Nm 6 O ring Renew Moisten ...

Page 123: ...olt 9 Nm 15 Seal Renew 16 Coarse oil separator Removing and installing page 118 17 Bolt Tightening sequence page 118 18 Upper part of sump Removing and installing page 124 19 Bolt Renew Tightening sequence page 118 20 Bolt Renew Tightening sequence page 118 21 Bolt 20 Nm 22 Seal 23 Bolt 9 Nm 24 Seal 25 Non return valve 26 Oil drain plug Renew 30 Nm Tightening sequence for sump bottom section Tight...

Page 124: ... o p y r i g h t b y V o l k s w a g e n A G Tightening sequence for sump top section Tighten bolts in sequence 1 to 13 in 2 stages as follows 1 Tighten bolts to 15 Nm 2 Turn bolts 90 further Tightening sequence for coarse oil separator Tighten bolts in the sequence 1 9 to 9 Nm 1 4 Removing and installing coarse oil sep arator Special tools and workshop equipment required Support bracket 10 222 A ...

Page 125: ...move left engine support page 17 Drain coolant page 133 Release vacuum hoses Item 17 page 141 and Item 13 page 141 from coolant pump Remove coarse oil separator 1 9 Installing Installation is carried out in the reverse order When installing note the following Coarse oil separator tightening sequence Specified torques page 116 Replenish coolant page 133 Check oil level and top up if necessary page ...

Page 126: ...page 116 Installation is carried out analogously in the reverse order note the following Before installing oil pump check strainer in oil suction pipe and oil galleries in upper part of sump for soiling Check that both centring sleeves for centring oil pump are present Renew baffle plate Note Plastic ribs that are permanently deformed during tightening are located on the baffle plate The plastic r...

Page 127: ... 222 A Hand drill with plastic brush Eye protection Silicone sealant D 174 003 A2 Removing Note To remove the sump lower part the engine has to be supported and raised by approx 15 cm This ensures the necessary space to remove the sump lower part Support engine with support bracket 10 222 A Unscrew bolts for right and left engine mounting page 17 Raise engine by approx 15 cm Remove engine guard if...

Page 128: ... necessary loosen using light blows with a rubber headed hammer Installing Specified torques Note Observe use by date of silicone sealant The sump must be installed within 5 minutes of applying sili cone sealing compound Remove sealant residues from sump upper part with a flat scraper WARNING Risk of eye injury Wear safety goggles Remove sealant residue from bottom part of sump e g with rotating p...

Page 129: ...st be installed within 5 minutes of applying sili cone sealing compound The bead of sealant must not be thicker than specified other wise excess sealant can enter the sump and obstruct the strainer in the oil intake pipe Thickness of sealant bead 2 3 mm Fit sump lower part immediately and tighten bolts 1 to 20 in 3 stages as follows 1 Tighten bolts hand tight 2 Tighten bolts to 8 Nm 3 Turn bolts 4...

Page 130: ...of sump Special tools and workshop equipment required Assembly tool T10118 Brake lining wear gauge VW 136 Torque wrench V A G 1331 Silicone sealant D 174 003 A2 Removing Remove gearbox Rep gr 34 Remove oil pump page 119 Remove sealing flange on gearbox side page 33 Unscrew bolts arrows DANGER Injury risk When removing upper part of sump spring of chain tensioner for oil pump drive jumps from upper...

Page 131: ...silicone sealing compound Use assembly tool T10118 to pull spring of chain tensioner for oil pump drive in direction of guide rail arrow Secure spring by inserting brake lining wear gauge VW 136 as shown in illustration into hole of guide rail Remove sealant residues from cylinder block with a flat scra per WARNING Risk of eye injury Wear safety goggles Remove remaining sealant on upper part of su...

Page 132: ...to clean sealing sur face of upper part of sump as illustrated arrow Thickness of sealant bead 2 3 mm Note The sump upper part must be installed within 5 minutes of ap plying silicone sealing compound The bead of sealant must not be thicker than specified other wise excess sealant can enter the sump and obstruct the strainer in the oil intake pipe Sump upper part and crankcase must be flush on gea...

Page 133: ... i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull brake lining wear gauge VW 136 out of guide rail arrow Spring now jumps back to installation position Assembly is performed analogously in the reverse order of re moval Amarok 2011 4 cylinder injection engine 2 0 l direct injection en...

Page 134: ...ng page 24 2 Seal Renew 3 O ring Not replacement part Include in items sup plied with valve unit 4 O ring Not replacement part Include in items sup plied with valve unit 5 Valve unit With O rings 6 Oil filter Removing and installing Amarok Mainte nance Booklet 11 Remove and install with oil filter tool 3417 7 Seal Renew 8 Oil pressure switch F22 Blue insulation Removing and installing page 130 Che...

Page 135: ...Removing WARNING Hot steam hot coolant can escape risk of scalding The cooling system is under pressure when the engine is hot Cover filler cap on expansion tank with a cloth and open carefully to dissipate pressure Drain coolant page 133 Remove bracket for ancillaries page 24 Unscrew bolts 4 and 5 and remove engine oil cooler 3 to gether with seal 2 Installing Installation is carried out in the r...

Page 136: ...moving Note Place a cloth underneath bracket for ancillaries to catch any es caping engine oil Detach connector 2 from oil pressure switch F22 1 Unscrew oil pressure switch F22 2 Installing Installation is carried out in the reverse order When installing note the following Specified torque page 128 Note Renew seal Insert new oil pressure switch F22 immediately in bore to avoid loss of oil 2 4 Remo...

Page 137: ... have run once Test procedure Note Place a cloth underneath bracket for ancillaries to catch any es caping engine oil Detach connector 2 from oil pressure switch F22 1 un screw oil pressure switch F22 Screw oil pressure tester V A G 1342 into oil filter bracket in place of oil pressure switch Start engine Oil pressure at idling speed 1 2 2 1 bar Oil pressure at 2000 rpm 1 6 2 1 bar Oil pressure at...

Page 138: ...fuel hydraulics acti vated charcoal filter system coolant and refrigerant brake fluid and vacuum and electrical wiring in their original po sitions To avoid damage to lines ensure sufficient clearance from all moving or hot components Note When the engine is warm the cooling system is under pres sure If necessary release pressure before beginning repair work Hoses are secured with spring type clip...

Page 139: ... g h t b y V o l k s w a g e n A G 1 2 Draining and filling coolant Special tools and workshop equipment required Refractometer T10007 Drip tray for workshop hoist VAS 6208 Hose clip pliers VAS 6340 Cooling system charge unit VAS 6096 Adapter for cooling system tester V A G 1274 8 Procedure Draining WARNING Steam may escape when expansion tank is opened Wear eye protection and protective clothing ...

