Professional Documents
Culture Documents
4-Cylinder Injection Engine (2.0 L Direct Injection PDF
4-Cylinder Injection Engine (2.0 L Direct Injection PDF
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
Workshop Manual
s a c
s
ce
le
un
pt
an
d
Amarok 2011 itte
y li
erm
ab
ility
ot p
wit
is n
h re
engine, turbocharger)
ole,
spec
urposes, in part or in wh
CFP
t to the co
Engine ID
A
Edition 02.2011
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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 n AG. Volkswagen AG do
lkswage es n
o ot g
yV
28 - Ignition system ir se
d b ua
ran
tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.4 Removing and installing ancillary bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2 Cylinder block (gearbox end) AG. Volkswagen
ag.e.n. . . . . . . . . . .A.G. d.o.es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
olksw no
2.1 Assembly overview - dsealing
by
V flange and drive plate . . t. g.ua. r. . . . . . . . . . . . . . . . . . . . . . . . . 29
e a
2.2 Removing and installing
tho
ris drive plate . . . . . . . . . . . . . . . . . . n.te.e .o . . . . . . . . . . . . . . . . . . . . . 30
2.3 au
Removing andss installing needle bearing in/from drive plate . . .r a.c. . . . . . . . . . . . . . . . . . . . 32
2.4 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . ce 33
e
nl
pt
du
an
3 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
itte
y li
erm
ab
3.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ility 36
ot p
spec
4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
es, in part or in w
at
1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
om
ion
c
his
e
do
riv
cum
for
en
g
t.
yi Co
op
2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
C py
ht. rig
rig ht
2.1 Assembly overview - timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
py by
co Vo
by lksw
2.2 Removing and installing inlet camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . .
cted
66
agen
Prote AG.
2.3 Removing and installing upper timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.4 Removing and installing timing chain cover (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.5 Renewing oil seal for vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.6 Camshaft timing chain - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.7 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.8 Assembly overview - balancer shaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.9 Removing and installing balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Contents i
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.1 General notes on the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.3 Assembly overview - sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.4 Removing and installing coarse oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.6 Removing and installing lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.7 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2 Oil filter bracket, oil pressure, engine oil cooler and oil supply line . . . . . . . . . . . . . . . . . . 128
2.1 Assembly overview - oil filter, engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.2 Removing and installing engine 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 . . . . . . . . . . . . . . . . . . . . . . . . . . e.n.A.G.. V . o. l.ks.w.a.g.en. A. G. . . . . . . . . . . . . . . 130
wag does
olks not
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . .ise. d. . . . . . . . . . . . . . . . . . . . . . . g.ua.ra.n . . . .
byV
132
or te
1 Cooling system . . . . . . . . . . . . . . . . . .a.ut.h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e o.r a. . 132
c
1.1 General notes on cooling system . . . s.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
ce
e
nl
pt
du
an
itte
y li
erm
ab
2 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
ility
ot p
wit
2.1 Coolant hose schematic diagram for vehicles with heat exchanger . . . . . . . . . . . . . . . . . . 139
, is n
h re
2.2 Coolant hose schematic diagram for vehicles with 2nd heat exchanger . . . . . . . . . . . . . . 140
hole
t to the co
3.1 Assembly overview - coolant pipes and continued coolant circulation pump V51 . . . . . . 141
3.2 Removing and installing continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . 142
3.3 Coolant pump and thermostat - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
rrectness of i
3.5 Removing and installing toothed belt for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3.6 Renewing oil seal for coolant pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
nform
ercia
ion
in t
or
his
do
riv
cum
or
en
ng
t.
yi Co
4.4 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cop py
rig 155
ht ht
rig
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
py by
co Vo
by lksw
cted agen
1 General notes on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Prote AG.
ii Contents
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
ce
e
nl
pt
3.4 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
du
an
itte
y li
3.5 Removing and installing filler neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
erm
ab
3.6 Assembly overview - fuel filter with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
ility
ot p
wit
3.7 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
, is n 177
h re
3.8 Removing and installing fuel pump control unit J538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
hole
spec
4 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
es, in part or in w
t to the co
4.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4.2 Removing and installing accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
rrectness of i
5 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
5.1 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
l purpos
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
nform
ercia
at
om
ion
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
c
in t
or
his
ate
do
riv
cum
or
en
ng
t.
yi
1.6 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Co
Cop py
t. rig
1.7 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pyri
gh by
ht
186
1.8 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
o Vo
by c lksw
cted agen
Prote AG.
2 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
2.3 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Contents iii
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
db ua
1 Assembly overview - partsoof ris the exhaust system . . . . . . . . . . . . . . n.te.e. . . . . . . . . . . . . . . .
e ra
239
h
1.1 Removing and installings aucatalytic
t
converter . . . . . . . . . . . . . . . . . . . . .or.ac. . . . . . . . . . . . . . 240
s
1.2 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
ce
le
un
pt
1.3 Removing and installing centre silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
an
d
itte
y li
1.4 Removing and installing rear silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
erm
ab
1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
ility
ot p
wit
1.6 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
is n
h re
1.7 Installation position and specified torque of the clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
ole,
spec
urposes, in part or in wh
t to the co
1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
rrectne
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
1.3 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
ss
1.4 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 248
o
cial p
f in
1.5 Removing and installing spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
form
mer
atio
m
n
c
i
or
n
1.8 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
iv Contents
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
00 Technical data
1 Technical data
Engine number
Engine data
5500 rpm
pt
du
an
itte
y li
ab
to 3750 rpm
ility
ot p
wit
h re
hole
Bore mm 82.5mm
spec
es, in part or in w
Stroke mm 92.8mm
t to the co
atio
m
n in
or c
Turbocharging/supercharging yes
thi
te
sd
a
o
r
rp
cu
o
en
ng
t.
yi Co
Secondary air injection t. Cop py
rig no
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
1
AG.
1. Technical data
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
1) If petrol with a RON rating of less than 95 is used, reduced power output and
torque must be expected.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Procedure
hole
spec
es, in part or in w
t to the co
Note
atio
All cable ties that are opened or cut through when the engine
om
n in
thi
sd
iva
o
r
Seal open lines and unions with clean plugs from engine bung
rp
cu
o
en
ng
t.
yi Co
op
Collect drained coolant in a clean container for re-use or dis
C py
t. rig
gh
posal.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
ce
le
un
pt
55 ; Bonnet .
an
d
itte
y li
Remove engine guard, if fitted Body, front; Rep. gr. 50 ;
rm
ab
pe
ility
Engine guard .
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Detach coolant hose -2- with both brackets -1-.
rrectness of i
Unscrew bolts -3-.
Pull latch -2- back.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
Press retaining lever -1- down and pull connector off.
co Vo
by lksw
cted agen
Prote AG.
Detach clip -1- of charge air hose -3- from connector nozzle
-2- of turbocharger.
Remove poly V-belt page 22 .
WARNING
The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)! wage
n AG. Volkswagen AG do
e
olks s no
The fuel system is also under pressure! Before opening V t gu
by ara
ed
the system, place cloths around the connections.ho
ris Then nte
eo
carefully loosen connection to release the pressure!
sa
ut ra
c
s
Wear eye and hand protection when performing any type
ce
e
nl
pt
du
of repair work on the fuel system!
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
Disconnect fuel lines -1- from bracket -2-.
te
sd
iva
o
r
cu
o
m
f
en
ng
t.
yi Co
Cop py
Note ht. rig
rig ht
py by
co Vo
by lksw
To prevent damage to condenser or to refrigerant lines and ho
cted agen
Prote AG.
ses, ensure that lines and hoses are not stretched, kinked or bent.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Unhook clips -1- and -3-.
es, in part or in w
t to the co
Uncover cable harness -2-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
cum
fo
en
ng
t.
yi Co
op py
Note
. C rig
ht ht
rig by
copy Vo
by lksw
Shear bolts must always be renewed. cted agen
Prote AG.
Release clip -2-, disconnect water hose -1- from radiator -3-
at bottom right and allow water to drain.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
wit
, is n
spec
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Detach retaining clips -3- with water hose -4- from cowling
-2-.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
pt
du
y li
ab
ility
ot p
Remove cowling.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Install support bracket -10 - 222 A- .
es, in part or in w
t to the co
Secure hook -10 - 222 A /10- and adapter -10 - 222 A /20- to
support bracket -10 - 222 A- .
rrectness of i
Connect adapter -10 - 222 A /20- to gearbox transport eye.
Remove bolts -2- and -3-.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
Unscrew the two upper bolts -1-. ss
au ac
ce
le
pt
an
intake hoses that have to be disconnected from the engine in
d
itte
y li
order to remove it.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
Caution
t to the co
Only a few millimetres of space are available between
plenum chamber and radiator/lock carrier for removing
rrectne
and installing the engine. The engine must therefore be
guided carefully when raising and lowering.
ss o
Raise and lower the engine slowly with the assistance of
cial p
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
en
ng
ce
e
nl
pt
du
Check needle bearing -arrow- in crankshaft. If it is damaged
an
itte
y li
or has turned blue, it must be renewed page 44 .
erm
ab
ility
ot p
If it is not damaged, lightly grease with high-temperature
wit
, is n
grease -G 052 133 A2- .
h re
hole
spec
Slightly grease the journal (not the teeth) of the gears as well.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
1.2 Securing engine on engine and gearbox support - VAS 6095 -
orm
m
atio
om
n in
or c
Special tools and workshop
thi
te
sd
equipment required
iva
o
r
rp
cu
Lifting tackle -2024 A-
o
m
f
en
ng
t.
yi Co
Workshop hoist -VAS Cop py
. rig
6100-
ht ht
rig by
copy Vo
Engine and gearbox sup
by lksw
cted agen
Prote
port -VAS 6095-
AG.
Prerequisite
Engine with gearbox removed and mounted on engine support
-T10359- .
Attach lifting tackle -2024 A- as shown and lift from engine and
gearbox jack -VAS 6100- using workshop crane -V.A.G 1383
A- .
Caution
AG. Volkswagen AG d
agen oes
olksw not
1.3 Notes on installing
V gu
d by ara
ise nte
or eo
h
Special tools and workshopaut equipment required ra
ss c
ce
le
pt
5051B-
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f in
Procedure
form
mer
n
c
i
or
n thi
e
Caution
t
sd
iva
o
pr
cum
r
fo
t.
plenum chamber and radiator/lock carrier for removing
yi Co
op
and installing the engine. The engine must therefore be
C py
t. rig
gh
guided carefully when raising and lowering.
ht
pyri by
Vo
o
by c lksw
Raise and lower the engine slowly with the assistance of
cted agen
Prote AG.
a second mechanic.
The workshop hoist -VAS 6100- must also be guided care
fully when raising and lowering the engine.
ce
e
nl
Caution
pt
du
an
itte
y li
erm
ab
Bring engine and gearbox together in longitudinal direc
ility
ot p
wit
, is n
h re
When bringing engine and gearbox together, make sure
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh
First tighten the two upper bolts -1-.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
Tighten new bolts -1- fors right engine mounting -A-.
s c
ce
e
nl
pt
Install catalytic converter page 240 .
du
an
itte
y li
Install air conditioner compressor Heating, air conditioning;
erm
ab
ility
Rep. gr. 87 .
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
installing starter .
Fit engine guard, if available Body, front; Rep. gr. 50 ; En
rrectness of i
gine guard .
l purpos
nf
ercia
orm
page 184 .
m
atio
om
and to ensure that the engine starts quickly after parts have been
thi
te
sd
a
o
r
rp
cu
o
en
ng
t.
sure pump are removed or renewed, Bleeding fuel system
yi Co
op
function must be carried out to bleed fuel system using vehicle
C py
t. rig
gh
diagnosis tester in Guided Functions page 209 .
ht
pyri by
Vo
o
by c lksw
This process takes 130 seconds. Fuel pumps are actuated a
cted agen
Prote AG.
total of 3 times in this case. The process must not be termi
nated prematurely.
Check oil level page 115 .
Note
Caution
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
Left engine mounting to engine support
rig ht
py by
co Vo
by lksw
cted
Bolt new engine mounting -3- to engine support -1- with nut
agen
Prote AG.
-2-.
Always renew nut -2- and tighten to 90 Nm + 90 (1/4 turn).
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Gearbox mounting to gearbox
Secure gearbox mounting -A- to gearbox with bolts -1-.
rrectness of i
Always renew bolts -1- and tighten to 50 Nm + 90 (1/4 turn).
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
Gearbox mounting to gearbox cross member Cop
yi Co
py
t. rig
Secure gearbox mounting -A- to gearbox cross member with gh ht
yri by
bolts -1-. cop Vo
by lksw
cted agen
Prote AG.
Always renew bolts -1- and tighten to 30 Nm + 90 (1/4 turn).
Removing and installing gearbox mounting Rep. gr. 34
13 Crankshaft group
1 Cylinder block (pulley end)
1 - Poly V-belt
Check for wear.
Do not kink.
Poly V-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.
. Volkswagen AG
gen AG does
Removing and installing Vol
ksw
a
not
page 22 . ed
by gu
ara
ris nte
When installing, make utho eo
ra
sure it is properly seatedss a c
on pulleys.
ce
e
nl
pt
du
an
2 - Guide roller
itte
y li
erm
ab
20 Nm
ility
ot p
wit
3 - Bolt
, is n
h re
Renew.
hole
spec
150 Nm + 90 further
es, in part or in w
t to the co
Use counterhold -
T10355- when loosen
ing and tightening
rrectness of i
l purpos
Caution
Risk of damage to en
nform
ercia
gine.
To
avoid disturbing valve
m
at
om
removed.
his
ate
do
priv
cum
for
4 - O-ring
en
ng
t.
yi Co
op
Renew. C py
t. rig
gh ht
yri
5 - Vibration damper
p by
co Vo
by lksw
cted
With poly V-belt pulley.
agen
Prote AG.
Caution
Risk of damage to en
gine.
To
avoid disturbing valve
timing, do not turn crank
shaft out of TDC posi
tion when vibration
damper is removed. agen
AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
6 - Bolt rise nte
tho eo
u ra
40 Nm ss a c
ce
e
nl
7 - Tensioning element for poly V-belt
pt
du
an
itte
Swing with spanner to slacken poly V-belt.
y li
erm
ab
Lock with locking tool -T40098- .
ility
ot p
wit
Removing and installing page 21 .
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing and installing ancillary bracket page 24 .
Removing and installing engine oil cooler page 129 .
rrectness of i
9 - Alternator
l purpos
nf
ercia
or
Specified torque Rep. gr. 27
m
m
atio
m
11 - Bolt
o
n in
or c
thi
Tightening sequence page 21 .
te
sd
iva
o
r
12 - Bolt
rp
cu
o
m
f
en
ng
n AG. Volkswagen AG do
wage es n
Poly V-belt route without air conditioner
yV
olks ot g
ua
b
ed ran
1- Vibration damper thoris tee
or
au ac
2- Guide roller ss
ce
le
un
pt
y li
erm
4- Alternator
ab
ility
ot p
5- Vane pump
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
poly V-belt
ss
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
Caution
pt
an
itte
y li
erm
ab
wit
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
22
AG.
Rep. gr.13 - Crankshaft group
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Removing
Caution
ce
le
pt
an
d
itte
Installing
y li
rm
ab
pe
ility
Installation is carried out in the reverse order. When installing,
ot
wit
note the following:
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
Alternator and air conditioner compressor must be firmly mounted
before poly V-belt is installed.
rrectness of i
l purpos
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
wage es n
Locking tool -T40098- yV
olks ot g
d b ua
ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
Removing
rrectne
f i
Caution
nform
mer
atio
i
or
n thi
e
sd
iva
cum
r
fo
en
ng
t.
yi Co
Cop py
To slacken poly V-belt turn tensioner in direction of -arrow-.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
WARNING
Caution
Note
Unscrew bolts -1- from front through belt pulley, unscrew bolt
-2- from rear.
AG. Volkswagen AG d
agen oes
olksw not
Note d byV gu
ara
ise nte
or eo
th
The vane spump
s au is shown without a belt pulley and without hy ra
c
draulic lines in the figure.
ce
e
nl
pt
du
an
itte
y li
ab
member.
ility
ot p
wit
, is n
h re
hole
spec
Release oil filter -arrow- using oil filter tool -3417- and remove
es, in part or in w
t to the co
oil filter.
Remove bolts from bracket of continued coolant circulation
pump -V51- .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
from coolant pump housing.
pt
du
an
itte
y li
Installing
erm
ab
ility
ot p
Installation is carried out in the reverse order. When installing,
wit
, is n
note the following:
h re
hole
spec
Specified torques page 19 .
es, in part or in w
t to the co
Note
rrectness of i
Renew bolts that are tightened with specified further tightening
angle.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
do
riv
parts catalogue .
p
cum
for
en
g
t.
yi Co
Cop py
Push bracket for ancillaries -1- onto connection, fit bolts and
t. rig
gh ht
yri
tighten, tightening sequence.
p by
co Vo
by lksw
cted agen
Install vane pump Rep. gr. 48 .
