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Running Gear, Axles, Steering PDF
Running Gear, Axles, Steering PDF
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Workshop Manual
Amarok 2011
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Running gear, axles, steering
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Repair Group
00 - Technical data
40 - Front suspension
42 - Rear suspension
44 - Wheels, tyres, vehicle geometry
48 - Steering
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Evaluating accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Checklist for evaluating running gear on accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Tyre types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 Raising wheel suspension to unladen position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Overview - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Assembly overview - subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Renewing anti-roll bar bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Removing and installing coupling rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 Wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 Assembly overview - wheel bearing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.3 Removing and installing wheel sw agen
bearing . . . . . . . . . . o.e.s n. o.t . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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4 Suspension strut, upper db
ise suspension link . . . . . . . . . . . . . . . .an.te. . . . . . . . . . . . . . . . . . . . . 24
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4.1 Assembly overview au - suspension strut, upper suspension link . . . r.ac. . . . . . . . . . . . . . . . . .
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4.2 Assembly overview s - suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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6 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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1 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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1.2 Assembly overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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1.3 Assembly overview - rear axle shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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1.4 Removing and installing bump stop for leaf spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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1.5 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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57
1.6 Removing and installing leaf spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.7 Renewing rubber bush for leaf spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.8 Removing and installing plastic insert for leaf spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Contents i
Amarok 2011
Running gear, axles, steering - Edition 01.2013
pt
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Adjusting camber and caster at front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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2.9 Adjusting front axle toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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1 Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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1.2 Removing and installing steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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2 Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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2.1 Assembly overview - steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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2.2 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.3 Handling and transporting steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.4 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.1 Assembly overview - steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.2 Removing and installing steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.3 Repairing steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.4 Checking shock absorber mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.5 Removing and installing shock absorber mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.6 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.7 Removing and installing track rod ball joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.8 Removing and installing boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4 Hydraulic power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
ii Contents
Amarok 2011
Running
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4.1 Assembly overview - vane pump rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.nt.e . . . . . . . . . .
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4.2 Assembly overview - hydraulic
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th lines, reservoir . . . . . . . . . . . . . . . . . . . . e.o.r a. . . . . . . . .... 121
4.3 s of vane pump . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . .
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Checking delivery pressure .... 121
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4.4 Removing and installing vane pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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4.5 Checking power steering fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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4.6 Bleeding steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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4.7 Check steering for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
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Contents iii
Amarok 2011
Running gear, axles, steering - Edition 01.2013
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iv Contents
Amarok 2011
Running gear, axles, steering - Edition 01.2013
00 Technical data
1 Evaluating accident vehicles
(VRL005375; Edition 01.2013)
1.1 Checklist for evaluating running gear on accident vehicles,
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Check tyres for cuts and impact damage in tread and on flanks.
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2 General information
2.1 Tyre types, page 3
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2. General information 3
Amarok 2011
Running gear, axles, steering - Edition 01.2013
3 Repair instructions
3.1 Steering rack, page 4
3.2 Gaskets and seals, page 4
3.3 Nuts and bolts, page 5
3.4 Electrical components, page 5
3.5 Raising wheel suspension to unladen position,
page 6
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chanical power-assisted steering system, see Self-study pro
gramme No. 317 ; Electromechanical Power-assisted Steering
with Double Pinion .
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Thoroughly clean all unions and the adjacent areas before
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Use only the grease and sealants with specified part numbers.
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3.4 Electrical components
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3. Repair instructions 5
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3.5.1 Raising front wheel suspension to unladen position
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Special tools and workshop
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All bolts on running gear components with bonded rubber
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If the vehicle is not strapped down, it may slip off the lifting
platform!
3. Repair instructions 7
Amarok 2011
Running gear, axles, steering - Edition 01.2013
WARNING
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Amarok 2011
Running gear, axles, steering - Edition 01.2013
WARNING
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Never raise or lower the vehicle while the engine and
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Do not leave engine and gearbox jack - V.A.G 1383 A-
under vehicle longer than necessary.
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Tighten respective nuts and bolts.
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40 Front suspension
1 Front axle
1.1 Overview - front axle, page 11
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4.1 Assembly overview -
suspension strut, upper sus
pension link, page 24
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Cop py
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Prote AG.
1. Front axle 11
Amarok 2011
Running gear, axles, steering - Edition 01.2013
2 Subframe
2.1 Assembly overview - subframe, page 12
2.2 Removing and installing anti-roll bar, page 12
2.3 Renewing anti-roll bar bushes, page 13
2.4 Removing and installing coupling rod, page 15
1 - Ladder frame
2 - Suspension strut
3 - Nut
Always renew after re
moving
110 Nm
4 - Bolt
5 - Coupling rod
Connects anti-roll bar to
trailing arm and wheel
bearing housing
AG. Volkswagen AG d
Removing and installing agen oes
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6 - Anti-roll bar aut
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Removing and installing s
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page 12 pt
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7 - Multi-point socket head bolt
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Always renew after re
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110 Nm
8 - Rubber mounting
nf
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Allocation Electronic
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9 - Clamp
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Cop py
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Bits - T10099-
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Removing ir se tee
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Note
un
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The following procedure is for the left side of the vehicle. The
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Installing
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Special tools and workshop equipment required
yi Co
Cop py
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Prote AG.
2. Subframe 13
Amarok 2011
Running gear, axles, steering - Edition 01.2013
Bits - T10099-
AG. Volkswagen AG d
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Removing s au ra
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Installing
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cial p
-arrow-.
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Note
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Depending on version, the stop -2- can be located on the left
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Tighten bolted connections to the anti-roll bar only if the vehi
cted agen
Prote AG.
cle is standing on its wheels and is unladen or if the vehicle is
raised and is in the unladen position (normal position)
page 6 .
Specified torques
2.1 Assembly overview - subframe, page 12
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Removing
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Remove bolts -arrows-.
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Install in reverse order. Note the following points:
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2. Subframe 15
Amarok 2011
AG. Volkswagen AG d
Running gear, axles, steering - Edition 01.2013 ksw
agen oes
not
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3 Wheel bearing ho eo
aut ra
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3.1 Assembly overview - wheel bearing assembly,
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page 16
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3.2 Removing and installing wheel bearing housing,
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page 17
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3.3 Removing and installing wheel bearing, page 20
hole
spec
3.1 Assembly overview - wheel bearing assembly
es, in part or in w
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1 - Wheel bearing
rrectness of i
Black sensor ring faces l purpos
inside of vehicle
Grey slide ring faces
outside of vehicle
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2 - Retaining ring
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Ensure proper seating.
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3 - Wheel hub
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Always renew after re
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150 Nm +180
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5 - Bolt
Prote AG.