Page 140: ...ot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Open filler cap 2 on expansion tank 1 Remove engine guard if fitted Body front Rep gr 50 Engine guard Amarok 2011 4 cylinder injection engine 2 0 l direct injection engine turbocharger Edition 02 2...

Page 141: ... additive Because of its higher boiling point the coolant improves en gine reliability under heavy loads particularly in countries with tropical climates Frost protection is required down to about 25 C in countries with arctic climates down to about 35 C The coolant concentration must not be reduced by adding wa ter even in warmer seasons and in warmer countries The coolant additive concentration ...

Page 142: ... hose 3 from expansion tank 1 Fill expansion tank 1 to capacity and reconnect coolant hose 3 Seal expansion tank 1 with cap 2 Start engine and keep engine speed at approx 2000 rpm until radiator fan starts up Check coolant level and top up if necessary When engine is at normal operating temperature the coolant level must be at the upper mark when engine is cold in the middle of the sha ded field 1...

Page 143: ...nto coolant expansion tank Clamp connector V A G 1274 B 1 into adapter for cooling system tester V A G 1274 8 Join connection piece V A G 1274 B 1 to cooling system tester V A G 1274 B using connecting hose supplied Using hand pump on tester build up a pressure of approx 1 0 bar DANGER Risk of scalding Before the cooling system tester V A G 1274 B is disconnected from the connecting hose or the co...

Page 144: ... t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Join connection piece V A G 1274 B 1 to cooling system tester V A G 1274 B using connecting hose supplied Operate hand pump The pressure relief valve should open at a pressure of 1 4 1 6 bar Amarok 2011 4 cylinder injection engine 2 0 l dire...

Page 145: ...V o l k s w a g e n A G 2 Coolant hose schematic diagram 2 1 Coolant hose schematic diagram for vehicles with heat exchanger 1 Heat exchanger for heater unit 2 Cylinder head connection 3 Circulating pump V 55 only for Climatronic 4 Auxiliary heater Depending on equipment 5 Circulating pump V 51 6 Radiator Renew coolant after replac ing Removing and installing page 152 7 Engine oil cooler 8 Turboch...

Page 146: ... w a g e n A G 2 2 Coolant hose schematic diagram for vehicles with 2nd heat exchanger 1 Connecting pipes for 2nd heat exchanger 2 Heat exchanger for heater unit 3 Shut off valve 4 Circulating pump V 55 only for Climatronic 5 Auxiliary heater Depending on equipment 6 Radiator Renew coolant after replac ing Removing and installing page 152 7 Circulating pump V 51 8 Engine oil cooler 9 Turbocharger ...

Page 147: ... Coolant hose To expansion tank 2 Coolant hose To heat exchanger Return line 3 Coolant hose To heat exchanger Supply 4 Coolant pipe 5 Coolant hose From coolant pipe to supplementary water pump 6 O ring 7 Coolant hose 8 Continued coolant circula tion pump V51 Removing and installing page 142 9 Coolant hose To water connection 10 Coolant pipe with coolant hose 11 Coolant hose To supplementary water ...

Page 148: ...i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 19 Coolant pipe 20 Bracket for continued coolant circulation pump V51 21 Coolant pipe Return line 22 Seal 23 Coolant pipe Supply 24 Coolant hose 25 Coolant hose To expansion tank 3 2 Removing and installing continued cool ant circulation pump V51 Special tools and workshop equipment required Hose clips up to 25 mm 3094...

Page 149: ...off coolant hoses arrows using hose clamps to 25 mm 3094 and remove Disconnect electrical connector 2 Remove bolt 1 and detach continued coolant circulation pump V51 Installing Installation is carried out in the reverse order note the following Note Hose unions and air intake pipes hoses must be free of oil and grease when installing Secure all hose connections with hose clips corresponding to the...

Page 150: ... Renew 3 Connection 4 Retaining clip Only for inserted ver sion Check for secure seat ing 5 Coolant temperature send er G62 Removing and installing page 145 6 O ring Renew 7 Coolant pump Removing and installing page 149 New coolant pump re move protective cap 8 Seal Renew 9 Centralising pin Qty 2 10 Toothed belt For coolant pump Removing and installing page 146 11 Toothed belt guard 12 Bolt 9 Nm 1...

Page 151: ...ing pin 19 O ring Renew 20 Connection 21 Bolt 9 Nm Coolant pump tightening sequence Tighten bolts for coolant pump in the sequence 1 5 to 9 Nm 3 4 Removing and installing coolant temper ature sender G62 Removing Engine cold Release clip 3 from pressure hose 4 Release hose clip arrow from throttle valve module J338 Unscrew bolt 1 from pressure pipe 2 and remove pressure pipe 2 Disconnect electrical...

Page 152: ...ecified torque page 144 Note Renew O rings Only demineralised distilled water to standard VDE 0510 may be used for mixing Tap water does not have the required quality to ensure the coolant s function Insert new coolant temperature sender G62 immediately into connection to avoid loss of coolant Hose unions and air intake pipes hoses must be free of oil and grease when installing Secure all hose con...

Page 153: ... n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Socket T10360 Removing Remove short coolant pipe page 141 Release long coolant pipe and lay aside page 141 Disconnect coolant hoses 1 and 2 and move clear to one side Unscrew bolts arrows and remove toothed belt guard Caution Risk of damage to thread The drive sprocket bolt has a left hand thread Amarok ...

Page 154: ...Installing Specified torque page 144 Installation is carried out in the reverse order When installing note the following Note Replace bolt for drive sprocket Renew seals and O rings Note installation position of V belt pulley page 144 Install short coolant pipe page 141 Replenish coolant page 133 3 6 Renewing oil seal for coolant pump drive Special tools and workshop equipment required Thrust piec...

Page 155: ...rive sprocket bolt has a left hand thread Apply thrust piece T10353 to oil seal 1 and press into cyl inder block as far as stop using bolt 2 take care not to tilt oil seal Fit toothed belt for coolant pump page 146 Install short coolant pipe page 141 Replenish coolant page 133 3 7 Removing and installing coolant pump Removing Remove short coolant pipe page 141 Release long coolant pipe and lay asi...

Page 156: ...Ignore arrow Installing Specified torque page 144 Installation is carried out in the reverse order When installing note the following Note Renew seals and O rings Coat O rings 4 with coolant coolants Electronic parts catalogue Check whether the two centring pins are fitted in the cylinder block install if necessary Fit connecting piece 2 into engine oil cooler 1 Push coolant pump 3 onto connecting...