Prote AG.
Removing
Remove poly V-belt page 22 .
Remove engine guard, if fitted Body, front; Rep. gr. 50 ;
Engine guard .
Turn vibration damper to TDC position -arrow- using coun G. Volkswagen
terhold -T10355- . lksw
agen
A AG do
es n
o ot g
yV ua
Notch on vibration damper must align with arrow
ris
ed marking on
b ran
tee
cover for timing chains (bottom). ut
ho
or
sa ac
Remove bolt for vibration damper using scounterhold -
ce
e
nl
T10355- .
pt
du
an
itte
y li
erm
ab
Caution
ility
ot p
wit
, is n
h re
Risk of damage to engine.
hole
spec
To avoid disturbing valve timing, do not turn crankshaft out
es, in part or in w
t to the co
rrectness of i
Installing
l purpos
at
om
io
Note
n
c
in t
or
his
ate
cum
or
en
ng
t.
yi Co
Cop py
t. rig
Lubricate sealing lip of oil seal with gear oil. opyri
gh by
Vo
ht
by c
Fit vibration damper (pay attention to shape of tooth -arrow-).
lksw
cted agen
Prote AG.
1 - Cylinder block
2 - 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.
AG. Volkswagen AG d
6 - Needle bearing lksw
agen oes
not
o
Removing and installing byV gu
ara
ed
nte
needle bearing horis
eo
page 32 aut ra
ss c ce
le
7 - Intermediate plate
un
pt
an
d
y li
rm
sleeves.
ab
pe
ility
wit
, is n
when assembling.
h re
hole
8 - Dowel sleeve
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
29
by lksw
cted agen
Prote 2. Cylinder block (gearbox end)
AG.
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Depth gauge
rrectness of i
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
Note
ss
f i
atio
om
n
c
n thi
21.1 mm
te
sd
iva
o
r
cum
r
fo
20.4 mm
en
ng
t.
yi Co
op
If the specification is not reached, replace all securing bolts and
C py
t. rig
gh
tighten.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Procedure
Gearbox removed.
Remove drive plate page 30 .
Place support -40 - 103- under drive plate when removing or
installing it.
Remove needle bearing using pipe section -VW 421- and
workshop press.
Thinner of pipe section -VW 421- to drive plate.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
2.4 Removing and installing sealing flange
a ac
ss
ce
le
on gearbox side
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Eye protection
hole
spec
es, in part or in w
Gearbox removed.
l purpos
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
n AG. Volkswagen AG do
Note lkswage es n
o ot g
byV ua
d ran
ir se
Observe use-by date of silicone sealant.
utho tee
or
a ac
The sealing flange must be installed within 5 minutes of ap ss
ce
le
pt
an
d
itte
y li
erm
ab
Remove sealant residues from cylinder block with a flat scra
ility
ot p
per.
wit
is n
h re
ole,
WARNING
spec
urposes, in part or in wh
t to the co
Risk of eye injury.
Wear safety goggles.
rrectness
Remove sealant residues from sealing flange, e.g. with rotat
o
cial p
f
ing plastic brush.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Note
After installing the sealing flange, wait about 30 minutes for the
sealant to dry. Only then fill with engine oil.
. Volkswagen AG
gen AG does
swa
Perform further assembly
by
Vol analogously in reverse order
k not of remov
gu
al. When doing rthis,
ise observe the following:
d ara
nt ee
tho or
Install drive
au plate page 30 . ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1 - Conrod bolt
45 Nm + 90 further
Renew.
Oil threads and contact agen
AG. Volkswagen AG d
oes
surface. olksw not
y V gu
d b ara
Use old bolt for measur orise nte
eo
ing radial clearance. auth
ra
ss c
To measure radial clear
ce
le
un
ance, tighten to 30 Nm
pt
an
d
y li
rm
ab
pe
ility
ot
wit
Note installation posi
, is n
h re
tion.
hole
spec
The conrod bearing cap
es, in part or in w
t to the co
and only on the appro
priate conrod due to the
breaking procedure
rrectness of i
(cracking) separating
l purpos
nform
ercia
Installation position:
m
a
Marking -B- faces to
com
tion in
wards pulley end.
r
te o
thi
Separating new conrod
s
iva
do
page 39 .
r
rp
cum
fo
en
g
3 - Bearing shells
n
t.
yi Co
op
Installation position
C py
t. rig
gh
page 38 .
ht
pyri by
Vo
co lksw
by
Do not interchange Prote
cted AG.
agen
used bearing shells
(mark).
Axial clearance new:
0.100.35 mm, wear
limit: 0.40 mm
Measure radial clearance using Plastigage; new: 0.020.06 mm; wear limit: 0.09 mm. Do not rotate
crankshaft when checking radial clearance.
4 - Pressure relief valve
27 Nm
5 - Oil spray jet
For piston cooling.
6 - Circlip
7 - Piston pin
If difficult to move, heat piston to approx. 60 C.
Remove and install using drift -VW 222 A- .
8 - Piston
Check page 38 .
ce
le
pt
an
d
y li
erm
ab
Checking ring gap page 37 .
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
2 parts
t to the co
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.
rrectne
Offset gaps of individual parts of oil scraper ring.
Checking ring gap page 37 .
ss
Ring-to-groove clearance cannot be checked.
o
cial p
f inform
11 - Conrod
mer
atio
Renew as set only.
om
n
c
n thi
e
sd
iva
o
pr
en
ng
t.
yi Co
Cop py
ht. rig
Checking piston ring gap
rig ht
py by
co Vo
by lksw
cted
Push ring at right angles from above down to approx. 15 mm
agen
Prote AG.
from bottom end of cylinder. Push in using a piston without
rings.
Piston ring New Wear limit
dimensions in mm
compression ring 0.20...0.40 0.80
Oil scraper ring 0.25...0.50 0.80
Checking piston
Measure approx. 10 mm from lower edge, offset 90 from pis
ton pin axis.
Difference between actual and nominal diameter max. 0.04
mm.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
s c
Checking cylinder bores s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
m
f
en
ng
t.
yi Co
Inside caliper 50 100 mm. t. Cop py
rig
gh ht
pyri by
Vo
co
Caution
by lksw
cted agen
Prote AG.
Note
Note
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
3.3 Piston and cylinder dimensions ss c
ce
le
un
pt
an
d
itte
y li
Caution
rm
ab
pe
ility
ot
wit
h re
grinding) may not be carried out using workshop tools! This will
hole
spec
t to the co
1)
Dimensions without graphite coating (thickness 0.02
mm). The graphite coating will wear down.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Note
ot p
wit
, is n
h re
Secure engine to repair stand using engine and gearbox support
hole
spec
-VAS 6095- when dismantling/assembling engine page 13 .
es, in part or in w
t to the co
1 - Cylinder block
rrectness of i
2 - Bearing shell for cylinder
l purpos
block
With oil groove.
nf
ercia
Do not interchange
orm
used bearing shells
m
atio
m
(mark).
o
n in
or c
Marking of crankshaft
thi
e
sd
iva
o
cation) page 41
r
rp
cu
o
m
f
en
ng
3 - Crankshaft
t.
yi Co
op py
After removing, place it t. C rig
gh ht
down so that the sender yri
p by
co Vo
wheel -item 5- is not
by lksw
cted agen
damaged and the crank
Prote AG.
7 - Bolt
10 Nm + 90 further
Renew.
Always renew sender wheel if securing bolts have been unscrewed.
8 - Sender wheel
For engine speed sender -G28- agen
AG. Volkswagen AG d
oes
lksw not
Can only be installed in one position, holes by are offset.
Vo gu
ara
ed
Always renew sender wheel if securinghoris bolts have been unscrewed. nte
eo
ut ra
Removing and installing Item s7s (page 40) .
a c
ce
le
9 - Thrust washers
un
pt
an
d
itte
For bearing 3.
y li
rm
ab
pe
ility
10 - Bolt
ot
wit
, is n
Renew.
h re
hole
spec
es, in part or in w
t to the co
Crankshaft tightening sequence
rrectness of i
Tighten crankshaft bolts in the sequence -1 5- as follows:
l purpos
nform
ercia
a
com
tio
4. Pre-tighten bolts -arrows- to 20 Nm.
n in
r
te o
thi
5. Turn bolts -arrows- 90 further using a fixed wrench.
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4. Crankshaft 41
Amarok 2011
4-cylinder injection engine (2.0 l direct injectionagengine,
en AG. V turbocharger)
olkswagen AG
do - Edition 02.2011
w es n
olks ot g
yV ua
Marking on bearing shell for cylinder block: rised b ran
tee
tho or
s au ac
s
Note
ce
le
un
pt
an
d
itte
y li
The marking on the cylinder block can be found engraved either
rm
ab
in the sump sealing surface or in the front end (gearbox side) of
pe
ility
ot
the cylinder block.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Identification on cylinder block is allocated to upper bearing shell
(bearing shell for cylinder block).
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
Procedure hor eo
aut ra
s c
Screw dial gauge -VAS 6079- with universal dial gauge holder s
ce
e
-VW 387- onto cylinder block and set against crank web.
nl
pt
du
an
itte
y li
ab
0.
ility
ot p
wit
Push crankshaft away from dial gauge and read off value.
, is n
h re
hole
Axial clearance:
spec
es, in part or in w
shaft
nform
ercia
at
Plastigage
om
ion
c
in t
or
Procedure
his
ate
do
priv
cum
for
Note
en
ng
t.
yi Co
Cop py
t. rig
Do not interchange used bearings. opyri
gh by
Vo
ht
by c
Bearing shells worn down to nickel layer must be renewed.
lksw
cted agen
Prote AG.
4. Crankshaft 43
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Remove main bearing caps and clean bearing caps and jour
nals.
Place a length of Plastigage corresponding 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: n AG. Volkswagen AG do
lkswage es n
New: 0.017 0.037 mm. byV
o ot g
ua
d ran
ir se
Wear limit: 0.15 mm utho tee
or
a ac
ss
4.6 Pulling needle bearing out of and driving into crankshaft
ce
le
un
pt
an
d
itte
y li
rm
ab
Special tools and workshop
pe
ility
equipment required
ot
wit
, is n
h re
Internal puller -Kukko 21/2-
hole
spec
es, in part or in w
22/1-
t to the co
Centring mandrel -3176-
Drift -VW 207 C-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
Procedure
Gearbox is separated from engine.
Note
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Installation depth dimension -a- = 1.5 to 1.8 mm.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Crankshaft 45
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Note
pt
an
d
itte
1. Tighten to 8 Nm
y li
erm
ab
ility
ot p
h re
ole,
spec
5 - Cylinder head
urposes, in part or in wh
page 48 .
Check for distortion
rrectne
page 48 .
6 - Cylinder head bolt
ss o
Renew.
cial p
f in
loosening page 48 .
atio
m
n
c
i
or
tightening page 46 .
thi
te
sd
a
Tighten in 3 stages:
iv
o
pr
cum
r
fo
1. Tighten to 40 Nm
en
ng
t.
yi Co
op py
2. Use fixed wrench to t. C rig
gh ht
turn 90 further yri
p by
o Vo
by c lksw
cted agen
3. Use fixed wrench to
Prote AG.
turn 90 further
7 - O-ring
Renew.
Lubricate with engine oil
8 - Plug
5 Nm
With ball head for engine cover panel
9 - Cap
With seal.
10 - O-ring
Renew.
Lubricate with engine oil
11 - Plug
12 - To intake manifold.
13 - Heat shield
n AG. Volkswagen AG do
wage
14 - Bolt olks es n
ot g
byV ua
20 Nm ir se
d ran
tee
tho
u or
15 - Bolt ss
a ac
20 Nm
ce
le
un
pt
an
d
itte
16 - To intake manifold/turbocharger
y li
erm
ab
ility
17 - Breather pipe
ot p
wit
is n
18 - O-ring
h re
ole,
spec
No replacement part available
urposes, in part or in wh
t to the co
19 - Seal
No replacement part available
20 - Bolt rrectne
Tightening sequence page 48 .
ss
21 - Crankcase breather
o
cial p
f inform
22 - Seal
mer
atio
n
c
23 - Seal
or
n thi
te
sd
a
Renew if damaged.
iv
o
pr
cum
r
fo
24 - Vacuum pump
en
ng
t.
yi Co
Removing and installing page 63 . t. Cop py
rig
gh ht
25 - Bolt yri
p by
co Vo
by lksw
Specified torque: 9 Nm. cted agen
Prote AG.
26 - Connection
27 - Retaining plate
28 - Bolt
9 Nm
29 - O-ring
Renew.
Lubricate with coolant
30 - Transport lug
31 - Bolt
25 Nm
1. Cylinder head 47
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
32 - Bolt
9 Nm
33 - Hall sender -G40-
34 - Partition
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Puller -T40039-
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
Counterhold tool -T10355-
aut ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Cylinder head 49
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Removing
Note
pt
an
d
itte
y li
ab
hot.
ility
ot p
wit
h re
spec
urposes, in part or in wh
t to the co
n
c
i
or
Caution
thi
te
sd
iva
o
r
cum
r
fo
en
ng
t.
Observe safety precautions when working on injection
yi Co
op
system page 160 .
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Release clip -2- for fuel pressurisation line -3- and detach from
high-pressure pump -1-.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
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.
Withdraw air filter housing upwards.
Release clip -3- from pressure hose -4-.
1. Cylinder head 51
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
Unplug following electrical connectors.
ce
e
nl
pt
du
an
itte
y li
erm
ab
3 - From variable intake manifold valve -N316- , fuel pressure
ility
ot p
wit
, is n
h re
hole
4 - From injectors.
spec
es, in part or in w
t to the co
6 - From intake air temperature sender -G42- .
rrectness of i
l purpos
nf
ercia
side.
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Release connectors -arrows- and simultaneously detach all
es, in part or in w
t to the co
connectors from ignition coils.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
t.
yi Co
op
Unscrew spark plugs using spark plug socket and extension C py
t. rig
-3122 B- . gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Cylinder head 53
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
Unscrew bolts -1 and 2- and lay oil supply line to one side.
wit
is n
h re
Unscrew bolt -3- and lay coolant line to one side.
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
Unscrew nuts -arrows- andsremove
au catalytic converter ac
page 240 . s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
-1-.
o
cial p
f inform
valve 1 -N205- .
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 55
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
Caution
itte
y li
rm
ab
pe
ility
wit
, is n
h re
hole
spec
-direction of arrow-.
rrectness of i
l purpos
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Remove sealing plug -arrow-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
en
g
t.
yi Co
sioner. Cop py
t. rig
gh ht
yri
Turn crankshaft in opposite direction to normal rotation p by
co Vo
-arrow 2- and lock in place using locking pin -T40011- .
by lksw
cted agen
Prote AG.
Note
1. Cylinder head 57
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Caution
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Caution
pt
an
d
itte
ab
ility
ot
wit
h re
spec
gasket.
es, in part or in w
t to the co
tio
erated.
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Cylinder head 59
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Note
WARNING
ce
e
nl
pt
du
an
itte
y li
erm
ab
must be turned with a wrench.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Note
nform
ercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
The timing chain links with markings must be positioned at the
pt
du
an
markings on the chain sprockets.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Fit camshaft timing chain: the drive chain/sprocket markings
es, in part or in w
t to the co
Use spanner to turn inlet camshaft in direction of -arrow- and
fit timing chain.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
c
Attach bearing saddle and screw in bolts -arrows- hand-tight.
um
for
en
ng
t.
Remove locking pin -T40011- .
yi Co
Cop py
ht. rig
Tighten bolts -arrows- for bearing saddle. rig ht
py by
co Vo
by lksw
Install regulating valve. cted agen
Prote AG.
WARNING
1. Cylinder head 61
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Puller -T40039-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Test procedure
es, in part or in w
t to the co
Note
rrectness of i
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
pt
du
y li
ab
wit
, is n
h re
finding function .
es, in part or in w
t to the co
Removing
l purpos
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Cylinder head 63
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Unscrew bolts -arrows- and remove vacuum pump.
es, in part or in w
t to the co
Note
rrectness of i
The vacuum pump must not be dismantled.
l purpos
Installing:
nf
ercia
or
Specified torques page 46 .
m
m
atio
m
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
cylinder head. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2 Chain drive
1 - 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 agen
AG. Volkswagen AG d
oes
lksw not
Tightening sequence by Vo gu
ara
page 66 . rise
d
nte
tho eo
u
8 - Timing chain cover (top) ss a ra
c
Removing and installing ce
e
nl
pt
du
page 66 . an
itte
y li
erm
ab
9 - Seal ility
ot p
Renew if damaged.
wit
, is n
h re
10 - O-ring
hole
spec
Renew.
es, in part or in w
t to the co
11 - Dowel pins
For centring cover
l purpos
at
13 - Bolt
om
ion
c
Renew.
in t
or
his
e
do
priv
cum
14 - Oil seal
for
en
ng
t.
yi
For vibration damper
Co
Cop py
t.
