Amarok 2011

Service
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system n AG. Volkswagen AG do
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2011 Volkswagen AG, Wolfsburg D3E8037FAC2

Amarok 2011 ➤
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Securing engine on engine and gearbox support - VAS 6095 - . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Assembly and gearbox mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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
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2.2 Removing and installing
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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
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3 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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3.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ility 36
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3.2 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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3.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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4.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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4.2 Allocation of crankshaft bearing shells (classification) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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4.4 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.5 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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4.6 Pulling needle bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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

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1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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1.3 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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1.4 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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2.1 Assembly overview - timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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2.2 Removing and installing inlet camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . .
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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 ➤
2.10 Renewing balancer shaft for inlet camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

2.11 Renewing balancer shaft for exhaust camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.12 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.2 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.3 Renewing valve stem seals with cylinder head installed . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.4 Renewing valve stem seals with cylinder head removed . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.5 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.6 Checking axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . .ise. d. . . . . . . . . . . . . . . . . . . . . . . g.ua.ra.n . . . .
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1 Cooling system . . . . . . . . . . . . . . . . . .a.ut.h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e o.r a. . 132
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1.1 General notes on cooling system . . . s.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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1.2 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
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1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
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2 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
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2.1 Coolant hose schematic diagram for vehicles with heat exchanger . . . . . . . . . . . . . . . . . . 139
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2.2 Coolant hose schematic diagram for vehicles with 2nd heat exchanger . . . . . . . . . . . . . . 140
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3 Parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 spec

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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
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3.4 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 145

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3.5 Removing and installing toothed belt for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3.6 Renewing oil seal for coolant pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
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3.7 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

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3.8 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

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4 Parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

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4.1 Assembly overview - parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . 152

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4.2 Assembly overview - air ducting with radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

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4.3 Removing and installing cowling with radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

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4.4 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cop py
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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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1 General notes on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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1.1 General notes on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

1.2 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.3 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
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Amarok 2011 ➤
1.4 Releasing pressure in high-pressure area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

2 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.1 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . e.n.A.G.. V. o. lk. s.w.a.ge. n.A.G. . . . . . . . . . . . . . . . . . . . 162
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3.1 Assembly overview - fuel tank . . . o.ris.e.d . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.an. te. . . . . . . . . . 167
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3.2 Removing and installing fuel tankaut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or.ac. . . . . . . 169
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3.3 Removing and installing fuel delivery s
unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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3.4 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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3.5 Removing and installing filler neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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3.6 Assembly overview - fuel filter with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
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3.7 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.8 Removing and installing fuel pump control unit J538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
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4 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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4.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4.2 Removing and installing accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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5 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
5.1 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
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21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
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1 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

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1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
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1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
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1.3 Instructions for hose connections with screw-type clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
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1.4 Assembly overview - charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

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

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1.6 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
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1.7 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pyri
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186
1.8 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
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2 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
2.3 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

1 Safety precautions and rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
1.1 General notes on self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2.1 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2.2 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
2.3 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.4 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2.5 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2.6 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
2.7 Assembly overview - fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.8 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
2.9 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.10 Renewing Teflon seal on injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
2.11 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
2.12 Removing and installing fuel pressure sender -G247- . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
2.13 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
2.14 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2.15 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
2.16 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
2.17 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3 Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Contents iii
Amarok 2011 ➤
3.1 Check fuel holding pressure upstream of high-pressure pump . . . . . . . . . . . . . . . . . . . . . . 229

3.2 Checking intake manifold change-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
3.3 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
3.4 Checking double non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
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26 - Exhaust system . . . . . . . . . . . .y V. o.lk.sw.a. . . . . . . . . . . . . o.e.s n.ot.g. . . . . . . . . . . . . . . . . 239
d
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1 Assembly overview - partsoof ris the exhaust system . . . . . . . . . . . . . . n.te.e. . . . . . . . . . . . . . . .
e ra
239
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1.1 Removing and installings aucatalytic
t
converter . . . . . . . . . . . . . . . . . . . . .or.ac. . . . . . . . . . . . . . 240
s
1.2 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
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1.3 Removing and installing centre silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
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1.4 Removing and installing rear silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
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1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
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1.6 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
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1.7 Installation position and specified torque of the clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
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spec
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
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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
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1.5 Removing and installing spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
form
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1.6 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
atio
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1.7 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