Page 157: ...Remove engine mounting left side page 17 Unscrew continued coolant circulation pump V51 with brack et Remove coarse oil separator page 118 Unscrew bolts arrows and remove connection Detach thermostat Installing Installation is carried out in the reverse order When installing note the following Specified torques page 144 Note Renew seals and O rings Clean sealing surface for O ring Coat O ring with...

Page 158: ...r only for vehi cles with air conditioning sys tem 6 Cap Check using cooling system tester V A G 1274 and adapter for cooling system tester V A G 1274 9 Test pressure 1 4 1 6 bar 7 Connector 8 Bolt 5 Nm 9 Expansion tank Checking cooling sys tem for leaks with cool ing system tester V A G 1274 and adapt er V A G 1274 8 page 136 With coolant tempera ture display sender G32 10 Bolt 5 Nm 11 Cowling wi...

Page 159: ...ued coolant circulation pump V51 19 Coolant hose Coolant hose schematic diagram page 139 20 Retainer 21 Radiator outlet coolant temperature sender G83 Coolant hose schematic diagram page 139 22 Retainer 23 Spring type clip Hose clip pliers VAS 6362 are recommended to install spring type clips 24 Radiator lower mounting 4 2 Assembly overview air ducting with radiator fan V7 1 Radiator 2 Radiator fa...

Page 160: ... i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 3 Removing and installing cowling with ra diator fan V7 Removing Remove engine guard if fitted Body front Rep gr 50 Engine guard Unclip coolant hose 1 from brackets 2 Unscrew securing bolts 3 for cowling 4 Separate connector 1 at cowling 2 Remove bolts 1 Detach retaining clips 3 with water hose 4 fro...

Page 161: ...u m e n t C o p y r i g h t b y V o l k s w a g e n A G Disengage cowling 2 at left and right To do this press re taining lever 1 forwards using a screwdriver and raise cowl ing 2 slightly Remove cowling Unscrew bolts arrows and remove radiator fan V7 1 Installing Install in reverse order Specified torque arrows 6 Nm 4 4 Removing and installing radiator Special tools and workshop equipment require...

Page 162: ...ve cowling page 154 Observe instructions for hose connections with screw type clips page 184 Remove coolant hose 1 at radiator 3 and remove connect ing hose 2 Remove right connecting hose leading to turbocharger from charge air cooler and place to one side Remove air duct mounting page 154 Unclip left radiator fastening 2 at condenser 3 Unclip right radiator fastening as well and pull condenser 3 ...

Page 163: ...e air cooler and remove it from radiator Undo and remove bolt 2 on right and left not shown in illus tration at radiator Installing Install in reverse order In the process note the following Note Before installing radiator check that radiator mountings 1 are correctly seated on front part of car 2 and if necessary reposi tion Insert radiator mounting into lock carrier 2 at bottom 1 do ing so trans...

Page 164: ...ly in the lock carrier Observe instructions for hose connections with screw type clips page 184 Caution The screw type clips on the charge air lines must always be tightened to 5 5 Nm If the torque is too low or too high the charge air hose may slip off the charge air pipe during vehicle operation Fit condenser 3 on radiator 1 on left and right so that it en gages securely in the catches 2 Caution...

Page 165: ...l the various lines e g for fuel hydraulics acti vated charcoal filter system coolant and refrigerant brake fluid and vacuum and electrical wiring in their original po sitions Ensure that there is sufficient clearance to all moving or hot components Note When the engine is warm the cooling system is under pres sure If necessary release pressure before beginning repair work Hoses are secured with s...

Page 166: ...uel delivery unit from a full or partly full fuel tank observe the following Even before work commences the extraction hose of an ac tivated fume extraction system has to be placed in the vicinity of the assembly opening of the fuel tank to extract any escap ing fumes If no exhaust gas extraction system is available a radial fan with a displacement greater than 15 m3 h can be used providing that m...

Page 167: ... area must be reduced to a residual pressure of approx 6 bar The appropriate procedure is described as fol lows Connect vehicle diagnostic tester and then carry out Guided Fault Finding Reducing high fuel pressure Switch off ignition WARNING The fuel lines are pressurized Wear eye protection and pro tective clothing to avoid eye injuries and skin contact Before opening the high pressure section wr...

Page 168: ...heck fuel tank for heavy soiling and clean if necessary Special tools and workshop equipment required Pressure gauge VAS 6550 Remote control V A G 1348 3A Test instrument adapter DSO 5 pin VAS 5565 Multimeter V A G 1715 Special wrench T10202 Measuring container ca pacity 3 litres Checking function and voltage supply page 162 Check fuel pressure page 164 Checking holding pressure page 165 2 1 1 Che...

Page 169: ...using final control diagnosis Connect vehicle diagnostic tester as follows Connect diagnosis cable connector to diagnostic connection in driver footwell Switch ignition on Press one after the other in the display the buttons for Vehicle self diagnosis Engine electronics and Final con trol diagnosis Press right arrow button on display to final control diagnosis for fuel pump electronics The fuel pu...

Page 170: ...avoid eye injuries and skin contact Be fore loosening hose connections wrap a cloth around the connection Then release pressure by carefully pulling hose off connection Voltage supply not OK Locate and eliminate open circuit referring to current flow di agram Current flow diagrams Electrical fault finding and Fitting locations Voltage supply OK Remove fuel delivery unit page 172 Check that electri...

Page 171: ...Specification 4 0 7 0 bar Fuel pressure OK check holding pressure page 165 If the specification is exceeded Pressure limiting valve in fuel delivery unit is defective Note The pressure limiting valve is integrated in the fuel delivery unit and cannot be renewed separately If the specification is not attained Fuel pump is defective renew fuel delivery unit page 172 2 1 3 Checking holding pressure T...

Page 172: ...s not drop now Note Leak must be sought on engine side Repeat holding pressure test This time close shut off tap A to check whether leak ac tually is on engine side Check fuel pipe to high pressure pump for leaks If no fault is found Renew high pressure pump page 226 If the pressure drops again Leak must be sought on fuel tank side proceed as follows Check fuel line leading to flange for leaks If ...

Page 173: ...ove and install us ing union nut tool 3217 2 Seal Renew if damaged Moisten with fuel when installing 3 Fuel delivery unit Note installation posi tion on fuel tank page 168 To remove first remove fuel tank page 169 Removing and installing fuel gauge sender page 173 4 Connecting hose 5 Spring type clip 6 Spring nut 7 Filler neck 8 Weld bolt with cap nut 9 Filler cap with retaining strap 10 Seal 11 S...