Renewing page 71 .
rig
gh ht
pyri by
Vo
co
15 - Plug
by lksw
cted agen
Prote AG.
Renew.
2. Chain drive 65
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
2.2 Removing and installing inlet camshaft
l purpos
Removing
m
tio
-1-.
n in
r
te o
thi
do
valve 1 -N205- .
r
rp
cum
fo
en
g
Installing
n
t.
yi Co
op py
Installation is carried out in the reverse order. When installing,
t. C rig
gh ht
yri
note the following: p by
o Vo
by c lksw
cted agen
Specified torque Prote AG.
2.1 Assembly overview - timing chain cover, page 65 .
Note
Renew O-ring.
ce
e
nl
pt
chain cover
du
an
itte
y li
erm
ab
Removing
ility
ot p
wit
Detach connector from inlet camshaft control valve 1 -N205-
, is n
h re
-1-.
hole
spec
Unscrew bolts -arrows- and remove inlet camshaft control
es, in part or in w
t to the co
valve 1 -N205- .
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
n in
or c
Installing
thi
te
sd
iva
o
Installation is carried out in the reverse order. When installing,
r
rp
cu
o
m
note the following:
f
en
ng
t.
yi Co
op
Specified torque C py
ht. rig
2.1 Assembly overview - timing chain cover, page 65 . rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Renew O-ring.
2. Chain drive 67
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
Removing
t.
yi Co
Cop py
t. rig
gh ht
yri
Caution p by
o Vo
by c lksw
cted agen
Prote AG.
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.
ce
e
nl
pt
du
an
itte
y li
erm
Note
ab
ility
ot p
wit
, is n
Always use thrust piece -T10368- when fitting bolt for vibration
h re
damper to avoid damaging splines.
hole
spec
es, in part or in w
t to the co
Screw bolt for vibration damper and thrust piece -T10368-
back in.
rrectness of i
Caution
l purpos
nform
ercia
at
of TDC position when bolt for vibration damper is re
om
io
moved.
n
c
in t
or
his
ate
do
priv
c
Remove guide roller -1-.
um
for
en
ng
t.
yi Co
op
Remove bolts -arrows- and pull guide tube for oil dipstick out
C py
t. rig
gh
of timing chain cover.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Chain drive 69
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
ce
le
un
Installing
pt
an
d
itte
y li
Specified torques
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
Observe use-by date of silicone sealant.
rrectness of i
The cover must be installed within 5 minutes after applying the
l purpos
silicone sealant.
Renew bolts that are tightened with specified further tightening
nform
ercia
angle.
m
a
com
tion in
r
te o
thi
Spray sealing surface with sealant remover and leave to act.
s
iva
do
r
cum
fo
per.
en
ng
t.
yi Co
Cop py
ht. rig
WARNING rig ht
py by
co Vo
by lksw
cted agen
Prote
Risk of eye injury.
AG.
Mask oil seal on both sides with adhesive tape to make sure
the seal remains clean.
Note
AG. Volkswagen AG d
agen oes
Note
yV
olksw not
gu
d b ara
ise nte
r
The cover ut must be installed within 5 minutes after applying
ho e o the
ra
silicone
s sealant.
s a c
ce
e
nl
an
wise excess sealant can enter the sump and obstruct the
itte
y li
erm
wit
, is n
quence
hole
spec
page 66 .
t to the co
Note
rrectness of i
l purpos
After fitting cover, let sealant dry for approx. 30 minutes. Only then
fill with engine oil.
nf
ercia
or
atio
om
thi
te
sd
a
o
r
rp
cu
o
m
f
en
ng
2. Chain drive 71
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
Caution
l purpos
nform
ercia
at
with chalk or felt-tipped pen for re-installation.
om
ion
c
in t
or
his
ate
do
riv
cum
for
t.
yi Co
op py
Remove poly V-belt from pulley on vibration damper.
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted
Caution
agen
Prote AG.
2. Chain drive 73
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Use thrust piece -T10354- and bolt for vibration damper to pull
in oil seal -arrow- onto stop.
Note
pt
du
an
itte
ab
gine guard .
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1 - Bolt
9 Nm
AG. Volkswagen AG d
2 - Chain tensioner agen oes
olksw not
V gu
by
Is spring-loaded rised ara
nte
o eo
Before removing, lock in aut
h
ra
place using locking pin - ss c
ce
e
T40011-
nl
pt
du
an
itte
3 - Tensioning rail for timing
y li
erm
ab
chain
ility
ot p
wit
4 - Guide pins
, is n
h re
20 Nm
hole
spec
es, in part or in w
5 - Bolt
t to the co
9 Nm
6 - Regulating valve
rrectness of i
Left-hand thread.
l purpos
35 Nm
Depending on model,
nf
ercia
orm
tool -T10352- or remov
m
atio
m
al tool -T10352/1- .
o
n in
or c
7 - Bolt
thi
te
sd
iva
Renew.
o
r
rp
cu
o
m
20 Nm + 90 further
f
en
ng
t.
yi Co
op
8 - Washer C py
t. rig
gh ht
yri by
9 - Bearing saddle op Vo
by c lksw
cted agen
Prote
10 - Guide rail for camshaft tim
AG.
ing chain
11 - Camshaft housing
12 - Camshaft timing chain
Before removing, mark running direction with paint.
13 - Guide rail for camshaft timing chain
14 - Guide pins
20 Nm
15 - Chain sprocket
Crankshaft
Installation position page 76 .
2. Chain drive 75
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.7 Removing and installing camshaft tim
ing chain
rrectness of i
Special tools and workshop equipment required
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Removing aut ra
c
ss
Remove timing chain cover (top) page 67 .
ce
le
un
pt
an
d
itte
y li
erm
ab
Caution
ility
ot p
wit
is n
h re
The timing valve has a left-hand thread.
ole,
spec
urposes, in part or in wh
t to the co
Depending on model, remove regulating valve using removal
tool -T10352- or removal tool -T10352/1- in
-direction of arrow-.
rrectness o
cial p
f inform
mer
atio
m
n
c
i
or
n
Engine guard .
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Chain drive 77
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
Press oil pump chain tensioner in direction of -arrow- and lock
erm
ab
in place using locking pin -T40011- .
ility
ot p
wit
, is n
h re
hole
spec
Remove oil pump chain.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
io
in t
r
sioner.
o
his
ate
do
riv
cum
or
en
ng
t.
yi Co
Remove camshaft timing chain from cylinder head. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
Note cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Note
l purpos
nform
ercia
at
om
ion
c
in t
or
do
priv
cum
or
en
ng
t.
yi Co
Fit timing chain onto crankshaft. Cop py
t. rig
gh ht
yri
Use spanner to turn inlet camshaft in direction of -arrow- and p by
co Vo
fit timing chain.
by lksw
cted agen
Prote AG.
Fit tensioning rail for timing chain and tighten bolt -2-.
Fit guide rail for camshaft timing chain and tighten bolts -1-.
2. Chain drive 79
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
1 - Bolt
AG. Volkswagen AG d
Renew. agen oes
olksw not
V gu
by
9 Nm rised ara
nte
ho eo
2 - Balancer shaft aut ra
ss c
Exhaust side
ce
le
un
pt
an
Must always be re
d
itte
y li
newed if removed.
rm
ab
pe
ility
Lubricate bearing with
ot
wit
engine oil
, is n
h re
hole
Renewing page 87 .
spec
es, in part or in w
t to the co
Installation position
page 81 .
rrectness of i
4 - Chain tensioner
l purpos
65 Nm
5 - Cylinder block
nform
ercia
6 - Balancer shaft
m
a
com
Must always be re
te o
thi
newed if removed.
s
iva
do
r
rp
en
g
engine oil
n
t.
yi Co
op
Renewing page 84 .
C py
t. rig
gh ht
yri by
7 - O-ring
op Vo
by c lksw
cted agen
Lubricate with engine oil Prote AG.
8 - Bearing mounting
Lubricate with engine oil
Installation position
page 81 .
9 - Intermediate shaft sprocket
For balancer shaft.
If bolt Item 12 (page 81) has been loosened, intermediate shaft sprocket will need to be renewed.
10 - Bolt
Renew.
9 Nm n AG. Volkswagen AG do
lkswage es n
11 - Washer byV
o ot g
ua
d ran
ir se
12 - Bolt utho tee
or
a a
If bolt has been loosened,ss intermediate shaft sprocket Item 9 (page 80) willc need to be renewed.
ce
le
Tightening sequence page 82 .
un
pt
an
d
itte
y li
13 - Guide rail
erm
ab
ility
For timing chain.
ot p
wit
is n
14 - Guide pins
h re
ole,
spec
20 Nm
urposes, in part or in wh
t to the co
15 - Tensioning plate
For timing chain.
rrectne
16 - Guide pins
20 Nm
ss o
17 - Timing chain
cial p
f in
Removing page 82
form
mer
atio
18 - Chain sprocket
om
n
c
i
or
n thi
te
sd
a
19 - Guide rail
iv
o
pr
cum
r
en
ng
t.
yi Co
20 - Guide pins t. Cop py
rig
gh
20 Nm
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Chain drive 81
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Caution
ce
e
nl
pt
du
an
itte
y li
loosen bolt and tighten again.
erm
ab
ility
ot p
wit
, is n
h re
4. Use fixed wrench to turn 90 further.
hole
spec
es, in part or in w
t to the co
module
rrectness of i
Removing
l purpos
Engine guard .
orm
m
atio
n in
or c
sd
iva
cu
o
m
f
en
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
Note
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
Fit timing chain. The timing chain links with coloured markings
s
must be positioned at the markings on the chain sprockets.
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Fit guide rail for timing chain and tighten bolts -4-.
Fit guide rail for timing chain and tighten bolts -3-.
Fit tensioning rail for timing chain and tighten bolt -2-.
Insert chain tensioner of timing chain -1- with locking fluid
Electronic parts catalogue .
2. Chain drive 83
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Note
pt
du
an
itte
y li
Puller -T10394-
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Puller -T10055-
Removing
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Remove engine guard, if fitted Body, front; Rep. gr. 50 ;
ot p
Engine guard .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Remove balancer shaft timing chain page 82 .
Remove intermediate shaft sprocket -1-.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
Unscrew bolt -2- for inlet camshaft balancer shaft.
co lksw
by
cted agen
Prote AG.
2. Chain drive 85
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Screw puller -T10055- into puller -T10394- and force out bal
ancer shaft in -direction of arrow-.
Installing
Note
Due to the small amount of play between the balancer shaft agand
en AG. V
olkswagen AG
does
ksw
cylinder block, the balancer shaft may need to be installed by Vol chilled. not
gu
Check whether the balancer shaft can be fitted into rise the cylinder
d ara
nte
block without exerting force. If this is not the case,
utho the balancer eo
ra
shaft must be chilled before installing. ss a c
ce
e
nl
pt
du
Specified torque
an
itte
y li
ab
80 .
ility
ot p
wit
, is n
spec
ing spray.
es, in part or in w
t to the co
Install new balancer shaft for inlet camshaft and tighten bolt
rrectness of i
-2-.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
86
AG.
Rep. gr.15 - Cylinder head, valve gear
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Caution
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
quence page 82 .
Check markings on intermediate shaft sprocket/balancer shaft
rrectness of i
-arrow-.
l purpos
n in
c
thi
te
sd
a
o
r
rp
cu
o
en
ng
t.
yi Co
op
Install poly V-belt page 22 . C py
t. rig
gh ht
yri by
Renew oil seal for coolant pump drive page 148 .
op Vo
by c lksw
cted agen
Prote
Fit toothed belt for coolant pump page 146 .
AG.
2. Chain drive 87
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Puller -T10394-
Puller -T10055-
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
Removing tho tee
or
au ac
ss ce
le
un
pt
Note an
d
itte
y li
erm
ab
The balancer shaft for the inlet camshaft must always be renewed
ility
ot p
after removing.
wit
is n
h re
ole,
Engine guard .
Remove lower timing chain cover page 67 .
rrectne
f in
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
Insert shell half -T10394/1- from puller -T10394- .
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Screw puller -T10055- into puller -T10394- and force out 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
80 .
2. Chain drive 89
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Note agen
AG. Volkswagen AG d
oes
olksw not
y V gu
b ara
If the balancer shaft does notorirest
se flat, the pipe for balancer shaft
d
nte
must be inserted again. aut h eo
ra
ss c
ce
e
nl
pt
du
an
quence. In the process, note the following:
itte
y li
erm
ab
Install balancer shaft module page 82 .
ility
ot p
wit
, is n
h re
hole
spec
Install timing chain cover (bottom) page 67 .
es, in part or in w
t to the co
Install timing chain cover (top) page 67 .
Install tensioner for poly V-belt page 21 .
rrectness of i
Install poly V-belt page 22 .
l purpos
nform
ercia
at
om
ion
c
his
ate
do
priv
cum
or
Note
f
en
ng
t.
yi Co
op
Use a ratchet spanner with a 24 mm socket to turn the vibration
C py
t. rig
gh
damper. Always turn the vibration damper in the engine's direc
ht
pyri by
Vo
o
tion of rotation to the TDC position. Do not correct TDC position
c by lksw
cted agen
by turning the damper in the other direction. Prote AG.
Measure the distance from the outer edge of web -A- to mark
ing -B- on the inlet camshaft.
Specification: 6164 mm.
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Chain drive 91
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
3 Valve gear
1 - Exhaust valve
Do not rework. Only lap
ping in is permitted.
Valve dimensions
page 94 . AG. Volkswagen AG d
agen oes
ksw
Checking valve guides by
Vol not
gu
ara
page 112 . rise d
nte
tho eo
2 - Cylinder headss au ra
c
ce
e
3 - Valve guide
nl
pt
du
an
itte
y li
erm
ab
4 - Valve stem seal
ility
ot p
wit
, is n
h re
head fitted
hole
spec
page 109 , with cylin
es, in part or in w
t to the co
page 109
5 - Valve spring
6 - Valve spring plate rrectness of i
l purpos
7 - Valve cotters
8 - Hydraulic compensation el
nf
ercia
ement
rm
m
atio
m
Do not interchange.
o
n in
or c
sd
iva
9 - Exhaust camshaft
o
r
rp
cu
o
en
ng
t.
yi
page 94 .
Co
Cop py
t.
Check radial clearance
rig
gh ht
yri by
with Plastigage (roller op Vo
by c lksw
rocker fingers re cted agen
Prote AG.
moved).
Radial clearance:
0.024 0.066 mm.
Runout: max. 0.04 mm.
10 - Cylinder head cover
With integrated camshaft bearings.
Clean sealing surface; reworking not permitted.
Remove sealant residue.
11 - Bolt
Renew.
Loosen page 93
Tightening sequence page 93 .
12 - O-ring
Renew.
Lubricate with engine oil
13 - Plug
14 - Inlet camshaft
Removing and installing page 94 .
AG. Volkswagen AG d
Check radial clearance lksw with Plastigage (rolleresrocker
agen o
not fingers removed).
Vo gu
Radial clearance: ed b 0.024 0.066 mm.
y ara
nte
ris
Runout: max.ut
ho 0.04 mm. eo
r
a ac
ss
15 - Cap
ce
le
un
pt
Renew.
an
d
itte
y li
Remove with cylinder head cover installed, pierce on one side of cover with an awl and pry out
rm
ab
pe
ility
16 - Inlet valve
ot
wit
, is n
h re
Do not rework. Only lapping in is permitted.
hole
spec
Valve dimensions page 94 .
es, in part or in w
t to the co
Checking valve guides page 112 .
rrectness of i
Cylinder head cover - release
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Tightening sequence for cylinder head cover cted agen
Prote AG.
Renew bolts.
1. Fit bolts in the sequence -1 6- and hand-tighten in several
stages.
2. Tighten bolts in the sequence -1 6- to 8 Nm using torque
wrench.
3. Turn 90 further in the sequence -1 6- using a fixed
wrench.