9.5 Nm
6 - Bracket
7 - Bolt
8 Nm
8 - Front left speed sensor -
G47- / front right speed sensor
- G45-
Before inserting speed
sensor, clean inner sur
face of fitting hole and
coat it with lubricating
paste Electronic
Parts Catalogue (ET
KA) .
9 - Splash plate
10 - Bolt
9.5 Nm
11 - Wheel bearing housing
Tapered hole must be free of oil and grease.
If necessary, clean with a dry cloth but do not use cleaning solutions.
Removing and installing page 17 .
12 - Tensioning disc
Rear-wheel drive vehicles only
13 - Drive shaft
Four-wheel drive vehicles only
Removing and installing page 45 .
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equipment required
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Remover - T10103-
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Ball joint puller - T10187-
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Torque wrench - V.A.G
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Cop py
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Prote AG.
Removing
Lift vehicle far enough to take weight off front axle Mainte
nance ; Booklet ; Descriptions of work; Raising the vehicle .
Vehicles with four-wheel drive
Loosen drive shaft bolt.
Note
3. Wheel bearing 17
Amarok 2011
Running gear, axles, steering - Edition 01.2013
Loosen nut on track rod ball joint but do not remove complete
ly.
Caution
Push track rod off wheel bearing housing and remove nut.
1- Ball joint puller - T10187-
Vehicles with four-wheel drive
n AG. Volkswagen AG do
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Unscrew and remove drive shafty Vbolt.
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Press out drive shaft. auth or
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2- Remover - T10103-
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When removing, make sure joints have adequate clearance.
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Remove nut -1- for coupling rod and pull bolt out of suspension
strut.
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brake pads .
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Remove brake disc. Cop py
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Remove cover plate. p by
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Remove brake line bracket from wheel bearing housing. Prote AG.
Caution
Caution
Caution
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r
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t.
yi Co
Cop py
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by
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Prote AG.
3. Wheel bearing 19
Amarok 2011
Running gear, axles, steering - Edition 01.2013
AG. Volkswagen AG d
agen oes
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au ra
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ce
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nl
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ab
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es, in part or in w
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at
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ion
c
in t
or
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do
priv
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t.
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Cop py
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pyri by
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by
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Prote AG.
Note
When doing this work, always make sure that the tools and
components are in the correct position and, if necessary, use
a second mechanic.
Place engine and gearbox jack - V.A.G 1383 A- below wheel
bearing housing throughout the entire process (to prevent ac
cidents caused by falling parts).
Removing
Remove bolt -1- and remove tensioning disc -arrow- from
wheel bearing housing -2-.
Vehicles with four-wheel drive
Remove drive shaft page 45
Continuation for all vehicles
AG. Volkswagen AG d
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aut ra
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Note
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spec
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Wheel bolts -2- must not protrude from backs of gripping pieces
t to the co
-3-.
rrectness of i
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5 - Bell T10205/2
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6 - Gripping pieces T10205/17
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7 - Press tool T10205/3
8 - Nut M20 - T10205/8-2
9 - Threaded rod M20 - T10205/8-1
Pull hub unit out of wheel bearing housing while holding tool
assembly in place.
Remove retaining ring from wheel bearing.
3. Wheel bearing 21
Amarok 2011
Running gear, axles, steering - Edition 01.2013
Note
Pull inner bearing race off hub, using -Kukko 17-2 splitter- to
do so.
Installing
Note
pt
an
d
itte
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rm
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pe
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hole
spec
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tion in
r
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Cop py
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Prote AG.
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3 - Press head T10205/13
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4 - Hydraulic cylinder VAS 6178
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5 - Support T10205/4
h re
hole
spec
6 - Wheel bearing
es, in part or in w
t to the co
7 - Press tool T10205/6
8 - Nut M20 - T10205/8-2
rrectness of i
9 - Threaded rod M20 - T10205/8-1
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Note
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3. Wheel bearing 23
Amarok 2011
Running gear, axles, steering - Edition 01.2013
Note
thread.
un
pt
an
d
itte
ab
pe
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wit
h re
hole
spec
es, in part or in w
WARNING
t to the co
rrectness of i
l purpos
nform
mercia
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com
tion in
r
te o
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t.
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Cop py
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pyri by
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by c lksw
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Prote AG.
1 - Bolt
Always renew after re
moving
50 Nm +90
2 - Nut
Always renew after re
moving
25 Nm +45
3 - Stop shell
4 - Bolt
Always renew after re
moving
50 Nm +90
5 - Upper suspension link
Tapered pin must be
free of oil and grease.
If necessary, clean with
a dry cloth but do not
use cleaning solutions.
Removing and installing
page 29
6 - Nut
Always renew after re
moving
30 Nm +90
7 - Wheel bearing housing
Tapered hole must be
free of oil and grease.
If necessary, clean with
a dry cloth but do not wage
n AG. Volkswagen AG do
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8 - Nut ir se tee
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Always renew after removingss a ac
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60 Nm +90
un
pt
an
d
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9 - Suspension strut
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10 - Bolt
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hole
spec
11 - Nut
es, in part or in w
110 Nm +180
12 - Eccentric washer
rrectness of i
If necessary, clean with a dry cloth but do not use cleaning solutions.
Removing and installing page 37
m
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com
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thi
14 - Eccentric bolt
s
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cum
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15 - Nut
t.
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Cop py
Always renew after removing
t. rig
gh ht
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by
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25
Prote AG.
4. Suspension strut, upper suspension link
Amarok 2011
Running gear, axles, steering - Edition 01.2013
110 Nm +180
16 - Ladder frame
Note
ce
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nl
pt
du
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1 - Bump stop
erm
ab
ility
ot p
2 - Shock absorber
wit
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Allocation Electronic
h re
hole
spec
es, in part or in w
3 - Coil spring
t to the co
Surface of coil must not
be damaged.
rrectness of i
Observe colour coding
l purpos
Allocation Electronic
parts catalogue ETKA
nf
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4 - Washer
orm
m
atio
5 - Suspension strut mounting
om
n in
c
6 - Nut
or
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moving
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25 Nm +45
t.
yi Co
Cop py
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Prote AG.
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erm
ab
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t to the co
Removing
rrectness of i
Remove wheel.
nform
ercia
ion
c
his
ate
cum
or
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t.
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Cop py
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Prote AG.
Note
Note
n AG. Volkswagen AG do
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When the upper nut is tightened, y V the piston rod must be se
o lks ot g
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Otherwise the lower nuts au can loosen, which will result in sub
t or
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s
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ab
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T50042- . h re
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spec
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Caution
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page 6 .
m
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Specified torques
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4.2 Assembly overview - suspension strut, page 26
Co
Cop py
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4.1 Assembly overview - suspension strut, upper suspen
gh ht
pyri by
sion link, page 24
co Vo
by lksw
cted agen
Prote AG.