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1.8 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
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iv Contents
Amarok 2011 ➤
00 – Technical data
1 Technical data
Engine number
Engine data
1.1 Engine number

New four digit engine codes have been introduced since model
year 2008. The first 3 digits refer to the mechanical configuration
of the engine. They are stamped onto the engine. The fourth digit
denotes the power output of the engine and depends on the en‐
gine control unit. The four digit engine code can be found on the
identification plate, the vehicle data sticker and the engine control
unit.
The engine number („engine code“ and „serial number“) can be
found at the joint between engine and gearbox -arrow-.
In addition, there is a sticker on the toothed belt guard with „engine
code“ and „serial number“.
The engine code is also included on the vehicle data sticker.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (maximum 4 characters) makes up the
„engine code“, and the second part (6 characters), the „serial
number“. If more than 999,999 engines were produced with the
same code letters, the first of the six digits is replaced by a letter.
1.2 Engine data

Engine code CFPA
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Output s
kW at rpm 118 kW at 3800 to
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5500 rpm
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Torque Nm at rpm 300 Nm at 1600

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to 3750 rpm
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Capacity cm3 1984 cm3

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Bore ∅ mm 82.5mm
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Stroke mm 92.8mm
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Valves per cylinder 4

Compression ratio 9.6:1
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Fuel according to DIN EN 228

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Firing order 1-3-4-2

Balancer shafts 2
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Catalytic converter yes

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Exhaust gas recirculation yes

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Turbocharging/supercharging yes
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Charge air cooler yes

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Camshaft timing control yes

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AG.
1. Technical data
Amarok 2011 ➤
1) If petrol with a RON rating of less than 95 is used, reduced power output and
torque must be expected.
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2 Rep. gr.00 - Technical data

Amarok 2011 ➤
10 – Removing and installing engine

1 Removing and installing engine
1.1 Removing engine
Special tools and workshop

equipment required
♦ Lifting tackle -2024 A-
♦ Support bracket -10 - 222
A-
♦ Hook -10 - 222 A /10-
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♦ Shackle -10 - 222
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1. Removing and installing engine 3

Amarok 2011 ➤
♦ Torque wrench -V.A.G

1331-
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Socket set 1/4", 22-piece -
VAS 5528-
♦ Workshop hoist -VAS
6100-
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♦ Engine bung set -VAS Vol
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4 Rep. gr.10 - Removing and installing engine

Amarok 2011 ➤
♦ Drip tray for workshop hoist

-VAS 6208-
♦ Step -VAS 6292/4-
♦ Hose clip pliers -VAS 6340-
♦ Retainer -T10014-
♦ High-temperature grease -
G 052 133 A2-
♦ Cable ties
♦ Square timber 10 x 30 x 10
cm
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Procedure
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Note
♦ Before carrying out further work, remove the battery. Check

rrectness of i
whether a coded radio is fitted. Obtain anti-theft coding be‐

forehand if necessary.
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♦ The engine is removed upwards.

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♦ The gearbox remains installed.

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♦ All cable ties that are opened or cut through when the engine
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is removed must be renewed/replaced in the same position

or c
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♦ Seal open lines and unions with clean plugs from engine bung
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♦ Collect drained coolant in a clean container for re-use or dis‐
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Amarok 2011 ➤
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damage to lines, ensure sufficient clearance from
all moving or hot components. olksw AG. V agen AG
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♦ Cut through cable ties carefully andVreinstall
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– Remove bonnet ⇒ General body repairs, exterior; Rep. gr.
ce
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55 ; Bonnet .
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– Remove engine guard, if fitted ⇒ Body, front; Rep. gr. 50 ;
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– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
h re
hole
and installing starter .
spec
es, in part or in w
– Drain coolant ⇒ page 133 .
t to the co
– Detach coolant hose -2- with both brackets -1-.
rrectness of i
– Unscrew bolts -3-.
– Pull latch -2- back.
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– Press retaining lever -1- down and pull connector off.
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Amarok 2011 ➤
– 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
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♦ The fuel system is also under pressure! Before opening V t gu
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the system, place cloths around the connections.ho
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carefully loosen connection to release the pressure!
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♦ Wear eye and hand protection when performing any type
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– Disconnect fuel lines -1 and 2-.
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– Disconnect fuel lines -1- from bracket -2-.
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Vehicles with air conditioning system:

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To prevent damage to condenser or to refrigerant lines and ho‐
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ses, ensure that lines and hoses are not stretched, kinked or bent.
To facilitate removing and installing engine without opening re‐

frigerant circuit:
– Secure air conditioner compressor to body so that the refrig‐
erant lines and hoses are not under tension.
– Remove AC compressor with hoses connected and secure to
body ⇒ Heating, air conditioning system; Rep. gr. 87 ; Re‐
moving and installing air conditioner compressor .
Continuation for all vehicles
– Remove catalytic converter ⇒ page 240 .
– Remove cover from fuse box above battery.

Amarok 2011 ➤
– Unscrew nut -2- of battery positive cable -1-.
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– Unhook clips -1- and -3-.
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– Uncover cable harness -2-.
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– Unscrew shear bolts -1- and remove bow -3-.

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– Release and pull off connector -2-.
– Unhook clips -2- and -3-.

– Release and pull off connector -1-.
– Open bracket -4- and detach wiring harness.

Amarok 2011 ➤
– Carefully cut through cable ties -arrows-.

– Lay wiring harness on engine and secure.
– Release clip -2-, disconnect water hose -1- from radiator -3-
at bottom right and allow water to drain.
– Disconnect water hoses -2 and 3- from radiator -1- at top left.

– Disconnect water hoses from water pipes.
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– Pull line -2- out of brake servo.

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– Open clip -1- and remove coolant hose -3-.

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– Remove vane pump for power steering with hoses connected

es, in part or in w
and secure to body ⇒ Running gear, axles, steering; Rep. gr.

t to the co
48 ; Removing and installing vane pump .

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Amarok 2011 ➤
– To do this, release circulating pump V 51 -2- from bracket

-1- in order to access bolt.
– Remove air filter housing ⇒ page 207 .
– Unplug all necessary electrical connectors.
– Disconnect all necessary vacuum hoses.
– Remove bolts -1-.
– Detach retaining clips -3- with water hose -4- from cowling
-2-.
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– Disengage cowling -2- at left and right. To do this, press re‐

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taining lever -1- forwards using a screwdriver and raise cowl‐

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ing -2- slightly.

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– Remove cowling.
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– Unscrew bolts -1- from left engine mounting -A-.

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Amarok 2011 ➤
– Unscrew bolts -1- from right engine mounting -A-.
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– Install support bracket -10 - 222 A- .
es, in part or in w
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– 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-.
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– Only unscrew bolt -1- beneath starter.
Caution
• Do not unscrew the two upper bolts -1-.
– Unscrew all connecting bolts for engine/gearbox at bottom and

in middle. The two upper bolts initially remain screwed in.
– Engage lifting tackle -2024 A- on workshop hoist -VAS 6100-
and attach to engine.
– Connect adapter -10 - 222 A /20- to lifting tackle -2024 A- and
workshop hoist -VAS 6100- and secure with retaining clip.

Amarok 2011 ➤
– Hang up lifting tackle -2024 A- as shown in figure, using hole

1 -arrow A- and hole 7 -arrow B-.
lkswage es n
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byV ua
d ran
ir se tee
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or
– Unscrew the two upper bolts -1-. ss
au ac
ce
le
– If necessary, disconnect all connecting, coolant, vacuum and

un
pt
an
intake hoses that have to be disconnected from the engine in
d
itte
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order to remove it.
erm
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ility
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– Carefully pull engine from gearbox in longitudinal direction. Do
wit
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not damage needle bearing in the crankshaft whilst doing this.
h re
ole,
spec
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
a second mechanic. f inform

mer
♦ The workshop hoist -VAS 6100- must also be guided care‐

atio
m
fully when raising and lowering the engine.

o
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
– When raising and lowering engine, make sure that neither

fo
en
ng
vacuum hose -1- nor connection -2- on vacuum pump are

t.
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op
damaged.
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– Guide vacuum hose -1-, connection -2- and vacuum pump cop Vo
by lksw
past plenum chamber when raising and lowering. cted agen
Prote AG.
– When raising and lowering engine, make sure that rollers of

belt drive and turbocharger do not damage radiator.
– When raising and lowering engine, pay attention to lines and
hoses to prevent these from being damaged.