Note
3. Valve gear 93
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Valve dimensions
Note
AG. Volkswagen AG d
Inlet and exhaust valves must not be reworked.ksw Only lapping-in
agen oes
not
is permitted. y Vol gu
db e
ara
ris nte
utho eo
ra
Dimension Inlet valve
ss
a Exhaust valve c
ce
le
pt
an
d
itte
y li
rm
ab
pe
ility
c mm 104.0 0.2 101.9 0.2
ot
wit
, is n
45 45
h re
hole
spec
es, in part or in w
t to the co
Special tools and workshop equipment required
rrectness of i
Puller -T40039-
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Removal tool -T10352/1- Prote
cted AG.
agen
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
Spacers -T40191-
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Valve gear 95
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Removing
Note
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
Pull off vacuum hose -2-. ss
ce
e
nl
pt
Unscrew securing bolt for air filter housing in area of coolant
du
an
itte
expansion tank.
y li
erm
ab
ility
Withdraw air filter housing upwards.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
Disconnect crankcase breatherVohose
lksw -1-. not
gu
y
db ara
Unscrew bolts -arrows-, remove
rise crankcase breather system nte
and detach from hoseau-2-tho for crankcase breather system in eo
ra
-direction of arrow-. ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Disconnect line -arrows-.
rrectness of i
Detach and remove electrical connector -1- from Hall sender
l purpos
-G40- .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Detach connector from inlet camshaft control valve 1 -N205- p by
o Vo
by c
-1-.
lksw
cted agen
Prote AG.
Unscrew bolts -arrows- and remove inlet camshaft control
valve 1 -N205- .
3. Valve gear 97
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Caution
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ility
terhold -T10355- .
ot
wit
, is n
t to the co
Note
rrectness of i
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectnes
Remove sealing plug -arrow-.
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Valve gear 99
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Note
Caution
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
Installing
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Sealing surfaces must be free of oil and grease.
Pistons must not be positioned at TDC.
rrectness of i
Ensure that all roller rocker fingers are properly seated on
l purpos
nform
ercia
at
om
ion
WARNING
c
in t
or
his
ate
do
cum
for
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Caution cted agen
Prote AG.
WARNING
ce
e
Note
nl
pt
du
an
itte
y li
If available, use 2nd set of spacers -T40191- or reuse -T40191/1- .
erm
ab
ility
ot p
wit
, is n
h re
Insert camshafts in cylinder head; markings -arrows- must be
hole
spec
positioned as shown.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
head cover, as illustrated -arrows-.
pt
du
an
itte
y li
Thickness of sealant bead: 2 ... 3 mm.
erm
ab
ility
ot p
wit
, is n
h re
Note hole
spec
es, in part or in w
t to the co
after applying the silicone sealant.
The bead of sealant must not be thicker than specified, other
rrectness of i
wise excess sealant can enter the sump and obstruct the
strainer in the oil intake pipe.
l purpos
nform
ercia
at
om
i
Fit cylinder head cover onto cylinder head.
on
c
in t
or
his
ate
do
priv
c
Tighten bolts in several stages, tightening sequence
um
for
page 92 .
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note op Vo
by c lksw
cted agen
Prote AG.
Take care to keep cylinder head cover level.
Use thrust piece -T10174- to drive in sealing cap -1- (do not
apply sealant).
- a -: 1 ... 2 mm
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Attach bearing saddle and screwho rise in bolts -arrows- hand-tight. nte
eo
ut ra
a
Remove locking pin -T40011-
ss . c
ce
e
nl
pt
du
an
itte
y li
Install regulating valve.
erm
ab
ility
ot p
wit
, is n
h re
Install timing chain cover (top) page 65 .
hole
spec
Install vacuum pump Rep. gr. 47 .
es, in part or in w
t to the co
Installing high-pressure pump Rep. gr. 24 .
Install air filter housing Rep. gr. 24 .
rrectness of i
Fit engine guard, if available Body, front; Rep. gr. 50 ; En
l purpos
gine guard .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
tension -3122 B-
an
d
itte
y li
erm
ab
Valve stem seal puller
ility
ot p
-3364-
wit
is n
h re
Valve stem seal fitting tool
ole,
-3365-
spec
urposes, in part or in wh
t to the co
Adapter -T40012-
Torque wrench -V.A.G
1331-
rrectne
Dismantling and assem
bling device for valve cot
ss o
ters -VAS 5161-
cial p
f inform
Guide plate for 2.0 l and 3.0
mer
atio
m
5161/19B-
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Secure guide plate for 2.0 ltr. and 3.0 ltr. FSI engine -VAS
5161/19B- with knurled screws -VAS 5161/12- to cylinder
head as shown.
Set piston of respective cylinder to bottom dead centre.
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
spec
Screw retainer -VAS 5161/6- with guide fork -VAS 5161/5- into
es, in part or in w
t to the co
outer threads of guide plate for 2.0 ltr. and 3.0 ltr. FSI engine
-VAS 5161/19B- .
Press installation cartridge -VAS 5161/8- down and turn
rrectness of i
tion in
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Pull off valve stem seals using valve stem seal puller -3364- .
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
If valve stem seal puller -3364- cannot be used on account of
restricted space, knock out pin -arrow- with a punch and re
move the impact extractor attachment.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Place lower part of valve stem seal puller -3364- onto valve Cop py
. rig
stem seal.
t
gh ht
pyri by
Vo
co
Insert punch -1- into bore in lower part of puller.
by lksw
cted agen
Prote AG.
Place installation lever on puller and pull out valve stem seal
-arrow-.
Installing valve stem seals
Inlet side
Exhaust side
Note
AG. Volkswagen A
If the valve cotters have been removed
lksw from the installationes no
agen G do
cartridge, they must first be inserted
db
yV
o
into the insertion device t gu
ara
-VAS 5161/18- . o
ir se nte
eo
h
ut ra
Press assembly cartridge
ss
a -VAS 5161/8- onto insertion device c
from above and pick up valve cotters.
ce
le
un
pt
an
d
itte
y li
ab
ility
ot
h re
spec
screw.
es, in part or in w
t to the co
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
Procedure
iv
o
pr
cum
r
fo
t.
yi Co
op
Mark allocation of roller rocker fingers and hydraulic compen C py
ht. rig
sation elements for reinstallation. rig ht
py by
co Vo
by lksw
Remove roller rocker fingers together with hydraulic compen cted agen
Prote AG.
sation elements and place down on a clean surface.
Insert cylinder head tensioning device -VAS 6419- into engine
and gearbox support -VAS 6095- .
Tension cylinder head on cylinder head tensioning device as
shown in illustration.
Connect cylinder head tensioning device to compressed air.
ce
le
Allow compressed air to flow into air cushion until it lies against
un
pt
an
valve disc.
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Secure guide plate for 2.0 litre. and 3.0 ltr. FSI engine -VAS
l purpos
nform
ercia
a
com
t
Insert drift -VAS 5161/3- into guide plate and use a plastic
ion in
hammer to knock loose the firmly seated valve cotters.
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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- .
Pull off valve stem seals using valve stem seal puller -3364- .
Installing valve stem seals
Caution
ce
e
nl
pt
du
an
itte
y li
erm
ab
5161- as shown.
ility
ot p
wit
, is n
h re
hole
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
Exhaust side
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
edb ara
Special tools and workshop
horis equipment required nte
eo
aut ra
Universal dialsgauge bracket -VW 387-
s c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Test procedure
Insert valve in guide. Valve stem end must be 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
ce
le
pt
an
d
y li
rm
ab
pe
ility
ot
wit
3.6 Checking axial clearance of camshafts
, is n
h re
hole
spec
Special tools and workshop equipment required
es, in part or in w
t to the co
Universal dial gauge bracket -VW 387-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Dial gauge -VAS 6079- t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Test procedure
AG . Volkswagen AG
Take measurements with retaining frame removed.
ksw
agen does
not
Vo l
y gu
Fit camshaft to be tested in retaining frame. isedb ara
nte
or eo
h
Attach dial gauge -VAS 6079- with universal
s aut dial gauge holder ra
c
-VW 387- to cylinder head. s
ce
e
nl
pt
du
Press camshaft against dial gauge by hand.
an
itte
y li
erm
ab
Set dial gauge to 0.
ility
ot p
wit
Press camshaft away from dial gauge and read off value:
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
17 Lubrication
1 Parts of lubrication system
Draining engine oil Maintenance ; Booklet 11
Engine oil page 115 .
Assembly overview - oil pump, sump page 116
Removing and installing sump page 120 .
Assembly overview - oil filter bracket and oil cooler page 128
Note
The oil level must not be above the max. mark - danger of damage
to catalytic converter! AG. Volkswagen A n G do
wage es n
Volks ot g
by ua
ed ran
Caution thoris tee
or
au ac
ss
If large quantities of metal chips and abraded material are
ce
le
un
pt
found during engine repair, this may indicate that the crank
an
d
itte
y li
rm
ab
subsequent damage, the following work must be carried out
pe
ility
following the repair:
ot
wit
, is n
h re
Thoroughly clean oil passages,
hole
spec
Renew oil spray jets,
es, in part or in w
t to the co
Renew engine oil cooler,
Renew oil filter element.
rrectness of i
l purpos
Oil capacities:
m
tion in
r
thi
s
iva
do
cum
fo
Maintenance ; Booklet 11
en
ng
t.
yi Co
op py
Checking oil level: t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Note
AG.
The oil level must not be above the max. mark - danger of damage
to catalytic converter!
Test prerequisites
Engine oil temperature at least 60 C.
Vehicle must be level (horizontal).
Wait a few minutes after switching engine off to allow oil to flow
back into sump.
Test procedure
Pull out dipstick, wipe off with a clean cloth and insert it again
to stop.
Pull out dipstick again and read oil level.
Markings on dipstick:
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 - 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. agen AG. Volkswagen AG do
ksw es n
5 - Bolt Vol ot g
d by ua
ran
e
9 Nm oris tee
th o u ra
sa c
6 - O-ring s
ce
e
nl
pt
Renew.
du
an
itte
y li
ab
ility
ot p
7 - Oil pump
wit
, is n
page 119 .
spec
es, in part or in w
8 - Centring sleeve
t to the co
9 - O-ring
Renew.
rrectness of i
-N428-
Removing and installing
nform
ercia
page 128 .
m
at
11 - Bolt
om
ion
c
in t
9 Nm
or
his
ate
12 - Chain tensioner
do
priv
cum
or
en
ng
t.
yi Co
Mark direction of rotation before removing. Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
116
agen
Prote AG.
Rep. gr.17 - Lubrication
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
14 - Bolt
9 Nm
15 - Seal
Renew.
16 - Coarse oil separator
Removing and installing page 118 .
17 - Bolt wage
n AG. Volkswagen AG do
es n
olks ot g
Tightening
d b sequence
yV page 118 . ua
r
e an
ris tee
18 - Upper ut part of sump
ho or
a ac
Removing
ss and installing page 124 .
ce
e
nl
pt
du
19 - Bolt
an
itte
y li
Renew.
erm
ab
ility
ot p
wit
, is n
h re
20 - Bolt
hole
spec
Renew.
es, in part or in w
t to the co
Tightening sequence page 118 .
21 - Bolt
rrectness of i
20 Nm
l purpos
22 - Seal
23 - Bolt
nf
ercia
9 Nm
orm
m
atio
24 - Seal
om
n in
or c
25 - Non-return valve
thi
te
sd
iva
cu
o
m
f
Renew.
en
ng
t.
yi Co
op
30 Nm C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Tightening sequence for sump (bottom section)
AG.
ce
e
nl
pt
du
an
Tightening sequence for sump (top section)
itte
y li
erm
ab
Tighten bolts in sequence -1 to 13- in 2 stages as follows:
ility
ot p
wit
, is n
1. Tighten bolts to 15 Nm.
h re
hole
spec
2. Turn bolts 90 further.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
at
om
io
Tighten bolts in the sequence -1 9- to 9 Nm.
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
Support engine.
Release clip -3- from pressure hose -4-.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Coarse oil separator, tightening sequence
ility
ot p
wit
, is n
h re
hole
spec
Replenish coolant page 133 .
es, in part or in w
t to the co
Check oil level and top up, if necessary page 115 .
rrectness of i
1.5 Removing and installing oil pump
l purpos
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
Remove sump (bottom section) page 120 .
Remove baffle plate -arrows-.
Note
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
Pull chain tensioner back ausing
ut assembly tool -T10118- and ra
c
have oil pump removed by a second mechanic. ss
ce
le
un
pt
Installing
an
d
itte
y li
rm
ab
Specified torques page 116 .
pe
ility
ot
wit
, is n
h re
the following:
hole
spec
Before installing oil pump, check strainer in oil suction pipe and
es, in part or in w
t to the co
Check that both centring sleeves for centring oil pump are
present.
rrectness of i
Renew baffle plate.
l purpos
Note
nform
mercia
a
Plastic ribs that are permanently deformed during tightening are
com
tion in
located on the baffle plate. The plastic rips ensure that the baffle
r
te o
plate rests without play and does not rattle. For this reason, the
thi
s
iva
cum
fo
en
ng
t.
yi Co
1.6 Removing and installing lower part of Cop py
ht. rig
rig ht
sump py by
co Vo
by lksw
cted agen
Prote
Special tools and workshop equipment required
AG.
Note
AG. Volkswagen AG d
agen oes
lksw not
To remove the sump lower part the engine has to bed bsupported
yV
o gu
ara
and raised by approx. 15 cm. This ensures the necessary
orise space nte
to remove the sump lower part. auth eo
ra
ss c
ce
le
pt
an
d
itte
y li
Unscrew bolts for right and left engine mounting page 17 .
rm
ab
pe
ility
Raise engine by approx. 15 cm.
ot
wit
, is n
h re
Remove engine guard, if fitted Body, front; Rep. gr. 50 ;
hole
spec
Engine guard .
es, in part or in w
t to the co
Drain off engine oil.
rrectness of i
Note
l purpos
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
rubber-headed hammer.
an
d
itte
y li
erm
ab
Installing
ility
ot p
wit
Specified torques
is n
h re
ole,
spec
urposes, in part or in wh
Note
t to the co
Observe use-by date of silicone sealant.
rrectne
The sump must be installed within 5 minutes of applying sili
cone sealing compound.
ss o
cial p
f in
scraper.
form
mer
atio
om
WARNING
n
c
i
or
n thi
te
sd
a
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
Remove sealant residue from bottom part of sump, e.g. with
by lksw
cted agen
Prote
rotating plastic brush.
AG.
Clean sealing surfaces until they are all oil- and grease-free.
Apply the bead of silicone sealant -D 174 003 A2- to the clean
sealing surface of the sump (lower part), as illustrated.
Note
Note
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
Removing
iv
o
pr
cum
r
fo
t.
yi Co
op
Remove oil pump page 119 . C py
t. rig
gh ht
yri
Remove sealing flange on gearbox side page 33 .
p by
o Vo
by c lksw
cted agen
Unscrew bolts -arrows-.
Prote AG.
DANGER!
Caution
Lever off upper part of sump on gearbox side first. When lev
ering off, exercise caution to ensure the timing chain cover is
not bent in the process.
Installing
Specified torque page 116 .
Note
WARNING
pt
an
d
itte
Note
y li
erm
ab
ility
ot p
upper part first without sealant and check gap between cover and
h re
ole,
not be corrected. Renew cover once sump upper part has been
installed.
t to the co
Clean sealing surfaces until they are all oil- and grease-free.
rrectne
Check oil galleries in sump upper part and crankcase for soil
ing.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Apply silicone sealant -D 174 003 A2- onto clean sealing sur
face of upper part of sump, as illustrated -arrow-.
Thickness of sealant bead: 23 mm
Note
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
2- Tighten bolts to 15 Nm.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
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.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
5 - Valve unit
y li
erm
ab
With O-rings
ility
ot p
wit
, is n
6 - Oil filter
h re
hole
spec
Amarok Mainte
es, in part or in w
t to the co
nance ; Booklet 11 .
Remove and install with
oil filter tool -3417- .
rrectness of i
7 - Seal
l purpos
Renew.
8 - Oil pressure switch -F22- nf
ercia
or
Blue insulation
m
m
atio
m
n in
c
page 130 .
or
thi
te
sd
a
o
r
rp
cu
nostic tester.
o
m
f
en
ng
20 Nm
t.
yi Co
Cop py
9 - Bolt ht. rig
rig ht
py by
23 Nm
co Vo
by lksw
cted agen
Prote AG.
10 - Connection
11 - Seal
Renew.
Coat with coolant additive; coolant additive Electronic parts catalogue .
12 - Engine oil cooler
See note page 129 .
Ensure clearance to adjacent components.
Removing and installing page 129 .
13 - Seal
Renew.
14 - Bolt
Tightening sequence
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
l purpos
WARNING
nform
ercia
a
The cooling system is under pressure when the engine is
com
tio
hot.
n in
r
te o
thi
Cover filler cap on expansion tank with a cloth and open
s
iva
cum
fo
en
ng
t.
yi Co
op py
Drain coolant page 133 . t. C rig
gh ht
pyri by
Remove bracket for ancillaries page 24 .
o Vo
by c lksw
cted agen
Prote AG.