3.1 Assembly overview - wheel bearing assembly,
page 16
ce
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Cop py
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Removing
c by lksw
cted agen
Prote AG.
Raise vehicle Maintenance ; Booklet ; Descriptions of work;
Raising vehicle .
Remove wheel.
Attach support - T10149- with a wheel bolt -A-.
Caution
AG. Volkswagen AG d
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Remove bolts -arrows- and removeisupper
ed b suspension link. ara
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Installing s aut ra
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s
Install in reverse order. Note the following points:
ce
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un
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Caution
pe
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wit
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hole
spec
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having bonded rubber mountings only if the vehicle is
standing on its wheels and is unladen or if the vehicle is
raised and is in the unladen position (normal position)
rrectness of i
page 6 .
l purpos
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Specified torques
m
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link
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Cop py
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Special tools and workshop equipment required yri
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Thrust plate - VW 402-
agen
Prote AG.
-- Tube - VW 426-
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Drift sleeve - 40 - 21-
rm
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a
Thrust piece - VW 454-
com
tion in
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te o
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ng
t.
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Cop py
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pyri by
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co lksw
by
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Prote AG.
Note
When doing this work, always make sure that the tools and com
ponents are in the correct position and, if necessary, use a second
mechanic.
Removing
Remove upper suspension link. page 29
Clamp upper suspension link in a vice.
ce
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nl
pt
du
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itte
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Always use suitably padded jaws in order to avoid damage to the
erm
ab
component.
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Use a chisel to bend metal collar up 3 mm. Then, saw off the
hole
spec
metal collar.
es, in part or in w
t to the co
Place component and tools in position as shown in illustration.
rrectness of i
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nf
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Installing
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Place component and tools in position as shown in illustration. C py
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Use removal wedge - 3409- to push rubber lip into the sus
p by
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Cop py
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Prote AG.
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5 - -VAS 6046-
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6 - -VAS 6046/3-
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hole
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plate is free.
rrectness of i
Ensure that coil spring is correctly seated in spring retainer -
l purpos
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mercia
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ion
c
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Cop py
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rig ht
py by
co Vo
by lksw
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Prote AG.
Set bottom of coil spring on spring retainer - VAS 6046/3- .
Ensure that coil spring is correctly seated in spring retainer -
VAS 6046/3- -arrow-.
Clamp coil spring.
Note
ce
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nl
pt
du
Specified torques
an
itte
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4.1 Assembly overview - suspension strut, upper suspen
ility
ot p
wit
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hole
spec
es, in part or in w
strut mounting
t to the co
Special tools and workshop equipment required
rrectness of i
Thrust plate - VW 401-
l purpos
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mercia
at
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ion
c
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or
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do
priv
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t.
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Cop py
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Tube - VW 415 A-
Tube - 2040-
AG. Volkswagen AG d
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Removing
Remove lower suspension link page 37 .
rrectness of i
Place component and tools in position as shown in illustration.
l purpos
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Installing
rm
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Cop py
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rig ht
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by lksw
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Prote AG.
Fit mounting from above and press in flush, together with tube
- 2040- .
Install lower suspension link page 37 .
Specified torques
4.1 Assembly overview - suspension strut, upper suspen
sion link, page 24
ce
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un
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Cop py
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Prote AG.
Removing
Raise vehicle Maintenance ; Booklet ; Descriptions of work;
Raising vehicle .
Remove wheel.
Remove nut -1- for coupling rod and pull bolt out of suspension
strut.
Remove bolted joint -2-.
ce
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Caution
un
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an
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Leave nut screwed on a few turns to protect thread on pin.
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pensation during the pressing-in process so that the suspension
link does not become slanted.
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3 - Retaining ring
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4 - Clamp
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Tightening page 51
5 - Boot
Check for splits and
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Material: Hytrel (poly
ester elastomer)
6 - Clamp
Always renew after re
moving
Tightening page 51
7 - Drive shaft
8 - Multi-point socket head bolt
Always renew after removing
Initial torque specification: 10 Nm
50 Nm +90
6. Drive shaft 43
Amarok 2011
Running gear, axles, steering - Edition 01.2013
9 - Locking plate
10 - Clamp
Always renew after removing
Tightening page 51 agen
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13 - Inner constant velocity joint
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6. Drive shaft 45
Amarok 2011
Running gear, axles, steering - Edition 01.2013
Loosen nut on track rod ball joint but do not remove complete
ly.
Caution
Push track rod off wheel bearing housing and remove nut.
1- Ball joint puller - T10187-
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Specified torques
4.1 Assembly overview - suspension strut, upper suspen
sion link, page 24
3.1 Assembly overview - wheel bearing assembly,
page 16
6. Drive shaft 47
Amarok 2011
Running gear, axles, steering - Edition 01.2013
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Remove both clamps and slide boot towards outer joint. Prote AG.
6. Drive shaft 49
Amarok 2011
Running gear, axles, steering - Edition 01.2013
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6. Drive shaft 51
Amarok 2011
Running gear, axles, steering - Edition 01.2013
Turn cage until the two rectangular windows -arrow- lie on joint
body.
Take out cage with hub.
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42 Rear suspension
1 Rear axle
1.1 Overview - rear axle, page 53
1.2 Assembly overview - rear axle, page 54
1.3 Assembly overview - rear axle shafts, page 56
1.4 Removing and installing bump stop for leaf spring,
page 57
1.5 Removing and installing rear axle, page 57
1.6 Removing and installing leaf spring, page 60
1.7 Renewing rubber bush for leaf spring, page 64
1.8 Removing and installing plastic insert for leaf spring, page
66
1.9 Removing and installing rear axle shaft, page 66
I-
1.2 Assembly overview -
rear axle, page 54
II -
1.3 Assembly overview -
rear axle shafts, page 56
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1. Rear axle 53
Amarok 2011
Running gear, axles, steering - Edition 01.2013
Note
It is not permitted to carry out welding and straightening operations on load-bearing or wheel-guiding sus
pension components.
Always renew self-locking nuts.
Always renew corroded nuts and bolts.
Bonded rubber bushes can be twisted only to a limited extent. Therefore, tighten the bolted connections of
components with bonded rubber bushes only when the wheel bearing housing is raised to unladen position
page 6 .
Always renew bonded rubber bush on both sides of the vehicle.
1 - Bolt
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90 Nm +180
2 - Nut
Always renew after re
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90 Nm +180
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8 - Shock absorber
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page 69
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12 - Spring retainer
13 - Final drive cover
14 - Seal
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Removing and installing page 60 .
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Before removing, mark position relative to final drive flange.