Page 174: ...er with pressure regulator Removing and installing page 177 26 Return line Blue or with blue marking Clipped onto fuel tank Check for secure seating To pull off flange press release button on connecting piece 27 Supply line To fuel filter page 167 Clipped onto fuel tank Check for secure seating Black To pull off flange press release button on connecting piece 28 Breather line 29 Breather line Inst...

Page 175: ...l tank Special tools and workshop equipment required Union nut tool 3217 Torque wrench V A G 1331 Torque wrench V A G 1332 Engine and gearbox jack V A G 1383 A Fuel extractor VAS 5190 Removing Note Fuel tank must be drained Use the fuel extractor VAS 5190 to do this Note safety precautions before starting installation work page 160 Observe rules for cleanliness page 160 Note Before carrying out fu...

Page 176: ...ck on fuel tank 4 and pull connecting hose off Extract fuel with the fuel extractor VAS 5190 via the opening Vehicles with lower protective cover Unbolt protective cover from bottom of fuel tank Continuation for all vehicles Support fuel tank with engine and gearbox jack V A G 1383 A Disconnect supply line 3 and return line 2 Note Press in buttons on hose couplings to do this Unscrew bolt arrow fo...

Page 177: ...ine and gearbox jack V A G 1383 A until filler neck and breather line can be removed Loosen clamp 2 for connecting hose 1 of filler neck on fuel tank 4 and pull connecting hose off Unclip breather line 3 on fuel tank 4 Note Immediately seal all openings on fuel tank with clean cloths Continue lowering fuel tank with engine and gearbox jack V A G 1383 A until connector 2 can be pulled off fuel deli...

Page 178: ...arkings arrows using hose clip pliers VAS 6362 Push on breather line 3 and engage securely Connections for breather and fuel lines must engage audibly when joined Clip fuel lines onto fuel tank Push connector onto fuel pump flange and clip wire onto fuel tank Ensure that fuel hose connections are tight Vehicles with lower protective cover Bolt protective cover to bottom of fuel tank 3 3 Removing a...

Page 179: ...it out of the fuel tank Installing Install in reverse order In the process note the following Install fuel delivery unit so that mark on flange of fuel delivery unit 1 is aligned with mark on fuel tank arrows 3 4 Removing and installing fuel gauge sender G Removing Remove fuel tank page 169 Remove fuel delivery unit page 172 Free lines 2 and unclip fuel gauge sender G to side arrows Remove fuel ga...

Page 180: ... s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 5 Removing and installing filler neck Special tools and workshop equipment required Hose clip pliers VAS 6362 Torque wrench V A G 1410 Removing Remove fuel tank page 169 Unscrew bolt 2 for filler neck 1 on underbody Open tank flap and clean inside tank flap unit thoroughly Unscrew cap Unscrew bolt 2 from tank flap unit Unclip tank ...

Page 181: ... w a g e n A G Unscrew nuts 2 from filler neck 1 at top of tank flap unit cut out Remove filler neck 1 from below filler neck must be turned when doing this Installing Install in reverse order Thread filler neck 1 in through wheel housing and position at top of tank flap unit cut out with nuts 2 Tighten nuts 2 to 5 Nm Tighten bolt 2 to 2 Nm Installing fuel tank Push hose 1 of filler neck onto conn...

Page 182: ...tank Ensure that fuel hose connections are tight 3 6 Assembly overview fuel filter with attachments 1 Fuel filter Direction of flow is marked with arrows Do not interchange con nections Removing and installing page 177 Installation position pin on filter housing must engage in notch of guide in filter bracket page 177 2 Retaining clip For fuel pressure regu lator Check for secure seat ing 3 Fuel s...

Page 183: ...ntainer Removing Note Note safety precautions before starting installation work page 160 Observe rules for cleanliness Place container under fuel filter WARNING Fuel system is under pressure Wear eye protection and pro tective clothing to avoid eye injuries and skin contact Before loosening hose connections wrap a cloth around the connec tion Then release pressure by carefully pulling hose off con...

Page 184: ...s w a g e n A G Installation position Pin 2 on filter housing must engage in notch of guide 1 in filter bracket Specified torque Component Nm Retaining clamp for fuel filter 3 3 8 Removing and installing fuel pump con trol unit J538 Note The fuel pump control unit J538 is installed on the fuel tank Lower fuel tank until control unit is accessible Detach connector from fuel pump control unit J538 L...

Page 185: ...lectronic power control EPC Assembly overview accelerator module page 179 Removing and installing accelerator module page 179 4 1 Assembly overview accelerator module Assembly overview 1 Connector 2 Securing nuts 10 Nm 3 Accelerator with electronic module The accelerator position sender passes the posi tion of the accelerator on to the engine control unit 4 2 Removing and installing accelerator mo...

Page 186: ...c c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Installing Installation is performed in the reverse sequence Specified torque Component Nm Accelerator module to body 10 Amarok 2011 4 cylinder injection engine 2 0 l direct injection engine turbocharger Edition ...

Page 187: ...Check for secure seat ing 2 Activated charcoal filter Location on fuel tank left Removing and installing only with fuel tank re moved 3 Breather line Check for secure seat ing 4 Quick release coupling Check for secure seat ing 5 Fuel line Check for secure seat ing 6 Clip 7 Activated charcoal filter sol enoid valve 1 N80 Valve closed with igni tion switched off When engine is warm valve will be act...

Page 188: ...ank must be lowered Test procedure Detach bleeder line Item 3 page 181 Note To do this press release button Connect hand vacuum pump VAS 6213 with adapter set V A G 1318 17 to breather line Operate hand vacuum pump VAS 6213 several times Vac uum must not build up If vacuum builds up Check breather line Item 1 page 181 on activated charcoal filter for soiling and clean if necessary If vacuum does n...

Page 189: ...nd measuring instruments are operated from front pas senger seat and the vehicle is involved in an accident there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is triggered 1 2 Rules for cleanliness When working on the charge air system pay careful attention to the following rules for cleanliness Thoroughly clean all unions and surrounding areas...

Page 190: ...on Normal screw type clips are used on the hose connections on the intake side On the hose connections on the delivery side there are screw type clips with barbs arrows Caution Do not loosen these screw type clips and pull back over the delivery hose Risk of damage to the hose If a clip has been removed it must be renewed together with the hose Screw type clips with locking hooks arrows may only b...

Page 191: ...186 Note 2 Seal 3 Hose clip Reinforced 5 5 Nm 4 Pressure hose To turbocharger Must be free of oil and grease before installing 5 Hose clip Reinforced 5 5 Nm 6 Hose clip Reinforced 5 5 Nm 7 Pressure hose To throttle valve Must be free of oil and grease before installing 8 Hose clip Reinforced 5 5 Nm 9 Securing bolt 10 Pressure sensor 11 Bolt 12 Rubber grommet 13 Pressure pipe Must be free of oil an...