AG. Volkswagen AG d
agen oes
olksw not
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ut
ho Amarok 2011e➤ eo
ra
a
4-cylinder injection engine (2.0 l direct
s injection engine, turbocharger) - Edition 02.2011 c
s
ce
e
nl
pt
du
– Check needle bearing -arrow- in crankshaft. If it is damaged
an
itte
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or has turned blue, it must be renewed ⇒ page 44 .
erm
ab
ility
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– 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
thi
te
sd
equipment required
iva
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rp
cu
♦ Lifting tackle -2024 A-
o
m
f
en
ng
t.
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♦ 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- .

Amarok 2011 ➤
– 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
Use securing pins arrows on hooks and locking pins to avoid

damage to engine.
– Secure engine to engine and gearbox support -VAS 6095- .
AG. Volkswagen AG d
agen oes
olksw not
1.3 Notes on installing
V gu
d by ara
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or eo
h
Special tools and workshopaut equipment required ra
ss c
ce
le
♦ Vehicle diagnosis, testing and information system -VAS

un
pt
5051B-
an
d
itte
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erm
ab
ility
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wit
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ole,
spec
t to the co
rrectness o
cial p
f in
Procedure
form
mer
Install in reverse order. In the process, note the following:

atio
om
n
c
i
or
n thi
e
Caution
t
sd
iva
o
pr
cum
r
fo
♦ Only a few millimetres of space are available between

en
ng
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.

Amarok 2011 ➤
– When raising and lowering engine, make sure that neither

vacuum hose -1- nor connection -2- on vacuum pump are
damaged.
– Guide vacuum hose -1-, connection -2- and vacuum pump
past plenum chamber when raising and lowering.
– When raising and lowering engine, make sure that rollers of
belt drive and turbocharger do not damage radiator.
– When raising and lowering engine, pay attention to lines and
hoses to prevent these from being damaged.
– Check whether dowel sleeves for centering engine/gearbox AG. Volkswagen AG d
are in cylinder block, install if necessary (gearbox removed).
lksw
agen oes
n o ot g
yV ua
– Check clutch release bearing for wear and, if necessary,
ris
ed re‐
b ran
tee
place (gearbox removed). ut
ho
or
a ac
ss
ce
e
nl
Caution
pt
du
an
itte
y li
erm
ab
• Bring engine and gearbox together in longitudinal direc‐
ility
ot p
tion, not at an incline.
wit
, is n
h re
• When bringing engine and gearbox together, make sure
hole
that needle bearing -arrow- is not damaged.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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om
n in
or c
thi
te
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t.
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Cop py
t. rig
gh
– First tighten the two upper bolts -1-.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ Specified torques for assembly mountings ⇒ page 17 .

♦ Electrical connections and routing ⇒ Electrical system; Rep.
gr. 97 .

Amarok 2011 ➤
– Tighten new bolts -1- for left engine mounting -A-.
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
– Install vane pump for power steering ⇒ Running gear, axles,
h re
hole
steering; Rep. gr. 48 ; Removing and installing vane pump .
spec
es, in part or in w
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Removing and
t to the co
installing starter .
– Fit engine guard, if available ⇒ Body, front; Rep. gr. 50 ; En‐
rrectness of i
gine guard .
l purpos
– Install bonnet ⇒ General body repairs, exterior; Rep. gr. 55 ;

Bonnet .
nf
ercia
– Fit new screw-type clips with „barb“, notes on screw-type clips
orm
⇒ page 184 .
m
atio
om
To prevent the high-pressure pump from running while it is empty

n in
or c
and to ensure that the engine starts quickly after parts have been
thi
te
sd
a
renewed, it is important to observe the following:

iv
o
r
rp
cu
o
♦ If components of fuel system between fuel tank and high-pres‐

f
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
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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
♦ Only reuse drained coolant if neither cylinder head nor cylinder

block have been renewed.
♦ Soiled coolant must not be reused.
– Replenish coolant ⇒ page 133 .