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50 Nm +90
19 - Bolt
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Shorter than Item 11 (page 54)
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43 Nm
20 - Bolt
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32 Nm
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21 - Oil drain plug
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23 - Bolt
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90 Nm +180
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24 - U bolt
Always renew after removing
25 - Saddle plate
26 - Nut
Always renew after removing
150 Nm +180
1. Rear axle 55
Amarok 2011
Running gear, axles, steering - Edition 01.2013
1 - Rear axle
2 - Bolt
Always renew after re
moving
150 Nm +90
3 - Bolt
Always renew after re
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4 - Brake carrier
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5 - Rear axle shaft
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Allocation of rear axle shafts
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The rear axle shafts are colour-coded. Observe proper installation
without exception:
A: yellow marking for left shaft in direction of travel
B: blue marking for right shaft in direction of travel
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Raise vehicle Maintenance ; Booklet ; Descriptions of work;
Raising vehicle .
Remove wheels.
Note
The following procedure is for the left side of the vehicle. The
procedure for the right side of the vehicle is identical.
1. Rear axle 57
Amarok 2011
Running gear, axles, steering - Edition 01.2013
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Disconnect brake hose -1- from brake line -arrow-.
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Unscrew adjustment nut -5- from front handbrake cable -1-.
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compensator -4-.
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Remove handbrake cable from control cable support bracket.
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Remove all cable ties -arrows- for speed sensor wire from
handbrake cable.
Disconnect speed sensor connector for ABS.
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Place engine and gearbox hjackrise - V.A.G 1383 A- under axle nte
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beam and tie it down with
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1. Rear axle 59
Amarok 2011 agen
AG. Volkswagen AG d
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Running gear, axles, steering - Edition 01.2013
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Unscrew nuts -1- from U bolts -2- and -3-. auth or
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Remove U bolts and saddle plate.
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extent.
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page 6 .
com
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Unfasten bolted joint of shock absorber -1- on rear axle
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1. Rear axle 61
Amarok 2011
Running gear, axles, steering - Edition 01.2013
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Note
Leaf spring guide pin must slide out of hole in axle beam; lever
out if necessary.
Watch out for brake hose. It must not be stretched.
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Make sure that guide pin of leaf spring engages in hole in axle
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Specified torques C py
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1. Rear axle 63
Amarok 2011
Running gear, axles, steering - Edition 01.2013
n AG. Volkswagen AG do
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Place component and tools in position as shown in illustration.
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Place component and tools in position as shown in illustration.
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Note
1. Rear axle 65
Amarok 2011
Running gear, axles, steering - Edition 01.2013
WARNING
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Release plastic insert -1- and carefully pull off bracket in
pe
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Note
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Before installing new insert, remove soiling on guides of bracket.
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Slide plastic insert onto bracket, they must audibly and per
nform
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Removing
Raise vehicle Maintenance ; Booklet ; Descriptions of work;
Raising vehicle .
Remove wheel.
Pull connector -2- off speed sensor -1-.
pt
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67
AG.
1. Rear axle
Amarok 2011
Running gear, axles, steering - Edition 01.2013
Note
Note
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axle beam and exert slight counter pressure.
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page 6 .
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Note
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The plastic stone guard must be renewed if damaged.
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Specified torques
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rosion, page 73
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1.6 Wheel change, installation requirements, page 73 erm
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1.8 Wheel change, wheel installation, page 76
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1.1 Torque settings for wheel bolts
Specified torque
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Component Specified torque
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Before fitting wheel, protect wheel centring seat against cor
on
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New wheels with a modified contour have been introduced for all
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vehicles as of model year 2005. C py
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The tyre fitting unit must be furnished with the tyre fitting head
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WARNING
If the tyre fitting unit has not yet been modified, please contact the
manufacture of the unit.
Notes on safety and conditions for removing and fitting tyres
(wheels with tyre pressure monitoring)
It is extremely important to adhere to the instructions and
warnings in the following descriptions.
Check whether the tyre pressure sensor should also be re
placed Vehicle diagnostic tester.
Note
Ensure that the tyre does not contact the tyre pressure sensor
during removal or fitting.
The tyre pressure sensor must not come into contact with wa
ter or be blown upon with compressed air when the wheel is
cleaned.
1. Wheels, tyres 71
Amarok 2011
Running gear, axles, steering - Edition 01.2013
Press both tyre beads off all round and liberally coat tyre and
wheel rim flange with tyre assembly paste -arrow-.
WARNING
If the tyre fitting unit has not yet been modified, please contact the
manufacture of the unit.
AG. Volkswagen AG d
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1.3 Removing tyre from wheel d b ara
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Tyres which have been filled or sealed using tyre sealant must
ss a be c
drained before removal.
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lergies.
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During this work, wear protective gloves and safety gog
gles.
rrectness of i
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at
area of tyre.
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1. Wheels, tyres
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Prote AG.
Amarok 2011
Running gear, axles, steering - Edition 01.2013
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phase is no indication of its internal temperature.
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To enable cold tyres to absorb heat from the ambient air as
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warm air to circulate around them effectively.
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blower for warming, since this can very quickly lead to critical
surface temperatures.
Except for warming with warm water or warm air (max. 50 ),
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there is no process available for warming tyres without dam
aging the tyre!
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When cold tyres (below 0 ) are transferred to a warm envi
cial p
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ronment (above 0 ), a layer of condensation immediately
form
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Warming times:
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Assuming a minimum room temperature of 19 and a tyre
temperature of 0 or more, a tyre should be kept at least at
19 for at least 2 hours
Assuming a minimum room temperature of 19 and a tyre
temperature of below 0 C, a tyre should be kept at least at 19
for at least 2.5 hours
Warming recommendations:
If possible, tyres should be stored in the workshop 1 day before
they are fitted (order preparation).
Store on an insulated base, pallet or the like, as high up as
possible
Position the tyres individually to allow the warm air to circu
late around them effectively.
Wipe off perspiration water.
Never heat with a radiator or hot air blower!
ce
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This is important to ensure that the wheel bolts and the wheels
nl
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are properly secured.
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Check to ensure that contact surfaces -arrows- on brake disc
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Prote AG.
1. Wheels, tyres 75
Amarok 2011
Running gear, axles, steering - Edition 01.2013
WARNING
pt
du
WARNING
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Specified torques
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2 Wheel alignment
2.1 Notes for wheel alignment, page 77
2.2 Necessity of wheel alignment, page 77
2.3 Test prerequisites, page 78
2.4 Test preparations, page 79
2.5 Specified values for wheel alignment, page 79
2.6 Wheel alignment procedure, page 81
2.7 Measuring vehicle longitudinal inclination, page 82
2.8 Adjusting camber and caster at front wheels, page 83
2.9 Adjusting front axle toe, page 83 n AG. Volkswagen AG do
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2.10 Vehicle data sticker, page 84 d b ua
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2.11 Steering angle sender - basic setting,
au page 85
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2.1 Notes for wheel alignment
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Wheel alignment must be performed only using a VW/AUDI-ap
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proved wheel alignment unit!