Page 192: ...2 Unclip water hose from pressure pipe Release lower clip Item 8 page 185 from socket to throttle valve module J338 Remove pressure pipe Installing Installation is performed in the reverse sequence 1 6 Removing and installing charge pres sure sender G31 Removing Disconnect electrical connector 4 from charge pressure sender G31 Unscrew bolts 2 and pull charge pressure sender G31 3 out of air duct 1...

Page 193: ...rd if fitted Body front Rep gr 50 Engine guard Drain coolant page 133 Undo and remove bolts 2 that fasten radiator to lock carrier 1 Vehicles with air conditioner Remove lock carrier General body repairs exterior Rep gr 50 Lock carrier Continuation for all vehicles Remove cowling page 153 Observe instructions for hose connections with screw type clips page 184 Remove coolant hose 1 and pressure ho...

Page 194: ...er removal work make sure that the refriger ant lines are not bent or stretched excessively Do not bend or stretch the refrigerant lines excessively Continuation for all vehicles Carefully remove radiator upwards together with charge air cooler When doing so take the radiator 2 past the refrigerant lines Note If the radiator 1 is to be replaced undo bolts of charge air cooler and remove it from ra...

Page 195: ... completely in the lock carrier Insert top radiator mountings 1 on right and left into the mounting on radiator 2 appropriately Observe instructions for hose connections with screw type clips page 184 Install cowling page 154 Replenish coolant page 133 Only for vehicles with air conditioning Install lock carrier General body repairs exterior Rep gr 50 Lock carrier Continuation for all vehicles Spe...

Page 196: ...e n A G Charge air system tester V A G 1687 Release hose clip 1 and detach pressure hose 3 from tur bocharger 2 Depending on hose diameter insert adapter 1687 10 1687 11 or 1687 12 in air duct 1 and secure with hose clip Connect charge air system tester V A G 1687 as shown in figure Prepare charge air system tester V A G 1687 as follows Unscrew pressure control valve 2 completely close valves 3 an...

Page 197: ...it until test circuit is full If necessary readjust pressure to 0 5 bar Check charge air system for leaks by hearing touching with commercially available leak detector spray or using ultrasonic tester V A G 1842 Note A small amount of air escapes through the valves and enters the engine Therefore a holding pressure test is not possible How to use the ultrasonic tester V A G 1842 operating instruct...

Page 198: ...e free of oil and grease before assembly The oil seal and seal ing surface must be oiled lightly only for connector couplings Charge air system must be free of leaks Renew self locking nuts Hose clip pliers VAS 6362 or hose clip pliers V A G 1921 are recommended for installation of spring type clips Fill turbocharger with engine oil at oil supply line connection After installing turbocharger run e...

Page 199: ...n only be renewed to gether with exhaust manifold and vacuum unit as one unit Removing and installing page 197 2 Hose 3 Vacuum unit for turbocharg er Can only be renewed to gether with turbocharg er 4 Hose clip 5 Hose 6 Hose 7 Bolt 3 Nm 8 Charge pressure control solenoid valve N75 9 Hose 10 Turbocharger air recircu lation valve N249 Note installation posi tion page 193 11 Bolt 7 Nm 12 O ring Renew...

Page 200: ... s w a g e n A G Part II Part I page 192 Part III page 195 Part IV page 196 1 Turbocharger Can only be renewed to gether with exhaust manifold and vacuum unit as one unit Removing and installing page 197 2 Bolt 9 Nm 3 Crankcase breather line 4 Seal Renew 5 Seal Renew 6 Bolt 30 Nm 7 Oil supply line 8 Bolt 9 Nm 9 Bolt 9 Nm 10 O ring Renew 11 Seal Renew 12 Bolt 35 Nm 13 Bolt 9 Nm 14 Bolt 35 Nm 15 Sea...

Page 201: ... 194 Part IV page 196 1 Seal Renew 2 Nut Renew Tightening sequence page 196 Coat exhaust manifold studs with high temper ature paste high tem perature paste Elec tronic parts catalogue 3 Bolt 35 Nm 4 Seal Renew 5 Coolant return line 6 Bolt 9 Nm 7 Turbocharger Can only be renewed to gether with exhaust manifold and vacuum unit as one unit Removing and installing page 197 8 Bolt 30 Nm 9 Retainer 10 ...

Page 202: ...4 Clamping rail Tightening sequence turbocharger Tighten bolts in sequence 1 to 5 in 4 stages as follows 1 Tighten bolts to 5 Nm 2 Tighten bolts to 12 Nm 3 Tighten bolts to 16 Nm 4 Tighten bolts to 25 Nm Part IV Part I page 192 Part II page 194 Part III page 195 1 Turbocharger Can only be renewed to gether with exhaust manifold and vacuum unit as one unit Removing and installing page 197 2 Vacuum ...

Page 203: ... i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Further specified torques Component Nm Right air duct to sump 10 Air duct to bracket 10 2 2 Removing and installing turbocharger Special tools and workshop equipment required Hose clip pliers V A G 1921 Hose clip pliers VAS 6340 Removing Drain coolant page 133 Release clip 3 unclip vacuum line 5 from guideway 2 Unclip...

Page 204: ...e n A G Detach intake hose 4 from turbocharger Remove air filter housing page 207 Remove catalytic converter page 240 Disconnect coolant hose from turbocharger Note For reasons of clarity following diagrams show installation posi tion with engine removed Remove heat shield arrows Unscrew crankcase breather system arrow from turbocharg er Pull off hose 1 from turbocharger Unscrew bolts 1 and 2 and ...

Page 205: ... p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Release hose clip 1 and detach pressure hose 3 from tur bocharger 2 Unplug electrical connections 1 and 2 and lay wiring to one side Unscrew bolts arrows and remove support for turbocharger Unscrew bolts arrows on oil return line Amarok 2011 4 cylinder inject...

Page 206: ... and hoses for charge air system must be free of oil and grease before assembly Secure all hose connections with hose clips corresponding to the series equipment Electronic parts catalogue Install catalytic converter page 240 Aligning exhaust system free of stress page 243 Replenish coolant page 133 Check oil level Amarok Maintenance Booklet 11 Note After installing turbocharger run engine for abo...