– Carry out road test and read fault memory.
Specified torques ⇒ page 17 .

Amarok 2011 ➤
1.4 Assembly and gearbox mountings

Left and right engine support to crankcase
Caution
• Nut -2- must not be loosened.

• If nut -2- is loosened, engine mounting must subsequently
be renewed.
♦ Engine mounting connection to engine support may only
be loosened if engine mounting is to be renewed.
– Secure engine support -1- to crankcase with bolts -3-.

– Always renew bolts -3- and tighten to 50 Nm + 180° (1/2 turn).
. Volkswagen AG
gen AG does
Right engine mounting to frame
Vol
ksw
a
not
by gu
d ara
– Secure engineomounting
ris
e -A- to frame with bolts -1-. nte
eo
h
ut ra
– Always renew
ss a
bolts -1- and tighten to 50 Nm + 90° (1/4 turn). c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Left engine mounting to frame

rrectness of i
– Secure engine mounting -A- to frame with bolts -1-.

l purpos

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
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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).

Amarok 2011 ➤
Right engine mounting to engine support

AG. Volkswagen AG d
– Bolt new engine mounting -3- to engine support -2- with nut lkswagen oes
not
-1-. db
yV
o gu
ara
e nte
ris
– Always renew nut -1- and tighten to 90 Nm + 90° (1/4
ut turn).
ho eo
ra
a c
ss
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Gearbox mounting to gearbox
– Secure gearbox mounting -A- to gearbox with bolts -1-.
rrectness of i
l purpos
– Removing and installing gearbox mounting ⇒ Rep. gr. 34
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
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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.
– Removing and installing gearbox mounting ⇒ Rep. gr. 34

Amarok 2011 ➤
13 – Crankshaft group
1 Cylinder block (pulley end)
1.1 Assembly overview - poly V-belt drive
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
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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
timing, do not turn crank‐

ion
c
shaft when bolt has been

in t
or
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.
❑ Removing and installing ⇒ page 27 .
1. Cylinder block (pulley end) 19

Amarok 2011 ➤
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
, is n
h re
hole
8 - Bracket for ancillaries
spec
es, in part or in w
❑ With oil filter and engine oil cooler
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
❑ Removing and installing ⇒ Rep. gr. 27 .

10 - Bolt
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
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f
en
ng

t.
yi Co
Cop py
13 - Sleeve
t. rig
gh ht
pyri by
Vo
o
14 - Vane pump
c by lksw
cted agen
Prote AG.
15 - Air conditioner compressor
❑ Do not unscrew or disconnect refrigerant hoses or pipes.
16 - Bolt
17 - Dowel sleeve
❑ For air conditioner compressor.
18 - Bolt
20 Rep. gr.13 - Crankshaft group

Amarok 2011 ➤
Bracket for ancillaries - tightening sequence

– Fit bracket for ancillaries (first tighten bolt -4-).
– Tighten bolts in the sequence -1 … 5- in 3 stages as follows:
1. Tighten bolts hand tight.
2. Tighten bolts to 20 Nm.
3. Turn bolts 90° further.
Poly V-belt route with air conditioning system

1- Vibration damper
2- Guide roller
3- Poly V-belt tensioning element
4- Alternator
5- Vane pump
6- Air conditioner compressor
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
3- Poly V-belt tensioning element

an
d
itte
y li
erm
4- Alternator
ab
ility
ot p
5- Vane pump
wit
is n
h re
ole,
spec
t to the co
1.2 Removing and installing tensioner for

rrectne
poly V-belt
ss
Special tools and workshop equipment required

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.

Amarok 2011 ➤
♦ Locking tool -T40098-
Removing
Caution
If a used belt runs in the opposite direction when it is refitted,

this can cause breakage.
♦ Before removing, mark direction of rotation of poly V-belt
with chalk or felt-tipped pen for re-installation.
– To slacken poly V-belt turn tensioner in direction of -arrow-.