Unscrew bolts -4 and 5- and remove engine oil cooler -3- to
gether with seal -2-.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
Specified torques page 128 .
Note
2. Oil filter bracket, oil pressure, engine oil cooler and oil supply line 129
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
ility
Place a cloth underneath bracket for ancillaries to catch any es
ot p
wit
, is n
h re
hole
spec
Detach connector -2- from oil pressure switch -F22- -1-.
es, in part or in w
t to the co
Unscrew oil pressure switch -F22- -2-.
Installing
rrectness of i
Installation is carried out in the reverse order. When installing,
note the following:
l purpos
orm
m
atio
Note
om
n in
or c
thi
Renew seal.
te
sd
iva
o
r
rp
cu
m
f
t.
yi Co
Cop py
t. rig
gh ht
yri by
2.4 Removing and installing oil supply line
op Vo
by c lksw
cted agen
to turbocharger
Prote AG.
Removing
Loosing securing bolt for oil supply line page 192 .
Loosen bolt at top and bottom of oil supply line.
Installing
Install in reverse order.
Test prerequisites
Oil level OK.
Engine oil temperature at least 80 C (radiator fan must have
run once) wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
Test procedure ed by ara
ris nte
tho eo
au ra
c
ss
Note
ce
le
un
pt
an
d
itte
y li
erm
ab
caping engine oil.
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
Screw oil pressure tester -V.A.G 1342- into oil filter bracket in
t to the co
place of oil pressure switch.
Start engine.
rrectne
Oil pressure at idling speed:1.2 ... 2.1 bar.
s
Oil pressure at 2000 rpm: 1.6 ... 2.1 bar.
s o
cial p
f in
Oil pressure at 3700 rpm: 3.0 ... 4.0 bar.
form
mer
atio
om
Note
c
i
or
n thi
te
sd
va
During the first 1000 km the oil pressure could be 3.0 to 4.0 bar
i
o
pr
cum
at 2000 rpm.
r
fo
en
ng
t.
yi Co
op py
Reassembly t. C rig
gh ht
pyri by
Specified torques page 128 .
o Vo
by c lksw
cted agen
Prote AG.
Install oil pressure switch.
2. Oil filter bracket, oil pressure, engine oil cooler and oil supply line 131
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
19 Cooling
1 Cooling system
General notes on cooling system page 132 .
n AG. Volkswagen A age G do
lksw es n
1.1 General notes eon
d b cooling system
yV
o ot g
ua
ran
ris tee
utho or
a ac
WARNING ss
ce
le
un
pt
an
Steam may escape when expansion tank is opened. Wear eye
d
itte
y li
protection and protective clothing to avoid eye injuries and
erm
ab
scalding. Cover cap with cloth and open carefully.
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
Caution
t to the co
When doing any repair work, especially in the engine compart
ment, pay attention to the following due to the cramped condi
rrectne
tions:
Route all the various lines (e.g. for fuel, hydraulics, acti
ss
vated charcoal filter system, coolant and refrigerant, brake
o
cial p
f i
fluid and vacuum) and electrical wiring in their original po
nform
sitions.
mer
atio
m
n
c
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Note t. Cop py
rig
gh ht
yri by
When the engine is warm, the cooling system is under pres
cop Vo
by lksw
cted
sure. If necessary, release pressure before beginning repair
agen
Prote AG.
work.
Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
Spring-type clip pliers -VAS 6340- or hose clip pliers -VAS
6362- are recommended for installation of spring-type clips.
When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
The arrows on the coolant pipes and coolant hoses must be
aligned with each other.
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.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
Special tools and workshop
ility
ot
equipment required
wit
, is n
h re
hole
Refractometer -T10007-
spec
es, in part or in w
t to the co
-VAS 6208-
Hose clip pliers -VAS 6340-
rrectness of i
Cooling system charge unit
l purpos
-VAS 6096-
Adapter for cooling system
nform
ercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Procedure:
Draining
WARNING
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Filling
Note
pt
du
an
itte
y li
ab
wit
, is n
h re
spec
es, in part or in w
VDE
05101)
l purpos
orm
m
n in
c
Procedure:
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
Test prerequisite
Engine at normal operating temperature
ss o
Test sequence:
cial p
f inform
mer
atio
WARNING
om
n
c
i
or
n
Hot steam may escape when expansion tank is opened. Place
thi
te
sd
a
o
pr
cum
r
fo
en
ng
t.
yi Co
op
Open filler cap on coolant expansion tank. C py
t. rig
gh ht
yri
Screw adapter for cooling system tester -V.A.G 1274/8- into
p by
co Vo
by lksw
coolant expansion tank. Prote
cted AG.
agen
DANGER!
If pressure drops:
Find leaks and rectify.
Checking pressure relief valve in filler cap:
Screw cap into adapter for cooling system tester -V.A.G
1274/9- .
Clamp connector -V.A.G 1274 B/1- into adapter for cooling
system tester -V.A.G 1274/9- .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2.1 Coolant hose schematic diagram for vehicles with heat exchanger
ce
e
nl
pt
du
an
ing.
itte
y li
erm
ab
Removing and installing
ility
ot p
page 152 .
wit
, is n
h re
7 - Engine oil cooler
hole
spec
es, in part or in w
8 - Turbocharger
t to the co
9 - Cylinder head
10 - Thermostat
rrectness of i
11 - Coolant pump
l purpos
12 - Expansion tank
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.2 Coolant hose schematic diagram for vehicles with 2nd heat exchanger
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
1 - Coolant hose
pt
an
d
itte
y li
To expansion tank.
erm
ab
ility
ot p
2 - Coolant hose
wit
is n
To heat exchanger
h re
Return line ole,
spec
urposes, in part or in wh
t to the co
3 - Coolant hose
To heat exchanger
Supply
rrectne
4 - Coolant pipe
ss
5 - Coolant hose
o
cial p
f in
From coolant pipe to
form
mer
supplementary water
atio
pump
om
n
c
i
or
n
6 - O-ring
thi
te
sd
va
7 - Coolant hose
i
o
pr
cum
r
fo
en
ng
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
n AG. Volkswagen AG do
swage es n
Hose clip pliers -V.A.G by V1921-
olk ot g
ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
Note
Note
olkswagen AG
en AG. V
Hose unions and air intake pipes/hoses must be free of oiloland
ksw
ag does
not
grease when installing. db
yV gu
ara
rise nte
Secure all hose connections with hose clips corresponding
au
tho to eo
ra
the series equipment Electronic parts catalogue
ss . c
ce
e
nl
pt
du
an
the screws of the used hose clips have to be sprayed with
itte
y li
erm
ab
penetrating spray before installing.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
Renew.
an
d
itte
y li
rm
3 - Connection
ab
pe
ility
ot
4 - Retaining clip
wit
, is n
h re
Only for inserted ver
hole
spec
sion.
es, in part or in w
t to the co
ing.
5 - Coolant temperature send
rrectness of i
er -G62-
l purpos
nform
ercia
6 - O-ring
m
Renew.
a
com
tion in
7 - Coolant pump
r
te o
thi
Removing and installing
s
iva
do
page 149 .
r
rp
cum
fo
t.
yi Co
move protective cap . Cop py
rig
ht ht
rig
8 - Seal py by
co Vo
by lksw
Renew. cted agen
Prote AG.
9 - Centralising pin
Qty. 2.
10 - Toothed belt
For coolant pump.
Removing and installing
page 146 .
11 - Toothed belt guard
12 - Bolt
9 Nm
13 - Bolt
Left-hand thread.
Renew.
10 Nm + 90 further
14 - Toothed belt drive sprocket
Note installation position.
15 - Oil seal
Renewing page 148 .
16 - Balancer shaft
17 - Thermostat
Removing and installing page 151 .
18 - Centralising pin
19 - O-ring
Renew.
AG. Volkswagen AG d
20 - Connection agen oes
olksw not
V gu
by ara
21 - Bolt rised
nte
ho eo
9 Nm s aut ra
c
s
ce
e
nl
pt
du
an
itte
y li
Coolant pump - tightening sequence
erm
ab
ility
ot p
wit
Nm.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
3.4 Removing and installing coolant temper
m
atio
om
n in
or c
thi
te
sd
a
Removing
iv
o
r
rp
cu
o
m
Engine cold
f
en
ng
t.
yi Co
op
Release clip -3- from pressure hose -4-. C py
t. rig
gh ht
yri by
Release hose clip -arrow- from throttle valve module -J338- . op Vo
by c lksw
cted agen
Prote
Unscrew bolt -1- from pressure pipe -2- and remove pressure
AG.
pipe -2-.
Remove support for intake manifold (remove nut -2- and bolt
-1-).
Disconnect electrical connector -1- at coolant temperature
sender -G62- .
Note
ce
le
un
pt
an
d
itte
y li
rm
ab
Note
pe
ility
ot
wit
, is n
Renew O-rings.
h re
hole
spec
Only demineralised / distilled water to standard VDE-0510
es, in part or in w
may be used for mixing. Tap water does not have the required
t to the co
quality to ensure the coolant's function.
Insert new coolant temperature sender -G62- immediately into
rrectness of i
connection to avoid loss of coolant.
l purpos
Hose unions and air intake pipes/hoses must be free of oil and
grease when installing.
nform
ercia
a
com
tion in
cum
fo
en
g
t.
yi Co
Cop py
t.
Install throttle valve module -J338- Rep. gr. 24 .
rig
gh ht
pyri by
Vo
o
by c
Check coolant level page 133 .
lksw
cted agen
Prote AG.
Socket -T10360-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
Removing
spec
es, in part or in w
t to the co
Release long coolant pipe and lay aside page 141 .
rrectness of i
Disconnect coolant hoses -1 and 2- and move clear to one
side.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c
Unscrew bolts -arrows- and remove toothed belt guard.
lksw
cted agen
Prote AG.
Caution
ce
e
nl
pt
du
an
itte
Installing
y li
erm
ab
Specified torque page 144 .
ility
ot p
wit
, is n
Installation is carried out in the reverse order. When installing,
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Replace bolt for drive sprocket.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
cum
for
en
ng
t.
yi
Special tools and workshop equipment required
Co
Cop py
t. rig
gh
Thrust piece -T10353-
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Procedure
Remove short coolant pipe page 141 .
Release long coolant pipe and lay aside page 141 .
Remove toothed belt for coolant pump page 146 .
Press screwdriver -1- firmly onto section -2- of oil seal
-arrow B-.
Lever out oil seal -arrow A-.
Clean contact surface and sealing surface.
ce
e
nl
pt
du
an
itte
y li
Risk of damage to thread.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Apply thrust piece -T10353- to oil seal -1- and press into cyl
t to the co
inder block as far as stop using bolt -2- (take care not to tilt oil
seal).
rrectness of i
Fit toothed belt for coolant pump page 146 .
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
Remove bolts -1 5-.
erm
ab
ility
ot p
Detach coolant pump from centring pin and pull off engine oil
wit
, is n
cooler.
h re
hole
spec
es, in part or in w
t to the co
Note
Ignore -arrow-.
rrectness of i
Installing
l purpos
nform
ercia
at
om
ion
c
in t
or
his
te
Note
a
do
priv
cum
for
t.
yi Co
Cop py
t. rig
gh ht
yri by
Coat O-rings -4- with coolant; coolants Electronic parts cop Vo
by lksw
catalogue . cted agen
Prote AG.
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 piece and centring pin
into cylinder block.
Note
ce
e
pt
du
an
gine mounting.
itte
y li
erm
ab
Remove engine mounting (left-side) page 17 .
ility
ot p
wit
, is n
h re
et.
hole
spec
es, in part or in w
t to the co
Unscrew bolts -arrows- and remove connection.
Detach thermostat.
rrectness of i
Installing
l purpos
nform
ercia
at
om
ion
c
in t
or
his
e
Note
at
do
priv
cum
or
en
ng
t.
yi Co
Cop py
Clean sealing surface for O-ring.
t. rig
gh ht
pyri by
Vo
o
by c
Coat O-ring with coolant, Coolants Electronic parts cata
lksw
cted agen
logue .
Prote AG.
9 - Expansion tank
pt
du
an
itte
ab
er -V.A.G 1274/8-
hole
spec
page 136 .
es, in part or in w
t to the co
10 - Bolt, 5 Nm
l purpos
or
12 - Bolt, 4 Nm
m
m
atio
m
13 - Breather line
o
n in
or c
thi
sd
iva
cu
o
m
f
en
ng
14 - Spring-type clip
t.
yi Co
op
Hose clip pliers -VAS 6340- or hose clip pliers -VAS 6362- are recommended for installation of spring-
C py
t. rig
gh
type clips.
ht
pyri by
Vo
co lksw
by
cted
15 - Bolt, 1.2 Nm
agen
Prote AG.
16 - Retainer
For continued coolant circulation pump -V51-
17 - Bolt, 4.5 Nm
18 - Continued 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
1 - Radiator
2 - Radiator fan -V7-
3 - Bolt, 5 Nm
4 - Bolt, 5 Nm
5 - Locking lug
Must be engaged in ra n AG. Volkswagen AG do
diator. lkswage es n
o ot g
byV ua
d
6 - Cowling o
ir se
ran
tee
th or
Removing and installing
au ac
ss
page 154 .
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
Engine guard .
du
an
itte
y li
erm
Unclip coolant hose -1- from brackets -2-.
ab
ility
ot p
Unscrew securing bolts -3- for cowling -4-.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
Separate connector -1- at cowling -2-.
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Installing
es, in part or in w
t to the co
Install in reverse order.
Specified torque -arrows- 6 Nm
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e
sd
iva
o
r
rp
cu
o
en
ng
t.
yi Co
op
Socket set 1/4", 22-piece -VAS 5528- C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
Undo and remove bolts -2- that fasten radiator to lock carrier
-1-.
Only for vehicles with air conditioning
Remove lock carrier General body repairs, exterior; Rep.
gr. 50 ; Lock carrier .
Continuation for all vehicles
Remove engine guard, if fitted Body, front; Rep. gr. 50 ;
Engine guard .
Drain coolant page 133 .
Remove cowling page 154 .
Observe instructions for hose connections with screw-type clips
page 184 .
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Unclip left radiator fastening
ised b -2- at condenser -3-. ara
nte
or eo
h
Unclip right radiator
s aut fastening as well and pull condenser -3- ra
c
off radiator -1-.s
ce
le
un
pt
an
d
itte
y li
Caution
erm
ab
ility
ot p
h re
ole,
spec
urposes, in part or in wh
Caution
rrectne
f inform
mer
n
c
i
or
cooler. When doing so, take the radiator -2- past the refrigerant
thi
e
lines.
t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
pt
an
d
itte
Undo and remove bolt -2- on right and left (not shown in illus
y li
rm
ab
tration) at radiator.
pe
ility
ot
wit
, is n
Installing
h re
hole
spec
Install in reverse order. In the process, note the following:
es, in part or in w
t to the co
rrectness of i
Note
l purpos
nform
ercia
tion:
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Insert radiator mounting into lock carrier -2- at bottom -1-, do
yri
p by
o Vo
ing so transversely to the direction of travel, and then turn it
c by lksw
cted agen
90".
Prote AG.
Insert top radiator mountings -1- on right and left into the
mounting on radiator -2- appropriately.
When installing the radiator, make sure that the catches -1- of
the radiator mounting on the left and right at the top have en
gaged completely in the lock carrier.
Observe instructions for hose connections with screw-type clips
page 184 .
Caution
Caution
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
Route all the various lines (e.g. for fuel, hydraulics, acti
itte
y li
vated charcoal filter system, coolant and refrigerant, brake
erm
ab
fluid and vacuum) and electrical wiring in their original po
ility
ot p
sitions.
wit
is n
h re
ole,
spec
urposes, in part or in wh
hot components.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
Note Prote
cted AG.
agen
ce
le
un
pt
fuel supply system
an
d
itte
y li
rm
ab
pe
ility
ot
Caution
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
tions:
Route all the various lines (e.g. for fuel, hydraulics, acti
vated charcoal filter system, coolant and refrigerant, brake
rrectness of i
fluid and vacuum) and electrical wiring in their original po
l purpos
sitions.
Ensure that there is sufficient clearance to all moving or
nform
ercia
hot components.
m
a
The fuel and the fuel lines in the fuel system can become
com
tio
very hot (danger of scalding)!
n in
r
te o
thi
The fuel system is also under pressure! Before opening
s
iva
do
the system, place cloths around the connections. Then
r
rp
cum
carefully loosen connection to release the pressure!
fo
en
ng
t.
yi Co
Wear eye and hand protection when performing any type Cop py
ht. rig
of repair work on the fuel system! rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
When removing and installing fuel gauge sender or fuel pump
(fuel 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 motor is not in air flow.