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Whenever wheels are aligned, both the front and rear axles must
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be measured.
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All the information required to perform alignment can be found in
the wheel alignment computer.
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Current data updates can be found in Volkswagen ServiceNet.
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ware; Hunter
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2.2 Necessity of wheel alignment
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The vehicle does not handle properly.
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Prote AG.
Vehicle has been involved in an accident and components
have been renewed.
Axle components have been removed and reinstalled.
Tyres are worn more on one side.
Components have been renewed
Front axle component was renewed. Alignment necessary
Yes No
Lower suspension link X
Wheel bearing housing X
Track rod/track rod ball joint X
Steering rack X
Suspension strut X
Anti-roll bar X
2. Wheel alignment 77
Amarok 2011
Running gear, axles, steering - Edition 01.2013
ce
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pt
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Track rod/track rod ball joint X
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Steering rack X
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Suspension strut X
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Anti-roll bar X
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Note
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Misalignment of steering wheel following removal and installation
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Rear axle
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All camber and toe values on the rear axle are prescribed by the
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2.3 Test prerequisites
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Check suspension, wheel bearing, steering and steering link Prote
cted AG.
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age for excessive play and damage.
Tread depth difference of no more than 2 mm on one axle.
Tyres inflated to correct pressures.
Vehicle unladen.
Fuel tank must be full.
Spare wheel and vehicle tools are stowed in correct locations.
Windscreen washer fluid reservoir must be full.
When checking wheel alignment, ensure that sliding plates
and turntables are not touching end stop.
Note
AG. Volkswagen AG d
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The existing lateral run-out of the wheel must be compensated
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alignment unit.
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Use brake pedal depressor to depress brake pedal. t. C rig
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2. Wheel alignment 79
Amarok 2011
Running gear, axles, steering - Edition 01.2013
Front axle Without flared wheel arches With flared wheel arches
Toe-in per wheel (indi +0 5 5 +0 5 5
vidual toe)
Maximum permissible max. 5' max. 5'
difference between
sides n AG. Volkswagen AG do
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Camber (in straight- -0 20 d b30yV
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Height at a standstill 525 17 mm 518 17 mm
when fuel tank is 90 %
full and a driver's weight
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of 75 kg.
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Rear axle Without flared wheel arches With flared wheel arches
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Driving axle angle +0 0 20 +0 0 20
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Height at a standstill 585 17 mm 578 17 mm
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when fuel tank is 90 % Prote
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full and a driver's weight
of 75 kg.
Alignment procedure
body
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Yes Inspect axle components and
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copy Vo
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Prote AG.
Amarok 2011
Running gear, axles, steering - Edition 01.2013
Check front axle toe Is actual value within toler No
ance?
End Yes Adjust page 83 .
AG. Volks
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1) If steering wheel is not centred, it must be straightened
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2.7 Measuring vehicle longitudinal inclina
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Special tools and workshop equipment required
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To calculate the caster at zero vehicle inclination, deduct the yri
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measured vehicle inclination value from or add it to the measured
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caster value.
Prote AG.
Example:
Measured vehicle longitudinal inclination Inclined
0 40'
forwards
Specified caster angle for front axle when vehicle + 4 50
longitudinal inclination is 0 60
Specified caster angle taking vehicle longitudinal 4 10
inclination into account 60
Vehicle inclining forwards: subtract measured inclined angle
from specification of 4 50'.
Vehicle inclining rearwards: add measured inclined angle to
specification of 4 50'.
Ensure longitudinal member surface is clean and smooth in
area where measurement is to be taken.
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Remove bolt -1- and replace with a new eccentric bolt Elec
tronic Parts Catalogue ETKA , but do not tighten.
rrectne
Remove bolt -2- and replace with a new eccentric bolt Elec
tronic Parts Catalogue ETKA , but do not tighten.
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Set camber and caster values and then tighten bolts -1- and
cial p
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-2- to prescribed torque setting.
form
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Specified torques
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2.9 Adjusting front axle toe
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Required special tools, test and measuring devices as well as
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auxiliary items
AG.
2. Wheel alignment 83
Amarok 2011
Running gear, axles, steering - Edition 01.2013
AG. Volkswagen AG d
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Loosen lock nut -1- while counterholding on head of track rod
erm
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-2-.
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Adjust toe by turning left and/or right track rod.
es, in part or in w
t to the co
To to this, it is possible to position an open jaw spanner on hex
agonal profile of track rod.
After turning track rods, ensure that boots are not twisted.
rrectness of i
Twisted boots wear out quickly.
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nform
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at
om
i
Counter hold on track rod ball joint -2-.
on
c
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It is possible that the value will change slightly when lock nut is
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However, if the measured toe value lies within the tolerance, the C py
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adjustment is correct.
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Fit spring-type clip to boot. cted agen
Prote AG.
Specified torques
3.3 Repairing steering rack, page 110
AG. Volkswagen AG d
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Prote AG.
2. Wheel alignment 85
Amarok 2011
Running gear, axles, steering - Edition 01.2013
pt
du
wheels
an
itte
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erm
ab
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hole
This will give you information about the nature of the vibration.
spec
es, in part or in w
tion occurs.
Raise the vehicle on a lifting platform immediately after the
rrectness of i
road test.
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Remove wheels.
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Prote
Rep. gr.44 - Wheels, tyres, vehicle geometry
AG.
Amarok 2011
Running gear, axles, steering - Edition 01.2013
Balance wheels.
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Dirt and rust in the area of the contact surfaces and centre of the
rrectness of i
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ion
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Note
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It is very important that the correct tools for centring and clamping
um
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the wheels are used on the wheel balancing system. Before com
n
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mencing any work, find out about the respective centring system
Cop py
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balancing machines - VAS 5271- , for example.
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This ensures that the wheel is 100% centred and that the
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wheel will be clamped without damage!
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The wheel cannot be centralised 100% with conical clamping
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spec
es, in part or in w
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of 10 grams at the wheel/rim.
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Procedure for balancing wheels and tyres
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Allow the wheel (together with tyre) to rotate on the wheel bal
ancing machine.
nform
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Check that the indicator lines on the sidewalls of the tyre near
the wheel rim flange run evenly.
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Check tyre profile with wheel/tyre rotating.
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If one-sided wear, flat spots from braking or severely washed out Cop py
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this case, the tyre must be renewed.