Page 207: ...m pump VAS 6213 to po sition B for pressure Caution The pressure must not exceed 750 mbar If the pressure is exceeded the vacuum unit can be damaged Operate hand vacuum pump VAS 6213 repeatedly observ ing linkage The linkage A should start to move at a pressure of approx 300 mbar and be at its limit stop at a pressure of approx 700 mbar The stroke of the linkage is approx 10 mm Note If no pressure...

Page 208: ...t memory Also the vacuum hoses and connections must be checked unme tered air Fuel hoses in engine compartment must be secured only with spring type clips The use of clamp or screw type clips is not permissible For trouble free operation of electrical components a voltage of at least 11 5 volts is necessary Do not use sealants containing silicone Particles of silicone drawn into the engine will no...

Page 209: ...and installing air filter element page 209 Removing and installing air mass meter G70 page 209 Assembly overview intake manifold page 211 Assembly overview fuel rail page 212 Removing and installing intake manifold with fuel rail page 211 Removing and installing injectors page 217 Renew Teflon seal on injector page 219 Cleaning injectors page 221 Removing and installing fuel pressure sender G247 p...

Page 210: ... N80 9 Intake air temperature sender G42 10 Throttle valve module J338 Throttle valve drive an gle sender G187 and throttle valve drive angle sender 2 G188 Each time after remov ing installing or renew ing throttle valve module J338 it must be re adapted to engine con trol unit J623 Removing and installing page 223 11 Wiring harness to engine control unit 12 Charge air pressure sender G31 Removing...

Page 211: ... Assembly overview air filter 1 Air duct Check for secure en gagement 2 Rubber bush Clipped into lower part of air filter 3 Air filter lower part 4 8 5 Nm Rubber bush clipped in to lower part of air filter 5 Water drainage pipe page 207 Clipped onto lower part of air filter Make sure it is mounted in correct position on longitudinal member Clean if soiled 6 Filter element Replacing air filter clea...

Page 212: ...ration 17 Intake hose It is essential that the marks on intake hose be in line with the webs on the turbocharger Clean oil from ends of hoses before installing Do not use lubricants containing oil To turbocharger With heater element for crankcase breather N79 and connection for crankcase breather cylinder head cover connecting pipe 18 Screw type clip 5 5 Nm Caution The screw type clips on the char...

Page 213: ...n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Water drainage pipe on lower part of air filter Water drainage pipe 1 is clipped into lower part of air filter arrow 2 3 Removing and installing air filter hous ing Special tools and workshop equipment required Torque wrench V A G 1410 Hose clip pliers VAS 6340 Removing Detach vacuum hose 2 from air filter upper part and air d...

Page 214: ...o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Disconnect electrical connectors 1 and 3 Loosen screw type clip 4 and remove intake hose from air mass meter G70 Note Item 2 can be disregarded Unscrew securing bolt 2 for air filter housing 1 in area of coolant expansion tank Pull air filter out of mountings Installing Install in reverse order In the process note the fo...

Page 215: ...alling Note Always use genuine part for air filter element Hose connections and hoses for charge air system must be free of oil and grease before assembly Do not use lubricants containing silicone during installation Air filter housings must be clean Secure all hose connections with hose clips corresponding to original equipment Parts catalogue To prevent malfunctions cover all critical engine air...

Page 216: ...he proper function of the air mass meter G70 it is important to observe the following notes and instructions Note If the air filter element is very dirty or wet dirt or water could reach the air mass meter G70 and affect the air mass value This would lead to loss of power since a smaller injection quantity is calculated Always use genuine part for air filter element Use a lubricant silicon to amou...

Page 217: ...tion for fuel supply line From fuel tank 8 Fuel pressure regulating valve N276 9 High pressure pump With fuel pressure regu lating valve N276 Fuel tank contains elec tric fuel pump which pumps fuel to mechani cal high pressure pump When installing the high pressure pump it is essential to ensure that no dirt enters the fuel system The fuel system must not be under pressure when installing the high...

Page 218: ...ottle G188 After removing installing or renewing throttle valve module J338 it must be re adapted to engine control unit J623 See Guided functions 20 Seal Renew 2 7 Assembly overview fuel rail 1 Injector With combustion cham ber ring seal Teflon ring seal always renew Renew O rings Check installation loca tion is correct Removing and installing page 217 2 Support ring 3 Fuel rail Removing and inst...

Page 219: ... valve drive angle sender 2 for electric throttle G188 After removing installing or renewing throttle valve module J338 it must be re adapted to engine control unit J623 See Guided functions 7 Nm 15 Bolts for intake manifold 9 Nm 16 Intake manifold flap potentiometer G336 After intake manifold flap potentiometer G336 has been renewed intake manifold flap potentiometer G336 must be adapted to engin...

Page 220: ...18 Hose clip pliers V A G 1921 Special wrench long reach T10347 Removing Note The injectors can only be accessed after removal of the intake manifold and fuel rail Combustion chamber ring seal Teflon and O ring must al ways be renewed Assembly overview intake manifold page 211 Assembly overview fuel rail page 212 WARNING Fuel system is under pressure The fuel pressure in the high pressure part of ...

Page 221: ... page 141 from intake manifold Disconnect coolant hose at front Item 14 page 141 and rear from coolant pipe Item 10 page 141 Unclip wiring harness for oil pressure switch F1 from intake manifold Disconnect vacuum line arrow to activated charcoal filter Unplug following electrical connectors 1 Activated charcoal filter solenoid valve 1 N80 2 For knock sensor 1 G61 3 From variable intake manifold va...

Page 222: ...ose 3 Detach vacuum hose 3 from vacuum pump 2 and brake servo Open spring type clip upper arrow and detach fuel pressur isation line from high pressure pump Loosen union nut of high pressure fuel line lower arrow at high pressure pump Note Fuel system must be depressurised Collect escaping fuel with a clean cloth Seal open connections with clean caps It is essential to en sure that no dirt enters ...

Page 223: ...d Carefully pull intake manifold with fuel rail slightly away from cylinder head Note Injectors can remain in fuel rail Seal intake ports with a clean cloth Disconnect intake manifold from fuel rail page 213 Installing Note Ensure injectors are installed correctly Fit intake manifold onto studs left and right on cylinder head Install in reverse order Specified torque assembly overview intake manif...

Page 224: ...om fuel rail Remove injectors if these are still in cylinder head Injector old version 1 Combustion chamber ring seal Teflon ring seal renew when fitting do not grease ring or use any other lubricant 2 The support ring must be replaced with an intermediate ring See next figure page 218 3 Injector 4 Spacer renew if damaged 5 O ring renew to install lightly lubricate with clean engine oil 6 Support ...