Prevent skin contact with fuel! Wear fuel-resistant gloves!
WARNING
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, wrap a cloth around the
connection.
pt
an
d
itte
y li
If the fault memory was cleared, the readiness code must be gen
erm
ab
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2 Fuel pump
Note
When replacing fuel delivery unit, check fuel tank for heavy soiling
and clean if necessary.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
t to the co
cessible.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
ing the connector without pressing the catch. If connector was
du
an
itte
not inserted correctly, repeat functional check of fuel pump.
y li
erm
ab
ility
Pull off connector -1-.
ot p
wit
, is n
Check contacts on plug and on fuel delivery unit for damage.
h re
hole
spec
Check voltage supply against current flow diagram with mul
es, in part or in w
timeter -V.A.G 1715- .
t to the co
Specification: approx. battery voltage.
rrectness of i
WARNING
l purpos
Fuel supply lines are under pressure! Wear eye protection and
protective clothing to avoid eye injuries and skin contact. Be
nf
ercia
o
fore loosening hose connections, wrap a cloth around the
rm
m
atio
connection. Then release pressure by carefully pulling hose off
om
connection.
n in
or c
thi
te
sd
iva
o
r
rp
cu
Voltage supply not OK:
o
m
f
en
ng
t.
yi
Locate and eliminate open circuit referring to current flow di
Co
op py
agram Current flow diagrams, Electrical fault finding and t. C rig
gh ht
Fitting locations. pyri by
Vo
co lksw
by
cted agen
Voltage supply OK: Prote AG.
Note
WARNING
Fuel supply lines are under pressure! Wear eye protection and
protective clothing to 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.
Release clip -2- and detach fuel pressurisation line -3- from
high-pressure pump -1-. Collect escaping fuel with a cloth.
Note
y li
rm
ab
Test prerequisite
pe
ility
ot
h re
spec
Test sequence:
es, in part or in w
t to the co
tion in
r
thi
s
iva
do
cum
pressure.
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
After pressure has built up, cut-off tap -B- of pressure tester
immediately. Lever is then at right angle to direction of flow.
If the pressure does not drop now:
Note
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
t to the co
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
3 Fuel tank
an
d
itte
y li
erm
ab
Assembly overview - fuel tank page 167 .
ility
ot p
wit
Removing and installing fuel tank page 169 .
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
3.1 Assembly overview - fuel tank
rrectne
1 - Union nut, 110 Nm
ss o
Remove and install us
cial p
f i
ing union nut tool
nform
-3217- .
mer
atio
m
2 - Seal
o
n
c
i
or
n
Renew if damaged.
thi
te
sd
va
o
pr
cum
installing
r
fo
en
ng
t.
yi Co
3 - Fuel delivery unit . Cop py
rig
ht
Note installation posi rig ht
py by
tion on fuel tank
co Vo
by lksw
cted
page 168 .
agen
Prote AG.
pt
du
an
itte
y li
ab
ility
ot p
Arrow on sender flange -1- must align with mark on fuel tank
wit
-arrows-.
, is n
h re
hole
t to the co
Note
rrectness of i
After installing fuel gauge sender, check whether fuel supply and
l purpos
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
Removing
rrectne
Note
Fuel tank must be drained. Use the fuel extractor -VAS 5190- to
ss o
do this.
cial p
f inform
mer
page 160 .
o
n
c
i
or
sd
iva
o
pr
cum
r
fo
en
Note
ng
t.
yi Co
Cop py
t. rig
Before carrying out further work, disconnect battery earth strap.
gh ht
yri by
For this reason, first check whether a coded radio is fitted. Obtain
op Vo
by c lksw
cted
anti-theft coding first if necessary.
agen
Prote AG.
Thoroughly clean area around filler neck -1- on fuel tank -4-.
Loosen clamp -2- for connecting hose -1- of filler neck 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- .
Note
Unscrew bolt -arrow- for securing fuel tank -1- on left cross
member.
Loosen securing straps in succession:
Unscrew bolt -arrow- for front securing strap -2- for fuel tank
-1-. swa
gen AG
. Volkswagen AG
does
k not
Vol gu
d by ara
e nte
ris
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Unscrew bolt -arrow- for rear securing strap -2- for fuel tank
-1-.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Unscrew bolts -arrows- for securing straps -2- for fuel tank
-1-.
Only lower fuel tank with engine 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-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
Note orise nte
eo
h
aut ra
s c
Immediately seal all openings on fuel tank with clean cloths. s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
V.A.G 1383 A- until connector -2- can be pulled off fuel delivery
es, in part or in w
t to the co
unit -1-.
Release fuel lines by pressing in circlip.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
cu
o
m
f
en
ng
Push hose -1- of filler neck onto connection on fuel tank -3-.
Position clamp -2- at assembly markings -arrows- using hose clip
pliers -VAS 6362- .
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
Install fuel delivery unit so that mark on flange of fuel delivery
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
sender -G-
a
com
tion in
r
Removing
te o
thi
s
iva
do
cum
fo
en
g
t.
yi Co
op py
Free lines -2- and unclip fuel gauge sender -G- to side
. C rig
ht ht
rig
-arrows-. py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Torque wrench -V.A.G 1410-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
Removing by c lksw
cted agen
Prote AG.
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 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.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
Tighten bolt -2- to 2 Nm.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
Push hose -1- of filler neck onto connection on fuel tank -3-.
at
om
ion
c
his
e
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
1 - Fuel filter
Direction of flow is
rrectne
marked with arrows.
Do not interchange con
ss
nections.
o
cial p
f i
Removing and installing
nform
page 177 .
mer
atio
m
n
c
i
or
n thi
engage in notch of guide
te
sd
a
in filter bracket
iv
o
pr
c
page 177 .
um
r
fo
en
ng
t.
yi
2 - Retaining clip
Co
Cop py
t. rig
For fuel pressure regu gh ht
yri by
lator. cop Vo
by lksw
cted agen
Check for secure seat
Prote AG.
ing.
3 - Fuel supply line
Black
From fuel tank.
To pull off, press release
button on connection.
4 - Fuel return line
Blue
To fuel tank.
To pull off, press release
button on connection.
5 - Fuel pressure regulator
4 bar.
6 - Seal
Renew.
7 - O-ring
Renew.
8 - Fuel supply line
Black
To engine.
To pull off, press release button on connection.
ce
e
10 - Retainer
nl
pt
du
an
itte
For fuel filter.
y li
erm
ab
Secured to fuel tank.
ility
ot p
wit
, is n
h re
hole
spec
3.7 Removing and installing fuel filter
es, in part or in w
t to the co
Special tools and workshop equipment required
Torque wrench -V.A.G 1783-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Container cop Vo
by lksw
cted agen
Prote
Removing
AG.
Note
WARNING
Pull off fuel lines -1-, -2- and -3- by pressing release button.
Remove bolt -4-.
Remove fuel filter.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
Note
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
Note
The fuel pump control unit -J538- is installed on the fuel tank.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
1 - Connector
pt
du
an
itte
y li
2 - Securing nuts
erm
ab
ility
ot p
10 Nm
wit
, is n
h re
3 - Accelerator with electronic
hole
module
spec
es, in part or in w
t to the co
sender passes the posi
tion of the accelerator
on to the engine control
rrectness of i
unit.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Installing
Installation is performed in the reverse sequence.
Specified torque:
Component Nm
Accelerator module to body 10
5 Activated charcoal
agen
AG.filter system
Volkswagen AG
doe
ksw s no
Vol t gu
d by ara
e nte
1 - Breather line tho
ris eo
au ra
Check for ssecure
s seat c
ing.
ce
e
nl
pt
du
an
2 - Activated charcoal filter
itte
y li
erm
ab
Location: on fuel tank,
ility
ot p
left.
wit
, is n
h re
Removing and installing
hole
spec
moved
es, in part or in w
t to the co
3 - Breather line
Check for secure seat
rrectness of i
ing.
l purpos
4 - Quick-release coupling
Check for secure seat
ing.
nform
mercia
5 - Fuel line
at
om
io
Check for secure seat
n
c
in t
or
ing.
his
ate
do
riv
6 - Clip
p
cum
for
en
g
t.
yi Co
op
enoid valve 1 -N80- C py
t. rig
gh ht
Valve closed with igni yri
p by
o Vo
tion switched off.
by c lksw
cted agen
Prote AG.
When engine is warm,
valve will be activated
(pulsed) by engine con
trol unit.
ce
le
Adapter set -V.A.G 1318/17-
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f in
Test prerequisite
form
mer
atio
om
n
c
i
or
n thi
te
sd
a
Test procedure
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Note pyri by
Vo
co lksw
by
cted agen
Prote AG.
To do this, press release button.
ce
e
nl
pt
du
an
itte
y li
erm
ab
1.1 Safety precautions
ility
ot p
wit
, is n
h re
hole
WARNING
spec
es, in part or in w
t to the co
When doing any repair work, especially in the engine compart
ment, pay attention to the following due to the cramped condi
tions:
rrectness of i
Route all the various lines (e.g. for fuel, hydraulics, acti
l purpos
nf
ercia
or
Ensure that there is sufficient clearance to all moving or
m
m
atio
hot components.
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
be used during a road test:
o
m
f
en
ng
t.
yi Co
Test equipment must always be secured on the rear seat and . Cop py
operated by a 2nd person.
t rig
gh ht
pyri by
Vo
co
If test and measuring instruments are operated from front pas
by lksw
cted agen
Prote
senger seat and the vehicle is involved in an accident, there is a
AG.
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
Caution
ce
e
nl
pt
du
an
itte
y li
with the hose.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Screw-type clips with locking hooks -arrows- may only be
es, in part or in w
t to the co
released. Loosen bolt of screw-type clips sufficiently to re
move hoses.
Screw-type clips that are only loosened can be reused.
rrectness of i
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
en
ng
t.
yi Co
op py
Observe rules for cleanliness page 183 .
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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
n AG. Volkswagen AG do
wage es n
7 - Pressure hose yV
olks ot g
ua
d b
To throttle
oris
e valve ran
tee
th or
Must au be free of oil and ac
ss
grease before installing.
ce
le
un
pt
8 - Hose clip
an
d
itte
y li
erm
Reinforced.
ab
ility
ot p
5.5 Nm
wit
is n
h re
9 - Securing bolt
ole,
spec
urposes, in part or in wh
10 - Pressure sensor
t to the co
11 - Bolt
12 - Rubber grommet
rrectne
13 - Pressure pipe
s
f i
14 - Hose clip
nform
mer
Reinforced.
atio
m
5.5 Nm
o
n
c
i
or
n thi
e
15 - Pressure hose
t
sd
iva
o
r
cum
r
fo
en
ng
16 - Hose clip
t.
yi Co
op py
Reinforced.
. C rig
ht ht
rig by
py
5.5 Nm co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
Installing
pt
du
an
itte
y li
Installation is carried out in the reverse order. When installing,
erm
ab
note the following:
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
Renew O-ring.
rrectness of i
l purpos
orm
m
n in
c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
Remove engine guard, 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 .
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
187
agen
Prote AG.
1. Charge air system
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Squeeze left and right catches -2- together and detach con
denser -3- from radiator -1-.
Caution
Caution
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
If the radiator -1- is to be replaced, undo bolts of charge air
hole
spec
cooler and remove it from radiator.
es, in part or in w
t to the co
Undo and remove bolt -2- on right and left (not shown in illus
tration) at radiator.
rrectness of i
Installing
l purpos
nform
mercia
at
om
io
Note n
c
in t
or
his
ate
en
tion:
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
When installing the radiator, make sure that the catches -1- of
h re
the radiator mounting on the left and right at the top have en
hole
spec
gaged completely in the lock carrier.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
Insert top radiator mountings -1- on right and left into the
thi
te
sd
a
o
r
rp
cu
o
en
ng
t.
page 184 .
yi Co
Cop py
t. rig
Install cowling page 154 .
gh ht
pyri by
Vo
o
by c lksw
Replenish coolant page 133 . cted agen
Prote AG.
Caution
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Release hose clip -1- and detach pressure hose -3- from tur
bocharger -2-.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op py
Depending on hose diameter, insert adapter -1687/10- , . C rig
ht ht
-1687/11- or -1687/12- in air duct -1- and secure with hose clip.
rig by
copy Vo
by lksw
cted
Connect charge air system tester -V.A.G 1687- as shown in
agen
Prote AG.
figure.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
Note
Caution
ce
e
nl
pt
du
an
itte
y li
How to use the ultrasonic tester -V.A.G 1842- operating
erm
ab
instructions
ility
ot p
wit
, is n
h re
detaching coupling.
hole
spec
es, in part or in w
Hose unions and air pipes/hoses must be free of oil and grease
t to the co
when installing.
Secure all hose connections with hose clips corresponding to
rrectness of i
the series equipment Electronic parts catalogue .
l purpos
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2 Turbocharger
Note
. Volkswagen AG
gen AG
Secure all hose connections withVhose
olks clips comparable to s not
wa oe d
production standard ed
by gu
ara
ris nte
o
Hose connections and hoses au
th for charge air system must be eo
ra
free of oil and grease before
ss assembly. The oil seal and seal c
ing surface must be oiled lightly only for connector couplings .
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Renew self-locking nuts.
ot
wit
, is n
Hose clip pliers -VAS 6362- or hose clip pliers -V.A.G 1921-
h re
hole
spec
es, in part or in w
t to the co
After installing turbocharger, run engine for about 1 minute at
idling and do not rev up immediately, this ensures that the tur
rrectness of i
bocharger is fully primed with oil
l purpos
nform
ercia
a
com
Part I
tion in
r
te o
do
Part III page 195
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1 - Turbocharger
Can 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
AG. Volkswagen AG d
8 - Charge pressure control lksw
agen oes
not
solenoid valve -N75- d by
Vo gu
ara
ise nte
r
9 - Hose ut
ho eo
ra
s a c
10 - Turbocharger air recircu s
ce
le
pt
an
d
itte
y li
erm
ab
tion page 193 .
ility
ot p
wit
11 - Bolt
is n
h re
ole,
7 Nm
spec
urposes, in part or in wh
12 - O-ring
t to the co
Renew.
13 - O-ring
rrectne
Renew.
s
14 - Connection
s o
cial p
f i
15 - Bolt
nform
mer
9 Nm
atio
om
n
c
i
or
n thi
te
sd
o
pr
cum
r
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Turbocharger 193
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Part II
Part I page 192
Part III page 195
Part IV page 196
1 - Turbocharger
AG. Volkswagen AG d
Can only be renewed agen
ksw to
oes
ol not
gether with dexhaust
by V gu
ara
manifoldorandise vacuum nte
eo
unit asaut one unit
h
ra
ss c
Removing and installing
ce
le
un
page 197 .
pt
an
d
itte
y li
2 - Bolt
rm
ab
pe
ility
9 Nm
ot
wit
, is n
h re
3 - Crankcase breather line
hole
spec
4 - Seal
es, in part or in w
t to the co
Renew.
5 - Seal
rrectness of i
Renew.
l purpos
6 - Bolt
30 Nm
nform
ercia
a
com
8 - Bolt
ion in
r
9 Nm
te o
thi
s
iva
do
9 - Bolt
r
rp
cum
fo
9 Nm
en
ng
t.
yi Co
op
10 - O-ring
C py
t. rig
gh ht
yri
Renew. p by
co Vo
by lksw
cted agen
11 - Seal Prote AG.
Renew.
12 - Bolt
35 Nm
13 - Bolt
9 Nm
14 - Bolt
35 Nm
15 - Seal
Renew.
16 - Coolant supply line
17 - Bolt
9 Nm
18 - Bolt
9 Nm
19 - Seal
Renew.
Part III
Part I page 192
Part II page 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 AG. Volkswagen AG d
tronic parts cataloguelkswagen oes
n o ot g
yV ua
3 - Bolt ris
edb ran
tee
35 Nm tho or
au ac
ss
4 - Seal
ce
le
un
pt
an
Renew.
d
itte
y li
rm
ab
ility
ot
wit
6 - Bolt
, is n
h re
hole
9 Nm
spec
es, in part or in w
7 - Turbocharger
t to the co
8 - Bolt
m
30 Nm
com
tion in
r
9 - Retainer
te o
thi
s
iva
do
10 - Support
r
rp
cum
fo
11 - Bolt
en
ng
t.
yi Co
op
30 Nm C py
t. rig
gh ht
yri by
12 - Bolt op Vo
by c lksw
cted agen
30 Nm Prote AG.
Coat bolt with high-temperature paste; high-temperature paste Electronic parts catalogue .