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Check true running of the wheel/tyre. If the wheel and tyre do
not run true although there are no flat spots, radial or lateral
run-out may be the cause.
Check the wheel for radial or lateral run-out page 91 .
If radial and lateral run-out are within the specified tolerance,
balance the wheel and tyre.
Note
If you detect vibration during the road test, it may be due to tol
erance in the wheel centring.
In unfavourable circumstances, the component tolerances of
wheels and hubs could cumulate. This too can lead to vibration.
This vibration can be eliminated by using a finish balancer.
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Before working with a finish balancer , the mechanic needs to
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To balance the wheels, set the wheels of the driven axle on
pe
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t to the co
when balancing the wheels, you should rotate the mounting po
sition of the wheel on the hub.
rrectness of i
Mark the point at which the imbalance is indicated.
l purpos
Then, unbolt the wheel and rotate its position on the hub so
that the marking points downwards.
nform
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Note
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First, tighten lowest wheel bolt hand-tight.
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Check whether the imbalance is less than 20 grams using the
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finish balancer.
Note
Note
WARNING
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The -VAS 6230 A- detects and stores the position of the maximum
ab
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measured radial force in the tyre. Then the position of the smallest
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distance between the wheel rim flange and the centre of the rim
is n
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is measured.
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spec
urposes, in part or in wh
t to the co
rrectne
3.5 Checking radial and lateral runout of
s
wheels and tyres
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f inform
Radial and lateral run-out occur when the wheel and tyre do not
mer
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For technical reasons, 100% true running is not possible.
c
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Therefore, the manufacturers of these components allow a pre
iva
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Note
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If the difference is greater than 1.3 mm, the lateral run-out is too
h re
ole,
great.
spec
urposes, in part or in wh
t to the co
In this case, you can reduce lateral run-out by match mounting
the tyre page 93 .
Extreme values on the tyre gauge due to small irregularities in the
rrectne
rubber may be disregarded.
s
Checking radial run-out
s o
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f i
Preload tyre gauge approx. 2 mm.
nform
mer
atio
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n
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Turn wheel slowly.
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cator needle.
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rig by
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If the difference is greater than 1 mm, the radial run-out is too
AG.
great.
In this case, you can reduce radial run-out by match mounting the
tyre page 93 .
Note
Note
pt
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Check wheel for true running and for radial and lateral runout .
ss o
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Note
form
mer
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If the specified values for radial and lateral run-out are not ex
o
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Note
If the specified values for radial and lateral run-out are not ex
ceeded, the wheel can be balanced to 0 gram.
If the radial and lateral run-out are not within the specified val
ues, the tyre must be rotated again.
Note
After fitting the tyres there will be fitting lubricant between the
tyres and the rim flanges.
You should therefore avoid severe braking and acceleration
manoeuvres for the first 100 or 200 km driven. The tyres may
otherwise rotate on the rims and the work will have been in
vain.
pt
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Note
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must be renewed.
spec
urposes, in part or in wh
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The vehicle was placed in a paint shop drying booth after being
cial p
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painted.
form
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from the tyre using workshop equipment.
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Flat spots caused by storage or handling can be removed only
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by running the tyres warm. by c lksw
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The method described below is not recommended in cold and
wintry weather.
WARNING
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Prote
cted AG. 3. Vibration due to wheels/tyres - causes and rectification
agen
Amarok 2011
Running gear, axles, steering - Edition 01.2013
48 Steering
1 Steering wheel
1.1 Assembly overview - steering wheel, page 96
1.2 Removing and installing steering wheel, page 96
1 - Steering column
Assembly overview
page 99 .
Removing and installing
page 100 .
2 - Steering wheel
Different versions possi
ble. Refer to Electron
ic Parts Catalogue
Removing and installing
page 96 .
3 - Bolt agen
AG. Volkswagen AG d
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Always renew after re by Vo gu
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es, in part or in w
t to the co
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nform
mercia
at
om
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c
in t
or
his
ate
do
priv
cum
for
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t.
1.2 Removing and installing steering wheel
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Cop py
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Special tools and workshop equipment required pyri by
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Removing
Remove airbag unit on driver side General body repairs,
interior; Rep. gr. 69 ; Airbag; Removing and installing airbag
unit on driver side .
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Turn steering wheel tokcentre
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(wheels
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1. Steering wheel 97
AG. Volkswagen AG d
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V
Amarok 2011 d by gu
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Running gear, axles, steering - Edition 01.2013 tho r eo
au ra
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Pull steering wheel -2- off steering column.
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Installing
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Put steering wheel -2- onto steering column.
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Centre markings of steering wheel and steering column
h re
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-arrows- must align.
spec
urposes, in part or in wh
t to the co
rrectness o
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mer
atio
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n
c
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Cop py
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2 Steering column
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2.1 Assembly overview - steering column, page 99
ility
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wit
, is n
h re
hole
spec
2.3 Handling and transporting steering column, page 104
es, in part or in w
t to the co
2.4 Checking steering column for damage, page 104
rrectness of i
l purpos
Note
nf
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It is not permitted to carry out welding and straightening operations on load-bearing or wheel-guiding sus
or
pension components.
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1 - Assembly carrier with t. Cop py
mounting
rig
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2 - Steering column
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Prote AG.
Removing and installing
page 100 .
3 - Bolt
Observe tightening se
quence page 103 .
20 Nm
4 - Bolt
Observe tightening se
quence page 103 .
8 Nm
5 - Nut
5 Nm
2. Steering column 99
Amarok 2011
Running gear, axles, steering - Edition 01.2013
AG. Volkswagen AG d
Torque wrench - V.A.G 1332- olksw
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, is n
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spec
es, in part or in w
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Removing
rrectness of i
Only the complete steering column is supplied as a replacement
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atio
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WARNING
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or c
thi
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t.
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Disconnect earth strap from battery Electrical system;
Co
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Rep. gr. 27 ; Battery; Disconnecting and reconnecting the
. C rig
ht ht
rig
battery . py by
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Wheels must be in straight-ahead position. Prote AG.
Unscrew bolt -arrow- from universal joint -1- and pull off uni
versal joint in -direction of arrow-.
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un
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Remove airbag General body repairs, interior; Rep. gr. 69 ;
ility
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is n
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ole,
spec
urposes, in part or in wh
t to the co
94 ; Removing and installing steering column switch .
Removal and installation of the coil connector with slip ring must
rrectne
be carried out with the wheels in the straight-ahead position.
Coil connector with slip ring is secured as a new part in the centre
s
position with a cable tie.
s o
cial p
f in
Vehicles with ESP
form
mer
atio
m
n
c
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and coil connector.
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Continuation for all vehicles t. Cop py
rig
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Unplug connector -1- from immobiliser reader coil - D2- .
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Pull connector -2- off steering lock housing.