Page 225: ...tor Note The combustion chamber seal must always be renewed prior to reinstallation of the injector Carefully remove old Teflon ring using a suitable tool e g cut open ring using razor blade or prise open ring with small screwdriver and then pull off forwards It is essential to ensure that groove and continuous ridge in groove surface are not damaged Note Injector must be renewed if groove is dama...

Page 226: ...180 and slight pressure slide calibra tion sleeve T10133 7 over injector until stop is reached Turn calibration sleeve T10133 7 in opposite direction Step 2 of calibration adaptation of Teflon ring is carried out with calibration sleeve T10133 8 Using a twist approx 180 and slight pressure slide calibra tion sleeve T10133 7 over injector until stop is reached Turn calibration sleeve T10133 7 in op...

Page 227: ...nalogously in reverse order Important It is essential to observe following points Moisten O rings of high pressure injectors with clean engine oil to aid insertion into fuel rail Renew all gaskets Fuel rail must be placed on injectors and evenly pressed in Install intake manifold with fuel rail page 211 2 11 Cleaning injectors Special tools and workshop equipment required Ultrasonic cleaner VAS 64...

Page 228: ...s button 3 to switch ultrasonic unit on Note As soon as the cleaning temperature is 50 degrees the set time will begin to elapse Each time after cleaning injector renew combustion chamber ring seal Teflon ring seal page 219 Then reinstall injectors page 217 2 12 Removing and installing fuel pressure sender G247 If fuel pressure sender G247 fails fuel pressure regulating valve N276 is switched off ...

Page 229: ... coolant line bolt arrow from intake manifold Disengage connector from fuel pressure sender G247 with assembly tool T10118 Unscrew fuel pressure sender G247 using double hexagon socket 1 2 27mm VAS 5301 7 Installing Install in reverse order Check tightening torque of connection before installing fuel pressure sender G247 Specified tightening torque of connection assembly overview fuel rail page 21...

Page 230: ...the throttle valve module must be adapted When cleaning the throttle valve nozzle it must not be scratch ed Remove throttle valve module J338 page 223 Open throttle valve by hand and lock it in open position using a suitable object e g wood or plastic wedge arrow WARNING Acetone is highly inflammable Observe accident prevention regulations and safety notes when handling highly inflammable fluids D...

Page 231: ...ssure pump Fuel tank contains elec tric fuel pump which pumps fuel to mechani cal high pressure pump When installing the high pressure pump it is essential to ensure that no dirt enters the fuel system The fuel system must not be under pressure when installing the high pressure pump proce dure for reducing fuel pressure page 161 Fuel lines must be free of tension when instal led Removing and insta...

Page 232: ... when installed ensure cleanliness 2 16 Removing and installing high pressure pump WARNING Fuel system is under high pressure It is essential to reduce fuel pressure before opening system For procedure please see page 161 Note Engine must be cold before high pressure pump is removed When installing the high pressure pump it is essential to en sure that no dirt enters the fuel system Collect escapi...

Page 233: ...nection for fuel pressurisation line high pressure side must be re newed See assembly overview high pressure pump item 11 page 225 Turn crankshaft until roller tappet is at bottom dead centre Insert high pressure pump into vacuum pump and tighten Tighten bolts hand tight Renew high pressure pump connection Specified torque assembly overview high pressure pump page 225 Now tighten bolts in diagonal...

Page 234: ...ntrol unit iden tification and with it the coding of the control unit used up to now Vehicle diagnostic tester Switch off ignition Disconnect battery Electrical system Rep gr 27 Remove shear bolts 1 and remove bow 4 Release and pull off connectors 2 and 3 Pull engine control unit out Installing Install in reverse order In the process note the following Insert engine control unit Insert and lock co...

Page 235: ... workshop equipment required K Jetronic pressure tester V A G 1318 Measuring container fuel resistant Protective gloves Test prerequisites Battery voltage at least 12 5 V Fuel filter OK Fuel tank at least 1 4 full Fuel pump control unit J538 OK Ignition switched off Checking fuel pressure WARNING The pressure in the high pressure part of the injection system must be reduced to a residual pressure ...

Page 236: ...h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Connect double connection V A G 1318 23 and adapter adapter set V A G 1318 17A to K Jetronic pressure tester V A G 1318 Attach adapter adapter set V A G 1318 17A to detached fuel pressurisation line Screw adapter V A G 1318 11 to K Jetronic pressure tester V A G 1318 Attach auxiliary hose arrow to pressure tester and hold it in co...

Page 237: ... longer rises at K Jet ronic pressure tester V A G 1318 If the specification is not attained Checking fuel pump delivery rate Rep gr 20 Checking holding pressure Check for leaks and check holding pressure by observing pressure drop at K Jetronic pressure tester V A G 1318 After 10 minutes there must be a residual pressure of at least 3 bar If the holding pressure drops below 3 bar Check threaded c...

Page 238: ...n there is a lack of elasticity or a lack of pulling power Special tools and workshop equipment required Hand vacuum pump VAS 6213 Test prerequisite Variable intake manifold valve N316 has been checked with a vehicle diagnostic tester If the intake manifold flap valve N316 is OK perform the follow ing tests Start engine and run at idling speed Have second person abruptly increase engine speed thro...

Page 239: ... m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove vacuum hose 1 leading to actuator for intake mani fold valve flap N316 from intake manifold flap valve N316 2 Move slide ring 1 on hand vacuum pump VAS 6213 to po sition A for vacuum Connect hand vacuum pump VAS 6213 to actuator for intake manifold flap valve N316 Operate hand vacuum pump VAS 6213 several times Vacuum actuator arrows mu...

Page 240: ...y V o l k s w a g e n A G 3 3 Checking fuel pressure sender G247 Special tools and workshop equipment required Assembly tool T10118 Deep hexagon socket 27 mm VAS 5301 7 Pressure sensor tester VAS 6394 1 Adapter VAS 6394 2 Test adapter VAS 5570 Torque wrench V A G 1331 Vehicle diagnosis tester Procedure Remove fuel pressure sender G247 page 222 Moisten tapered seal of adapter VAS 6294 2 with clean ...

Page 241: ... c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew plug 2 and screw fuel pressure sender G247 into tester VAS 6394 1 Specified torque 27 Nm Connect pressure line of tester VAS 6394 1 to adapter VAS 6394 2 Connect fuel pressure sender and electrical connector of fuel pressure sender using test instrument adapter VAS 5570 Amarok 2...

Page 242: ...nics 011 Measured values Select measured value block 1 4 0 and acknowledge with Q The actual fuel pressure value is shown in display zone 3 meas ured by the fuel pressure sender G247 Start engine Compare pressure on tester VAS 6394 1 with actual value displayed on vehicle diagnostic tester A maximum pressure deviation of 5 bar is permissible If deviation is greater than 5 bar renew fuel pressure s...