13 - Nut
Do not unscrew to remove turbocharger
Renew.
30 Nm
2. Turbocharger 195
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Coat exhaust manifold studs with high-temperature paste; high-temperature paste Electronic parts
catalogue
AG. Volkswagen AG d
14 - Clamping rail ksw
agen oes
not
Vol
by gu
d ara
rise nte
tho eo
Tightening sequence - turbocharger ss au ra
c
ce
e
Tighten bolts in sequence -1 to 5- in 4 stages as follows:
nl
pt
du
an
itte
y li
1. Tighten bolts to 5 Nm.
erm
ab
ility
ot p
2. Tighten bolts to 12 Nm.
wit
, is n
h re
3. Tighten bolts to 16 Nm.
hole
spec
4. Tighten bolts to 25 Nm.
es, in part or in w
t to the co
rrectness of i
l purpos
Part IV
Part I page 192
nform
ercia
at
om
ion
Part III page 195
c
in t
or
his
ate
do
priv
1 - Turbocharger
cum
for
en
g
t.
yi Co
op
gether with exhaust C py
t. rig
manifold and vacuum gh ht
yri by
unit as one unit cop Vo
by lksw
cted agen
Removing and installing
Prote AG.
page 197 .
2 - Vacuum unit for turbocharg
er
Check page 200 .
Removing and installing
page 200 .
3 - Bolt
10 Nm
4 - Nut
9 Nm
Secure with sealing
wax; sealing wax
Electronic parts cata
logue .
5 - Locking plate
Renew.
6 - Knurled nut
ce
e
nl
pt
Air duct to bracket du 10
an
itte
y li
erm
ab
2.2 Removing and installing turbocharger
ility
ot p
wit
, is n
h re
hole
spec
Hose clip pliers -V.A.G 1921-
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
Drain coolant page 133 .
Release clip -3-, unclip vacuum line -5- from guideway -2-.
Unclip line -1- for air mass meter -G70- .
2. Turbocharger 197
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Note
AG. Volkswagen AG d
agen oes
lksw not
For reasons of clarity, following diagrams show installation
byV
o
posi gu
ara
tion with engine removed. ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Remove heat shield -arrows-.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
Unscrew crankcase breather system -arrow- from turbocharg
yi Co
op
er.
C py
ht. rig
rig ht
py by
Pull off hose -1- from turbocharger. co Vo
by lksw
cted agen
Prote AG.
Unscrew bolts -1 and 2- and lay oil supply line to one side.
Unscrew bolt -3- and lay coolant line to one side.
Release hose clip -1- and detach pressure hose -3- from tur
bocharger -2-.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
Unscrew bolts -arrows- and remove support for turbocharger.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
Unscrew bolts -arrows- on oil return line. Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Turbocharger 199
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Note
ce
Aligning exhaust system free of stress page 243 .
e
nl
pt
du
an
itte
y li
erm
ab
ility
Check oil level, Amarok Maintenance ; Booklet 11 .
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
After installing turbocharger, run engine for about 1 minute at
idling and do not rev up immediately, this ensures that the turbo
charger is fully primed with oil
rrectness of i
l purpos
atio
m
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Test prerequisite:
Hose from turbocharger via charge pressure control solenoid
valve -N75- to vacuum unit must have through-flow (not be
blocked).
Charge pressure control solenoid valve -N75- OK.
Procedure:
Connect hand vacuum pump -VAS 6213- to vacuum unit
-arrow-.
Caution
Note
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
201
op Vo
by c lksw
Prote
cted AG.
agen 2. Turbocharger
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
AG. Volkswagen AG d
agen
24 Mixture preparation - injection
oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
1 ss a
Safety precautions and rules for c
ce
le
cleanliness
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
1.1 General notes on self-diagnosis
rrectne
The engine control unit has a self-diagnosis capability. Before
carrying out repairs and fault finding, read fault memory. Also
the vacuum hoses and connections must be checked (unme
ss o
tered air).
cial p
f inform
Fuel hoses in engine compartment must be secured only with
mer
atio
m
permissible.
o
n
c
i
or
sd
va
o
pr
cum
r
fo
t.
yi
drawn into the engine will not be burnt in the engine and dam
Co
Cop py
age the Lambda probe.
t. rig
gh ht
pyri by
Vo
o
Vehicles are fitted with a crash fuel shut-off circuit. This is in
c by lksw
cted agen
tended to reduce the danger of a vehicle fire in a crash as the Prote AG.
fuel pump is switched off by the fuel pump relay.
The system also improves the starting characteristics of the
engine. When the driver's door is opened, the fuel pump is
activated for 2 seconds in order to build up pressure in the fuel
system, note safety measures page 160 .
2 Injection system
Overview - fitting locations page 204
Assembly overview - air filter page 205 .
Removing and installing air filter page 207 .
Removing and installing air filter element page 209
Removing and installing air mass meter -G70- page 209
Assembly overview - intake manifold page 211 .
Volkswa AG. gen AG
agen does
Assembly overviewV-ofuel
lksw rail page 212 not
gu
by ara
ed
Removing and risinstalling intake manifold with fuel rail ntee
page 211 tho
au .
or
ac
ss
Removing and installing injectors page 217 .
ce
e
nl
pt
du
an
itte
y li
erm
ab
Cleaning injectors page 221
ility
ot p
wit
, is n
h re
hole
page 222
spec
es, in part or in w
t to the co
page 223 .
Cleaning throttle valve module -J338- page 224
Assembly overview - high-pressure pump with fuel pressure reg rrectness of i
l purpos
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
an
itte
y li
ab
ility
ot p
h re
spec
t to the co
at
om
io
in t
or
Pull all ignition coils out of cylinder head using puller -T40039- .
his
ate
do
riv
cum
for
en
g
t.
yi Co
op
Removing and installing page 66 .
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
204
agen
Prote AG.
Rep. gr.24 - Mixture preparation - injection
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
1 - Air duct
Check for secure en
gagement.
2 - Rubber bush
Clipped into lower part
of air filter agen
AG. Volkswagen AG d
oes
olksw not
V
3 - Air filter lower part d by gu
ara
rise nte
o
4 - 8.5 Nm auth eo
ra
s c
Rubber bush clipped in s
ce
e
nl
pt
du
an
itte
y li
5 - Water drainage pipe
erm
ab
page 207
ility
ot p
wit
Clipped onto lower part
, is n
h re
of air filter.
hole
spec
Make sure it is mounted
es, in part or in w
in correct position on
t to the co
longitudinal member
Clean if soiled.
rrectness of i
6 - Filter element
l purpos
nance ; Booklet 11
m
at
ion
saturation indication in
c
in t
or
Combi instrument
his
ate
Maintenance ; Book
do
priv
let 11
um
for
en
ng
t.
yi
7 - Air filter upper part
Co
Cop py
t. rig
gh
8 - 2 Nm
ht
pyri by
Vo
co lksw
by
9 - O-ring
cted agen
Prote AG.
Renew if damaged.
10 - Intake manifold pressure sender -G71-
11 - 1.6 Nm
12 - Retainer
For coolant hose mounting.
13 - O-ring
Renew if damaged.
14 - Air mass meter -G70-
Removing and installing page 209 .
15 - 1.6 Nm
16 - Screw-type clip, 5.5 Nm
Caution
The screw-type clips on
the charge air lines must
always be tightened to agen
AG. Volkswagen AG d
5.5 Nm. If the torque is
oes
olksw not
V gu
too low or too high, the d by ara
ise nte
charge air hose may slip thor eo
off the charge air pipe s au ra
c
during vehicle operation. s
ce
e
nl
pt
du
an
itte
y li
17 - Intake hose
erm
ab
ility
ot p
It is essential that the marks on intake hose be in line with the webs on the turbocharger.
wit
, is n
h re
hole
spec
Do not use lubricants containing oil.
es, in part or in w
To turbocharger.
t to the co
With heater element for crankcase breather -N79- and connection for crankcase breather/cylinder head
cover connecting pipe.
rrectness of i
18 - Screw-type clip, 5.5 Nm
l purpos
Caution
nform
ercia
at
om
io
always be tightened to
n
c
in t
r
his
e
do
riv
cum
or
en
ng
t.
during vehicle operation.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
19 - Vacuum hose
c by lksw
cted agen
Prote AG.
20 - Retainer
For wiring harness.
21 - Heat shield
22 - 2 Nm
23 - Mounting for air duct
Secured to lock carrier.
Check for secure engagement.
24 - 8.5 Nm
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
2.3 Removing and installing air filter hous
d ran
ir se tee
tho
ing u or
a ac
ss
ce
le
pt
an
d
itte
y li
Torque wrench -V.A.G 1410-
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
Hose clip pliers -VAS 6340-
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
Detach vacuum hose -2- from air filter upper part and air duct
-3- from air filter lower part -1-.
Note
Unscrew securing bolt -2- for air filter housing -1- in area of
coolant expansion tank.
Pull air filter out of mountings. n AG. Volkswagen AG do
lkswage es n
Installing byV
o ot g
ua
d ran
ir se tee
Install in reverse order. In the process, note
uth the following:
o
or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Unscrew all bolts from air filter upper part and remove upper
part.
Remove air filter insert upwards.
Installing
Note
pt
an
d
y li
erm
ab
clean cloth when blowing out the air filter housing with com
ot p
wit
pressed air.
is n
h re
ole,
t to the co
Check for salt residue, dirt and leaves in air mass meter and
intake hose (engine intake side).
rrectne
f in
-G70-
atio
om
n
c
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
Pull off connector -3- for air mass meter -G70- .
Loosen screw-type clip -4- and remove intake hose from air
mass meter -G70- .
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
Unscrew bolts -arrows- from air massau meter -G70- and care or
ac
fully pull air mass meter -G70- -1- out of air filter housing guide. ss
ce
le
un
Installing pt
an
d
itte
y li
rm
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
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
rrectness of i
quantity is calculated.
l purpos
a
com
Check for salt residues, dirt and leaves in air mass meter -G70-
ion in
thi
s
iva
and leaves from top and bottom part of air filter housing by
en
ng
t.
yi
rinsing out or using a vacuum cleaner if necessary.
Co
Cop py
t. rig
gh ht
Install in reverse order. yri
p by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
2 - Intake air temperature
du
an
sender -G42- itte
y li
erm
ab
ility
- Activated charcoal filter sole
ot p
wit
noid valve 1 -N80-
, is n
h re
With double non-return
hole
spec
valve, checking Vehi
es, in part or in w
t to the co
4 - Intake manifold
Removing and installing
rrectness of i
page 213 .
l purpos
nform
ercia
flaps)
m
at
om
io
pump
n
c
in t
or
20 Nm
his
ate
do
riv
cum
or
line
f
en
ng
t.
yi Co
From fuel tank t. Cop py
rig
gh ht
yri
8 - Fuel pressure regulating p by
o Vo
by c
valve -N276-
lksw
cted agen
Prote AG.
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-pressure pump; procedure for
reducing fuel pressure page 161
Fuel lines must be free of tension when installed.
Removing and installing page 226 .
10 - Roller tappet
Can remain inserted in vacuum pump after removal of high-pressure pump, removable
11 - Connection for fuel supply line
Renew.
40 Nm
12 - High-pressure fuel line
Fuel lines must be free of tension when installed.
27 Nm
13 - Intake manifold flap air flow control valve -N316-
14 - Injectors
Renew O-ring and Teflon ring
Check installation location is correct
ce
e
nl
pt
du
1 - Injector
an
itte
y li
With combustion cham
erm
ab
ility
ber ring seal (Teflon ring
ot p
wit
seal), always renew
, is n
h re
Renew O-rings
hole
spec
Check installation loca
es, in part or in w
t to the co
tion is correct
Removing and installing
page 217 .
rrectness of i
2 - Support ring
l purpos
3 - Fuel rail
Removing and installing
nform
ercia
page 213 .
m
at
om
4 - High-pressure pump
on
c
in t
or
do
priv
en
g
t.
yi Co
pumps fuel to mechani Cop py
t. rig
cal high-pressure pump. opyri
gh by
Vo
ht
ce
le
un
pt
an
d
7 - Bolts for high-pressure pump
itte
y li
erm
ab
20 Nm
ility
ot p
wit
8 - Connection for fuel pressurisation line to fuel rail
is n
h re
ole,
Renew.
spec
urposes, in part or in wh
40 Nm
t to the co
9 - Union nut of fuel pressurisation line
27 Nm
rrectne
10 - Air flow control flaps (intake manifold flaps)
s
11 - Seal
s o
cial p
f
Renew.
inform
mer
12 - Intake manifold
atio
m
n
c
i
or
n thi
13 - Vacuum unit for air flow control flaps (duct partition)
te
sd
iva
o
pr
c
14 - Throttle valve module -J338- , throttle valve drive for electric throttle operation -G186-
um
r
fo
en
ng
Throttle valve drive angle sender 1 for electric throttle -G187- and throttle valve drive angle sender 2 for
t.
yi Co
op
electric throttle -G188- C py
ht. rig
rig ht
After removing, installing or renewing throttle valve module -J338- it must be re-adapted to engine control py by
o Vo
unit -J623- . See Guided functions.
by c lksw
cted agen
Prote AG.
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 engine control unit -J623- . Use vehicle diagnostic tester for this.
Each time after intake manifold flap potentiometer -G336- or intake manifold has been removed or in
stalled, intake manifold flap potentiometer -G336- must be adapted to engine control unit -J623- . See
Guided functions.
17 - Fuel pressure sender -G247-
27 Nm
Lubricate thread with clean engine oil
Always renew connection and tighten to 25 Nm
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
Removing
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
es, in part or in w
ways be renewed.
Assembly overview - intake manifold page 211 .
l purpos
at
om
WARNING
ion
c
in t
or
his
e
do
riv
cum
or
en
ng
page 161 .
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
214
cted agen
Prote AG.
Rep. gr.24 - Mixture preparation - injection
Amarok 2011
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
ce
e
nl
pt
du
an
itte
y li
6 - Intake air temperature sender -G42-
erm
ab
ility
ot p
wit
Detach connector -1- from Hall sender -G40- .
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
Unclip vacuum hose to air filter -2- and detach from air filter
thi
te
sd
a
housing -1-.
iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
Detach vacuum hose -3- from vacuum pump -2- and brake
servo.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Open spring-type clip -upper arrow- and detach fuel pressur
by lksw
cted agen
Prote
isation line from high-pressure pump.
AG.
Note
Release oil filter with Hazet securing strap -2171-1- or with oil
filter tool -3417- and remove oil filter.
Unscrew bolts from intake manifold using socket -T10347- .
Note
ce
le
un
pt
Injectors can remain in fuel rail.
an
d
itte
y li
Seal intake ports with a clean cloth.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Installing
urposes, in part or in wh
t to the co
Note
rrectne
Ensure injectors are installed correctly.
ss
Fit intake manifold onto studs (left and right) on cylinder head.
o
cial p
f inform
Install in reverse order.
mer
atio
Specified torque: assembly overview - intake manifold
om
page 211 .
c
i
or
n thi
te
o
pr
cum
r
en
ng
t.
yi Co
op py
2.9 Removing and installing injectors
t. C rig
gh ht
pyri by
Vo
o
by c lksw
Special tools and workshop equipment required Prote
cted AG.
agen
Note
ce
e
nl
For identification purposes, mark the modified tool with the
pt
du
an
letter A after the tool number.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
at
om
ion
c
Removing
in t
or
his
ate
do
priv
cum
or
en
ng
t.
yi Co
op
Carefully withdraw injectors from fuel rail. C py
ht. rig
rig ht
Remove injectors if these are still in cylinder head.
py by
co Vo
by lksw
cted agen
Injector (old version)
Prote AG.
Note
AG. Volkswagen AG d
Note agen oes
olksw not
V gu
d by ara
e
The combustion chamber horiseal
s
must always be renewed prior to nte
eo
aut
reinstallation of the injector ra
ss c
ce
le
un
pt
Carefully remove old Teflon ring using a suitable tool (e.g. cut
an
d
itte
open ring using razor blade, or prise open ring with small
y li
erm
ab
screwdriver and then pull off forwards). It is essential to ensure
ility
ot p
wit
is n
damaged.
h re
ole,
spec
urposes, in part or in wh
Note
t to the co
Injector must be renewed if groove is damaged.
rrectne
Before fitting new Teflon ring, combustion residues must be
s
cleaned off seal groove and injector shaft using clean cloth.
s o
cial p
f inform
mer
Note
atio
om
n
c
n thi
sd
va
o
pr
cum
r
fo
en
ng
t.
yi
Place assembly cone -T10133/5- with a new Teflon ring -1- on
Co
op py
injector -2-. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
to assembly cone -T10133/5- until Teflon ring engages in seal
pt
du
an
ring. No lubricants whatsoever may be used.
itte
y li
erm
ab
ility
ot p
wit
Note
, is n
h re
hole
spec
Pushing Teflon ring onto injector stretches Teflon ring. For this
es, in part or in w
reason, the Teflon ring has to be shrunk again after it has been
t to the co
pushed on. This is done in 2 stages. The procedure is described
below.
rrectness of i
Step 1 of calibration (adaptation) of Teflon ring is carried out with
l purpos
nf
ercia
or
tion sleeve -T10133/7- over injector until stop is reached. Turn
m
m
atio
calibration sleeve -T10133/7- in opposite direction.
om
n in
or c
thi
e
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
The injector must insert easily. If necessary, wait until the
h re
hole
combustion chamber seal has contracted sufficiently.
spec
es, in part or in w
Ensure the injectors are correctly seated and positioned in the
t to the co
cylinder head.