Unbolt earth cable for steering column.
Remove earth cable and steering column switch line from ca
ble retainer.
Fold floor covering back slightly.
AG. Volkswagen AG d
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Unscrew lower securing boltth-arrow-
or on left from mounting eo
bracket. s au ra
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nl
pt
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erm
ab
ility
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wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
Unscrew bolts -arrows- from steering column and hold steer
l purpos
ing column.
nform
mercia
at
om
ion
c
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or
his
ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
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Lower steering column -2- slightly and carefully pull back
Prote AG.
Caution
Installing
Install in reverse order. Note the following points:
ce
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un
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d
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ab
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
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nform
ercia
a
com
t
The correct installation position of the steering column relative to
ion in
the mounting bracket is guaranteed only in this way.
r
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s
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Note
fo
en
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t.
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When installing steering column, adhere strictly to bolting se t. C rig
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p by
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WARNING
umn
s
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WARNING
erm
ab
ility
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Adherence to proper steering column handling is essen
is n
h re
tial.
ole,
spec
urposes, in part or in wh
t to the co
steering column, leading to safety risks.
rrectne
Proper steering column handling and transport
Use both hands to transport steering column.
ss o
cial p
f
Hold steering column at upper jacket tube and in area just
inform
above lower universal joint.
mer
atio
Do not touch or contaminate plastic tube on intermediate
om
n
steering shaft.
c
i
or
n thi
te
sd
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pr
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t.
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Cop py
t. rig
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AG. Volkswagen AG d
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pt
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ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.
3 Steering rack
3.1 Assembly overview - steering rack, page 106
3.2 Removing and installing steering rack, page 107
3.3 Repairing steering rack, page 110
3.4 Checking shock absorber mountings, page 110
3.5 Removing and installing shock absorber mountings, page
111
3.6 Removing and installing track rod, page 114
3.7 Removing and installing track rod ball joint, page 116
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3.8 Removing and installing boot, page
yV
118
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3.1 Assembly overviewho - steering rack
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1 - Ladder frame
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2 - Steering column
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3 - Bolt
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Always renew after re
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spec
moving
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35 Nm +90
t to the co
4 - Pressure line
Various versions
rrectness of i
Allocation Electronic
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32 Nm
m
at
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6 - Return line
on
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7 - Banjo bolt
his
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35 Nm
p
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8 - Sealing ring
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Always renew after re t. C rig
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9 - Power steering rack
agen
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pt
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ab
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wit
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spec
es, in part or in w
t to the co
Removing
Raise vehicle Maintenance ; Booklet ; Descriptions of work;
rrectness of i
Raising vehicle .
l purpos
Remove wheels.
Remove engine/gearbox guard, if fitted General body re
nf
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atio
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Clamp off suction hose and return line using hose clamps to
o
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c
25 mm diameter - 3094- .
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Cop py
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Loosen nut on track rod ball joint but do not remove complete
ly.
Caution
AG. Volkswagen AG d
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Leave nut screwed on a few turns to protect thread on pin. d by Vo gu
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Push track rod off wheel bearing housing and remove
s nut.
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1- Ball joint puller - T10187-
an
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Unscrew bolt -arrow- from universal joint -1- and pull off uni
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spec
es, in part or in w
t to the co
rrectness of i
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com
tion in
r
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Unscrew pressure line -1- from steering rack and pull it out.
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Close off line with a plastic bag and adhesive tape.
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Remove banjo bolt -2- for return line from steering rack.
Co
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Close off line with a plastic bag and adhesive tape.
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Remove bolts -arrows- for steering rack -1- from ladder frame.
Note
Note
Installing
Install in reverse order. Note the following points:
Note
pt
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9 - Sealing ring
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spec
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Left.
Identified with an arrow pointing in direction of travel
rrectness of i
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and/or the rubber collar of the shock absorber mountings may
Co
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110
cop Vo
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Rep. gr.48 - Steering Prote
cted AG.
agen
Amarok 2011
Running gear, axles, steering - Edition 01.2013
completely and the base of the steering rack may, in the lower
position, completely contact the steering rack connection.
The threaded connection of the steering rack is not affected by
wear to the bush and is OK.
Using commercially available 0.5 mm feeler gauge, check gap
between base of steering rack and steel support.
If the rubber collar of the shock absorber mounting -arrow- can
be felt, then it is not necessary to renew the shock absorber
mounting.
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If the gap -arrow- is smaller than the rfeeler
ise
d gauge, then both shock ran
tee
absorber mountings should be renewed.utho
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Removing and installing shock absorber mountings
ce
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un
page 111 .
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3.5 Removing and installing shock absorber
l purpos
mountings
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tion in
r
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un
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Removing
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Undo bolt of rear bush of bevel gear.
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Remove bolts -arrows- for steering rack -1- from ladder frame.
wit
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spec
urposes, in part or in wh
Note
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Bolt on left side of vehicle is screwed into a nut.
rrectne
Unscrew bolt -arrow- from universal joint.
s
Pull off steering rod in -direction of arrow-.
s o
cial p
f
Pull steering rack forwards until the damping bushes are easily
inform
accessible.
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Note
fo
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Use a standard nut with a washer instead of the nut of the as
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sembly tool.
rig by
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Tighten standard nut with washer.
Pull out shock absorber mounting by pulling threaded rod
-3301M- downwards.
ce
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pt
otherwise the shock absorber mountings may become twisted.
an
d
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The assembly lubricant Electronic Parts Catalogue (ETKA)
rm
ab
must first evaporate.
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ility
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wit
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hole
spec
es, in part or in w
t to the co
Note
rrectness of i
The markings on the shock absorber mountings -arrows- must be
aligned to the direction of travel.
l purpos
nform
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com
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-3301M- upwards.
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If necessary, counterhold nut -3301- with spanner.
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cum
fo
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri
Press in shock absorber mounting 5 mm further than dimension
p by
co Vo
by lksw
specified. Then push it back 5 mm until the rubber lips are uni Prote
cted AG.
agen
formly seated on both sides.
Note
2) If the tolerance is greater than the permissible value, wheel alignment must be
carried out. page 77
Specified torques
3.1 Assembly overview - steering rack, page 106
Component Specified torque
Rear bush of bevel gear 60 Nm + 90
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nform
ercia
at
om
ion
c
Remove wheel.
in t
or
his
ate
Loosen nut on track rod ball joint but do not remove complete
do
riv
ly.
p
cum
for
en
ng
t.
yi Co
op
Caution
C py
ht. rig
rig ht
py by
co Vo
Leave nut screwed on a few turns to protect thread on pin.
by lksw
cted agen
Prote AG.
Push track rod off wheel bearing housing and remove nut.
1- Ball joint puller - T10187-
Clean outside of power steering rack in vicinity of boot.