Page 243: ... n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Hand vacuum pump VAS 6213 Auxiliary measuring set V A G 1594C Test prerequisite Activated charcoal filter solenoid valve 1 N80 has been checked with vehicle diagnostic tester and is OK Detach connector 1 and breather hose 3 from activated charcoal filter solenoid valve 1 N80 2 Move slide ring 1 on hand vacuum pump VAS 621...

Page 244: ...o activated charcoal filter solenoid valve 1 N80 Connect contacts of solenoid valve to battery using auxiliary leads 1 This opens the activated charcoal filter system sol enoid valve 1 N80 Then operate hand vacuum pump VAS 6213 several times Vacuum must build up Disconnect battery again cut power If vacuum does not build up Renew double non return valve 1 Double non return valve activated charcoal...

Page 245: ...ust sys tem free of tension page 243 3 Exhaust pipe bracket 4 Bolt 20 Nm 5 Nut 40 Nm Renew Coat studs of turbo charger with high tem perature paste High temperature paste Electronic parts cata logue 6 Centre silencer Cutting point page 242 Aligning exhaust sys tem free of tension page 243 7 Mounting Renew if damaged Check pretension page 243 8 Rear silencer Aligning exhaust system free of tension ...

Page 246: ...position Bolt connections point to the right Nuts point upwards α approx 20 Installation position of rear clamp Install clamp so that ends of bolts do not protrude beyond bot tom of clamp Bolt connections point downwards 1 1 Removing and installing catalytic con verter Removing Detach connector for Lambda probe 1 heater downstream of catalytic converter Z29 arrow and lay leads to one side Detach c...

Page 247: ...ng bolts 1 for catalytic converter 2 Unscrew bolts 2 from bracket 1 Release clip 2 between catalytic converter and centre si lencer Unscrew nuts arrows and remove catalytic converter up wards Installing Installation is carried out in the reverse order When installing note the following Specified torques page 239 Note Renew seals gaskets and self locking nuts 1 2 Removing and installing exhaust man...

Page 248: ...Removing and installing centre silencer Procedure Special tools and workshop equipment required Engine and gearbox jack V A G 1383 A Support gearbox with engine and gearbox support V A G 1383 A Release gearbox mounting from gearbox To do so loosen bolts 1 Remove cross member 2 for gearbox mounting 3 to do so unscrew bolts 1 Release double clip 2 to rear silencer to do so loosen se curing nuts 1 Re...

Page 249: ...g Release double clip 2 to rear silencer to do so loosen se curing nuts 1 Detach rubber connector 2 in direction of arrow from brack et 1 Remove rear silencer downwards Installing Install in reverse order Threaded connection faces to rear Aligning exhaust system page 243 1 5 Checking exhaust system for leaks Start engine and run at idling speed Plug tailpipes e g with cloths or sealing plugs and l...

Page 250: ... c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Torque wrench 5 50 Nm V A G 1331 The exhaust system must be aligned when cold Procedure Loosen bolts of double clamp 3 Tighten bolts hand tight Align exhaust system until the marking 4 is visible Align bolts of double clamp 3 horizontally Align rubber mountings 1 for front silencer 2 and rear si lencer 1 in such a way that dimension a is 8...

Page 251: ...ontinuous clip Specified torque and mounting dimensions of clamping sleeve Clamp A with 2 individual clips Specified torque 25 Nm Installation dimensions a 5 mm only for front clamp Clamp B with continuous clip Specified torque 35 Nm Installation dimensions a 8 5 mm only for front clamp Installation dimension a for vehicles with marking on front ex haust pipe 1 Clamp 2 Front exhaust pipe a Install...

Page 252: ...y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Installation position of rear clamp Install clamp so that end of bolt arrow does not extend be yond lower edge of clamp Threaded connection faces to rear Amarok 2011 4 cylinder injection engine 2 0 l direct injection engine tu...

Page 253: ...fter fault finding repairs or component tests the engine starts runs for a short period and then stops then the fault may be that the immobilizer is blocking the engine control unit In this case the control unit must be adapted using vehicle diagnosis tester under Guided functions 1 2 Safety precautions To prevent injuries to persons and or damage to the injection and ignition system the following...

Page 254: ...lling page 252 Gold plated contacts 2 20 Nm The specified torque in fluences the function of the knock sensor 3 Ignition coil with output stage N70 N127 N291 N292 Removing and installing page 248 4 Spark plug 25 Nm If a spark plug is re placed regrease igni tion coil with final output stage page 249 Type and electrode gap page 253 Remove and install with spark plug socket and extension 3122 B 5 O ...

Page 255: ...uller T40039 onto uppermost thick rib arrow of ignition coils with final output stages The lower ribs may be damaged if they are used Pull all ignition coils approx 30 mm out of spark plug recess using puller T40039 Release connectors and simultaneously detach all connectors from ignition coils arrows Installing Note When fitting new spark plugs the ignition coil must be re greased using lubricati...

Page 256: ...g e n A G Apply a thin line of lubricating paste G 052 141 A2 around the ignition coil sealing hose arrow The bead must be 1 2 mm thick Insert all spark plugs loosely into spark plug recess Align ignition coils with connectors arrows and push all con nectors simultaneously onto ignition coils Evenly push ignition coils onto spark plugs by hand 1 5 Removing and installing spark plugs Note Observe d...

Page 257: ...Spark plug socket and extension VAS 3122B Puller T40039 Removing Pull all ignition coils approx 30 mm out of spark plug recess using puller T40039 Release connectors arrows and simultaneously detach all connectors from ignition coils Remove ignition coil with final output stage Unscrew spark plugs with spark plug spanner VAS 3122B Installing Fit new spark plugs with spark plug spanner VAS 3122B Sp...

Page 258: ...imultaneously Note Do not strike with a hammer or similar tool Evenly push all ignition coils plus final output stages onto spark plugs by hand 1 6 Removing and installing knock sensor 1 G61 Removing Detach connector 2 from knock sensor I G61 Remove coolant pump page 149 Note The knock sensor I G61 is located under the intake manifold behind the coolant pump Unscrew knock sensor I G61 Installing I...

Page 259: ...se electrical connector without assembly tool T10118 press connector on engine speed sender G28 in with a screw driver and at the same time raise release tab with a thin wire hook Loosen securing bolt arrow with socket AF 4 mm T10370 and remove speed sender Installing Install in reverse order In the process note the following Specified tightening torque of fastening bolt for engine speed sender G2...

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