If it is not possible to insert the injector by hand, use the puller
rrectness of i
-T10133/2A- -2- with a hammer -T10133/3- to insert the injec
tor.
l purpos
nf
ercia
or
Important: It is essential to observe following points
m
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
Note
Note
Note
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
WARNING
n AG. Volkswagen AG do
wage es n
Unscrew coolant line bolt -arrow- from intake manifold.y Volks ot g
ua
b
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Disengage connector from fuel pressure sender -G247- with
rrectness of i
assembly tool -T10118- .
l purpos
nform
ercia
Installing
m
a
com
t
Install in reverse order.
ion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
- fuel rail page 212 .
yi Co
Cop py
t. rig
Specified tightening torque of fuel pressure sender -G247- : gh ht
yri by
assembly overview - fuel rail page 212 . cop Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
If a new engine control unit -J623- is installed, the throttle valve
es, in part or in w
t to the co
module must be adapted.
When cleaning the throttle valve nozzle it must not be scratch
ed.
rrectness of i
l purpos
nform
ercia
a
com
tion in
WARNING
r
te o
thi
s
iva
do
cum
en
g
t.
yi Co
Wear eye protection and protective clothing to avoid eye inju Cop py
ht. rig
ries and skin contact. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
WARNING
1 - Roller tappet
Can remain inserted in
vacuum pump after re
moval of high-pressure
pump
2 - O-ring
Renew.
3 - High-pressure 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 AG. Volkswagen AG d
fuel system. olksw
agen oes
not
yV gu
The fuel system must ed b ara
nte
is
not be under pressure hor eo
when installing the high- aut ra
s c
pressure pump; proce s
ce
le
pt
an
d
y li
rm
ab
Fuel lines must be free
pe
ility
of tension when instal
ot
wit
, is n
led.
h re
hole
t to the co
4 - Fuel pressure regulating
valve -N276-
rrectness of i
6 - Injectors
nform
ercia
a
com
ti
do
cum
fo
en
g
t.
yi Co
Cop py
9 - Bolts for high-pressure pump ht. rig
rig ht
py by
20 Nm
co Vo
by lksw
cted agen
Prote AG.
10 - Connecting piece for fuel supply line from fuel tank
11 - Connection for fuel supply line
Renew.
WARNING
Note
Removing
Detach connector from fuel pressure regulating valve
AG. Volks-N276-
wagen AG
agen does
-1-. V olksw not
by gu
ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
pt
du
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
spec
t to the co
rrectness of i
l purpos
orm
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
Removing lksw
agen oes
not
Vo gu
by
Before removing engine control unit, read the control ised unit iden ara
nte
tification and, with it, the coding of the controlutunit
ho used up to
r eo
ra
now Vehicle diagnostic tester. ss a c
ce
e
pt
du
an
itte
y li
Disconnect battery Electrical system; Rep. gr. 27 .
erm
ab
ility
ot p
wit
, is n
h re
Release and pull off connectors -2- and -3-.
hole
spec
Pull engine control unit out.
es, in part or in w
t to the co
Installing
Install in reverse order. In the process, note the following:
rrectness of i
Insert engine control unit.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
te
do
priv
cum
or
en
ng
t.
yi Co
Check previous coding and code new control unit Vehicle t. Cop py
diagnostic tester.
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3 Checking components
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Measuring container, fuel-resistant
es, in part or in w
t to the co
Protective gloves
Test prerequisites
rrectness of i
Battery voltage at least 12.5 V
l purpos
nform
ercia
a
com
tion in
Ignition switched off.
r
te o
thi
s
Checking fuel pressure
iva
do
r
rp
cum
fo
en
ng
WARNING
t.
yi Co
Cop py
t. rig
gh ht
The pressure in the high-pressure part of the injection pyri by
Vo
o
system must be reduced to a residual pressure
by c lksw
cted agen
page 161 .
Prote AG.
Release clip -2- and detach fuel line -3- from high-pressure
pump -1-.
ce
e
nl
Screw adapter -V.A.G 1318/11- to K-Jetronic pressure tester
pt
du
an
-V.A.G 1318- .
itte
y li
erm
ab
Attach auxiliary hose -arrow- to pressure tester and hold it in
ility
ot p
collecting container.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
Close pressure tester shut-off valve.
nl
pt
du
an
itte
y li
Lever is at right angle to direction of flow -arrow-.
erm
ab
ility
ot p
Connect vehicle diagnosis tester.
wit
, is n
h re
Select Engine electronics in the self-diagnosis program.
hole
spec
Then select final control diagnosis.
es, in part or in w
t to the co
In selection list select Fuel pump electronics and press
Start.
rrectness of i
l purpos
Note
nf
ercia
orm
m
atio
Read off fuel pressure at K-Jetronic pressure tester -V.A.G
om
1318- .
n in
or c
thi
e
Specification: 5 to 8 bar
t
sd
iva
o
r
rp
cu
Stop procedure once fuel pressure no longer rises at K-Jet
o
m
f
en
ng
Note
Note
n AG. Volkswagen AG do
lkswage es n
o ot g
Check fuel system for leaks. d byV ua
ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Perform check only if there is a loss of torque. This means when
es, in part or in w
t to the co
Special tools and workshop equipment required
rrectness of i
Hand vacuum pump -VAS 6213-
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Test prerequisite cted agen
Prote AG.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
equipment required
ility
ot p
wit
Assembly tool -T10118-
, is n
h re
hole
spec
27 mm -VAS 5301/7-
es, in part or in w
t to the co
Pressure sensor tester -
VAS 6394/1-
rrectness of i
Adapter -VAS 6394/2-
l purpos
nf
ercia
1331-
orm
m
atio
Vehicle diagnosis tester
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Procedure:
Remove fuel pressure sender -G247- page 222 .
Moisten tapered seal of adapter -VAS 6294/2- with clean en
gine oil and screw into fuel rail. Specified torque: 27 Nm.
ce
le
un
pt
Connect pressure line of tester -VAS 6394/1- to adapter -VAS
an
d
itte
6394/2- .
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
ton once.
un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
Press button -A- for 2 seconds, then light will be switched on
hole
spec
for 20 seconds.
es, in part or in w
t to the co
If the digital pressure gauge -VAS 6394/1- reading is not 0 bar,
carry out a zero calibration procedure operating instruc
tions .
rrectness of i
Connect vehicle diagnosis tester to diagnostic connection.
l purpos
nform
ercia
a
com
tion in
r
Vehicle self-diagnosis
te o
thi
s
iva
do
Self-diagnosis
r
rp
cum
fo
en
g
01 - Engine electronics
n
t.
yi Co
Cop py
011 - Measured values gh
t. rig
ht
pyri by
Select measured value block 1 4 0 and acknowledge with
co Vo
by lksw
cted agen
Q. Prote AG.
WARNING
Repeat test with new fuel pressure sender -G247- and com
pare two readings.
If readings again fail to correspond:
Perform line test vehicle diagnostic tester .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Auxiliary measuring set -V.A.G 1594C-
rrectness of i
Test prerequisite
l purpos
nform
ercia
at
charcoal filter solenoid valve 1 -N80- -2-.
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
rm
ab
it, the intake manifold must be removed.
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
1 - Seal
erm
ab
ility
ot p
Renew.
wit
is n
h re
2 - Catalytic converter
ole,
spec
Protect catalytic con
urposes, in part or in wh
t to the co
knocks and impact
Removing and installing
rrectne
page 240 .
Aligning exhaust sys
s
tem free of tension
s o
page 243 .
cial p
f inform
3 - Exhaust pipe bracket
mer
atio
m
4 - Bolt
o
n
c
i
or
n
20 Nm
thi
te
sd
va
5 - Nut
i
o
pr
cum
r
fo
40 Nm
en
ng
t.
yi Co
Renew. Cop py
ht. rig
Coat studs of turbo
rig ht
py by
o Vo
charger with high-tem by c lksw
cted agen
perature paste. Prote AG.
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 243 .
9 - Rear clamp
Align exhaust system free of tension before tightening page 243 .
Installation position page 240 .
Tighten bolted connections evenly.
10 - Bolt
20 Nm
11 - Retainer
12 - Front clamp
Align exhaust system free of tension before tightening page 243 .
Installation position page 240 .
ce
le
Installation position of front clamp un
pt
an
d
itte
y li
Install clamp in illustrated angle position.
rm
ab
pe
ility
Bolt connections point to the right.
ot
wit
, is n
h re
Nuts point upwards.
hole
spec
es, in part or in w
= approx. 20
t to the co
rrectness of i
l purpos
nform
ercia
a
com
tio
tom of clamp.
n in
r
te o
thi
Bolt connections point downwards.
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Unscrew bolts -2- from
ut
ho bracket -1-. eo
ra
s a c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Release clip -2- between catalytic converter and centre si
l purpos
lencer.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
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
ce
le
Support gearbox with engine and gearbox support -V.A.G
un
pt
an
d
1383 A- .
itte
y li
rm
ab
Release gearbox mounting from gearbox. To do so, loosen pe
ility
ot
bolts -1-.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
ti
Remove cross member -2- for gearbox mounting -3-; to do so,
on in
unscrew bolts -1-.
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Install double clamp so that end of bolt -arrow- does not extend
beyond lower edge of double clamp.
Threaded connection faces to rear.
Aligning exhaust system page 243 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
et -1-.
Remove rear silencer downwards. t to the co
Installing
rrectne
f in
atio
om
n
c
i
or
n thi
te
sd
va
o
pr
cum
r
fo
en
ng
t.
Start engine and run at idling speed.
yi Co
Cop py
t. rig
Plug tailpipes (e.g. with cloths or sealing plugs) and leave
gh ht
yri by
plugged until leak test is complete.
op Vo
by c lksw
cted agen
Prote AG.
Listen for noise at connection points (cylinder head/exhaust
manifold, exhaust manifold/front exhaust pipe, etc.) to locate
any leaks.
Rectify any leaks that are found.
n AG. Volkswagen AG do
lkswage es n
Vo ot g
The exhaust system must be aligned when d cold.
by ua
ran
ir se tee
o
Procedure: auth or
ac
ss
Loosen bolts of double clamp -3-.
ce
e
nl
pt
du
an
Tighten bolts hand tight.
itte
y li
erm
ab
Align exhaust system until the marking- 4- is visible.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
o
Align bolts of double clamp -3- horizontally.
rm
m
atio
m
Align rubber mountings -1- for front silencer -2- and rear si
o
n in
c
thi
te
sd
a
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
Gradual introduction of clamp with continuous clip.
erm
ab
ility
ot p
wit
Specified torque and mounting dimensions of clamping sleeve.
, is n
h re
hole
Clamp -A- with 2 individual clips.
spec
es, in part or in w
Specified torque: 25 Nm.
t to the co
Installation dimensions -a- 5 mm (only for front clamp)
rrectness of i
Clamp -B- with continuous clip.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
haust pipe
o
m
f
en
ng
t.
yi Co
1 - Clamp Cop py
t. rig
gh ht
yri
2 - Front exhaust pipe p by
o Vo
by c lksw
cted agen
a - Installation dimension Prote AG.
A - Marking
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
28 Ignition system
1 Repairing ignition system
General notes on ignition system page 247 .
Safety precautions page 247 .
Assembly overview - ignition system page 248 .
Removing and installing ignition coils with output stages
page 248 .
Spark plug test data page 253 .
ce
e
nl
pt
du
Guided functions.
an
itte
y li
erm
ab
If, after fault finding, repairs or component tests, the engine
ility
ot p
starts, runs for a short period and then stops, then the fault
wit
, is n
h re
In this case, the control unit must be adapted using vehicle
hole
spec
diagnosis tester under Guided functions.
es, in part or in w
t to the co
1.2 Safety precautions
To prevent injuries to persons and/or damage to the injection and rrectness of i
ignition system, the following must be observed:
l purpos
Do not touch or pull off ignition coils with output stage when
engine is running or turning at starter speed.
nf
ercia
atio
om
n in
sd
a
from the ignition coils and the injectors. Read and clear fault
iv
o
r
rp
cu
m
f
en
ng
t.
yi
Always switch off ignition before cleaning engine.
Co
Cop py
t. rig
Disconnecting and connecting the battery must only be done
gh ht
pyri by
with the ignition switched off, otherwise the engine control unit
o Vo
by c lksw
cted
could be damaged.
agen
Prote AG.
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
ce
le
un
pt
an
d
Gold-plated contacts.
itte
y li
erm
ab
2 - 20 Nm
ility
ot p
wit
The specified torque in
is n
h re
fluences the function of
ole,
spec
urposes, in part or in wh
t to the co
3 - Ignition coil with output
stage -(N70, N127, N291,
N292)-
rrectne
Removing and installing
page 248 .
ss
4 - Spark plug, 25 Nm
o
cial p
f in
If a spark plug is re
form
mer
i
or
n thi
e
sd
va
page 253 .
i
o
pr
cum
r
fo
t.
yi
spark plug socket and
Co
op py
extension -3122 B- . t. C rig
gh ht
pyri by
5 - O-ring
co Vo
by lksw
cted agen
Prote
Renew.
AG.
Puller -T40039-
AG. Volkswagen AG d
Lubricating paste -G 052 141 A2- olksw
agen oes
not
y V gu
b
Removing rise
d ara
nte
tho eo
au ra
ss c
Note
ce
le
un
pt
an
d
itte
y li
Observe safety precautions page 247 .
rm
ab
pe
ility
Assembly overview - ignition system page 248 .
ot
wit
, is n
h re
To detach spark plugs, fit puller -T40039- onto uppermost,
hole
spec
thick rib -arrow- of ignition coils with final output stages.
es, in part or in w
t to the co
The lower ribs may be damaged if they are used.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Align ignition coils with connectors -arrows- and push all con
nectors simultaneously onto ignition coils.
Evenly push ignition coils onto spark plugs by hand.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
1.5 Removing and installing spark plugs aut
ho eo
ra
ss c
ce
le
un
pt
an
d
Note
itte
y li
rm
ab
pe
ility
wit
, is n
h re
spec
es, in part or in w
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Puller -T40039-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
Removing
rm
ab
pe
ility
Pull all ignition coils approx. 30 mm out of spark plug recess
ot
wit
using puller -T40039- .
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
do
cum
fo
en
g
t.
yi Co
Cop py
Installing
t. rig
gh ht
pyri by
Vo
o
by c
Fit new spark plugs with spark plug spanner -VAS 3122B- .
lksw
cted agen
Prote AG.
Specified torque: 30 Nm
Insert all spark plugs with final output stage loosely into spark
plug recess.
ce
e
nl
pt
du
an
itte
y li
Evenly push all ignition coils plus final output stages onto spark
erm
ab
ility
plugs by hand.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.6 Removing and installing knock sensor 1
-G61-
rrectness of i
Removing
l purpos
nform
ercia
at
om
ion
c
Note
in t
or
his
ate
do
riv
cum
or
en
ng
t.
yi Co
op py
Unscrew knock sensor I -G61- .
t. C rig
gh ht
pyri by
Vo
o
Installing by c lksw
cted agen
Prote AG.
Install in reverse order.
Specified torque page 248 .
Removing
Detach connector -2- from engine speed sender -G28- at right
below coarse oil separator -1-.
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
Loosen securing bolt -arrow- with socket AF 4 mm -T10370-
ce
le
un
pt
and remove speed sender.
an
d
itte
y li
rm
ab
Installing
pe
ility
ot
wit
Install in reverse order. In the process, note the following:
, is n
h re
hole
spec
sender -G28- 5 Nm.
es, in part or in w
t to the co
rrectness of i
l purpos
tion in
thi
Spark plugs
s
iva
do
r
rp
en
ng
t.
Electrode gap 1.01.1 mm
yi Co
Cop py
t.
Specified torque 25 Nm
rig
gh ht
pyri by
Vo
o
Change interval by c Maintenance ; Booklet ; Service ta
lksw
cted agen
Prote
bles
AG.