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
track rod.
Installing
rrectne
Install in reverse order. Note the following points:
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
Make sure that correct track rod ball joint is installed on each
en
ng
t.
yi
side.
Co
Cop py
ht. rig
ht
Arrow on track rod ball joint must always point in direction of trav
rig by
opy Vo
el. by c lksw
cted agen
Prote AG.
I - Left track rod ball joint
II - Right track rod ball joint
Note
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
joint
ole,
spec
urposes, in part or in wh
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
Torque wrench - V.A.G 1332-
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
Raise vehicle Maintenance ; Booklet ; Descriptions of work;
Raising vehicle .
Remove wheel.
Loosen nut on track rod ball joint but do not remove complete
ly.
Caution
Push track rod off wheel bearing housing and remove nut.
1- Ball joint puller - T10187-
AG. Volkswagen AG d
agen oes
Loosen nut -1-. Vo lksw not
gu
by ara
d
Mark position of track rod ballorisjoint
e
on track rod. nte
eo
th
au ra
Unscrew track rod ball joint
ss -2- from track rod. c
ce
e
nl
Installing
pt
du
an
itte
y li
Install in reverse order. Note the following points:
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Make sure that correct track rod ball joint is installed on each
rrectness of i
side.
l purpos
Arrow on track rod ball joint must always point in direction of trav
el.
nform
ercia
ion
c
in t
Screw track rod ball joint onto track rod as far as previously
or
his
e
do
priv
cum
en
ng
t.
yi
Install wheel and tighten bolts or nuts page 71 .
Co
Cop py
t. rig
gh ht
Check wheel alignment after completing the installation yri
p by
o Vo
page 77 .
c by lksw
cted agen
Prote AG.
Specified torques
3.3 Repairing steering rack, page 110
Note
Removing
Raise vehicle Maintenance ; Booklet ; Descriptions of work;
Raising vehicle .
Turn steering wheel to straight-ahead position.
AG. Volkswagen AG d
Remove wheel. lksw
agen oes
not
Vo gu
by
Clean outside riseof steering rack in vicinity of boot.
d ara
nte
tho eo
No dirt musts abe allowed to enter the steering rack through a de
u ra
c
fective rubber boot during this operation.
s
ce
e
nl
pt
du
y li
erm
ab
wit
h re
hole
Installing
spec
es, in part or in w
(ETKA) .
l purpos
Caution
nf
ercia
atio
om
n in
or c
thi
sd
iva
o
r
rp
cu
m
f
en
ng
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1 - Spring retainer
2 - Bush
Drive bush back slightly
when installing vane
pump.
3 - Bolt
24 Nm
4 - Bolt
9 Nm
5 - Pressure line n AG. Volkswagen AG do
lkswage es n
o ot g
Note byV ua
d ran
ir se tee
tho
or
When installing, press on to stop in ss
au ac
vane pump. ce
le
un
pt
an
d
Contains
itte
y li
erm
6 - Suction hose
wit
is n
h re
spec
7 - Clamp
s
Install on marking on
s o
suction hose.
cial p
f inform
8 - Sealing ring
mer
atio
moving
c
i
or
n thi
te
sd
9 - Vane pump
iva
o
pr
Allocation Electronic
um
r
fo
en
ng
11 - Bolt
23 Nm
12 - Bolt
24 Nm
1 - Reservoir
2 - Sealing cover with dipstick
Check power steering
fluid level page 127 .
3 - Spring retainer
For reservoir
4 - Clamp
5 - Return hose
6 - Suction hose
7 - Clamp
8 - Bolt
9 Nm
9 - Spring retainer AG. Volkswagen AG d
agen oes
For engine control unit olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
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le
un
pt
an
d
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
thi
pump
s
iva
do
r
rp
cum
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
y V gu
d b ara
rise nte
tho eo
u ra
Power steering tester - V.A.G 1402- ss a c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness
Adapter set - V.A.G 1402/6-
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.
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
With engine idling, turn shut-off valve to position -1- (not longer
than 5 seconds) and read pressure from power steering tester
- V.A.G 1402- .
rrectness of i
l purpos
Note
nform
ercia
Ensure that the shut-off valve is not closed in position -1- for more
than 5 seconds to avoid damage to the vane pump.
m
a
com
tion in
r
thi
s
iva
do
110120 bar
r
rp
cum
fo
t.
yi Co
op py
Remove pressure gauge and adapter.
. C rig
ht ht
rig by
py
Bleed steering system page 127 .
co Vo
by lksw
cted agen
Prote AG.
Check hydraulic fluid level and top up with hydraulic fluid if
necessary page 127 .
Check steering system for leaks page 128 .
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
WARNING
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
Clamp off suction hose using hose clamps, up to 25 mm -
pe
ility
3094- . ot
wit
, is n
h re
Open spring-type clip -1- and pull suction hose off vane pump.
hole
spec
Close off suction hose with a plastic bag and adhesive tape.
es, in part or in w
t to the co
Remove bolts -2- and pull pressure line out of vane pump.
Close off pressure line with a plastic bag and adhesive tape.
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.
Note
ce
e
nl
pt
it is essential to fill vane pump with hydraulic fluid Electronic
du
an
Parts Catalogue (ETKA) and to rotate pump by hand prior to itte
y li
erm
ab
installation. Otherwise vane pump may be damaged or be
ility
ot p
wit
, is n
h re
Fluid type: hydraulic fluid Electronic Parts Catalogue (ET
hole
KA) .
spec
es, in part or in w
t to the co
Installing
Install in reverse order. Note the following points:
rrectness of i
Fill vane pump with hydraulic oil.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
o
r
rp
cu
o
m
Mount clamp -2- on mark -arrow A-.
f
en
ng
t.
yi Co
op
Install poly V-belt Power unit; Rep. gr. 13 ; Cylinder head, C py
t. rig
pulley end; Removing and installing poly V-belt .
gh ht
pyri by
Vo
o
by c lksw
Bleed steering system page 127 . cted agen
Prote AG.
AG. Volkswagen AG d
Note agen oes
olksw not
V gu
d by ara
ise nte
The cap must be fully hor screwed on in order to obtain an accurate eo
ut
fluid level reading.
ss a ra
c
ce
le
un
pt
Check fluid level: fluid level should be in area -A-.
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
When fluid is at operating temperature (approx. 80 ):
rrectne
Unscrew filler cap.
Wipe dipstick with a clean, lint-free cloth.
ss o
Screw filler cap on hand tight and unscrew again.
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
sd
va
o
pr
cum
r
fo
en
ng
t.
yi
Check fluid level: fluid level should be in area -B-.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
Note cted agen
Prote AG.
Note
Lower vehicle.
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
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.