– Lock tensioner with locking tool -T40098- .
– Remove poly V-belt from tensioner.
– Remove bolt -1- and take off tensioner for poly V-belt from
bracket for ancillaries.
Installing
Installation is carried out in the reverse order. When installing,
note the following: gen AG
. Volkswagen AG
d a oes
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• Specified torque ⇒ page 19 . y Vol gu
b ara
ed nte
ris
– Install poly V-belt ⇒ page 22 . utho eo
ra
a c
ss
ce
e
nl
pt
1.3 Removing and installing poly V-belt

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
22
AG.
Rep. gr.13 - Crankshaft group
Amarok 2011 ➤
Removing
Caution

AG. Volkswagen AG d
agen oes
olksw not
V gu
by
– To slacken
rised poly V-belt turn tensioner in direction
ara of -arrow-.
nte
ho eo
– Lock
aut tensioner with locking tool -T40098- . ra
ss c
ce
le
– Remove poly V-belt.

un
pt
an
d
itte
Installing
y li
rm
ab
pe
ility
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
– Fit poly V-belt as shown in figure.

nform
ercia
Vehicles with air conditioner

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Vehicles with no air conditioner

Amarok 2011 ➤
– Turn tensioner in -direction of arrow- and withdraw locking tool

-T40098- .
– Release tensioner.
– Check that poly V-belt is properly seated.
– Start engine and check that poly V-belt runs properly.
1.4 Removing and installing ancillary brack‐

et
♦ Drip tray for workshop hoist -VAS 6208-
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
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Removing
rrectne

ss o
cial p
f i
Caution
nform
mer
atio

om

c
i
or
n thi
e

t
sd
iva

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.

Amarok 2011 ➤

Note
Place a cloth underneath bracket for ancillaries to catch any es‐

caping engine oil.
– Detach connector -2- from oil pressure switch -F22- -1-.

– Unbolt water pipe ⇒ Item 19 (page 141) from bracket for an‐
cillaries.
– Release clip -3- from pressure hose -4-.
– Release hose clip -arrow- from throttle valve module -J338- .

– Unscrew bolt -1- from pressure pipe -2- and remove pressure
pipe -2-.
– Remove alternator ⇒ Rep. gr. 27 .
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
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.

Amarok 2011 ➤
– Disconnect electrical connector -1- for magnetic clutch on air

conditioner compressor.
WARNING
Risk of injury caused by refrigerant.

♦ The air conditioner refrigerant circuit must not be opened.
– Remove bolts -arrows- for air conditioner compressor.
Caution
Danger of damage to refrigerant lines and hoses.

♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
– Tie up air conditioner compressor together with refrigerant ho‐

ses to longitudinal member (refrigerant hoses remain connec‐
ted).
Note
Hydraulic lines and vane pump remain connected.
– 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
– Place vane pump with attached hydraulic lines on longitudinal

erm
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
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f
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 Amarok 2011 ➤
agen oes
4-cylinder injection engine (2.0Vloldirect
ksw injection engine, turbocharger)
not
g
- Edition 02.2011
y ua
db ran
rise tee
– Remove bolt -arrow- for dipstick uguide
tho tube. or
s a ac
– Unscrew bolts -1 … 5- and detach bracket for ancillary units s
ce
e
nl
from coolant pump housing.
pt
du
an
itte
y li
Installing
erm
ab
ility
ot p
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
♦ Renew O-rings and seals.
nform
mercia
at
om
ion
c
in t
or
his
e
– Coat O-rings -4- with coolant additive, coolants ⇒ Electronic

at
do
riv
parts catalogue .
p
cum
for
en
g
– Insert connection -2- into coolant pump housing -3-.

n
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.
– If present, fit air conditioner compressor ⇒ Rep. gr. 87 .

– Install alternator ⇒ Rep. gr. 27 .
– Install poly V-belt ⇒ page 22 .
1.5 Removing and installing vibration damp‐

er
♦ Locking pin -T10060 A-

Amarok 2011 ➤
♦ Counterhold tool -T10355-
Removing
– Remove poly V-belt ⇒ page 22 .
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
of „TDC“ position when vibration damper is removed.
t to the co
rrectness of i
Installing
l purpos
• Specified torque ⇒ page 19 .

Installation is carried out in the reverse order; note the following:
nform
mercia
at
om
io
Note
n
c
in t
or
his
ate
♦ Renew bolt for vibration damper.

do
priv
cum
or
♦ Renew O-ring -1-.

f
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.

Amarok 2011 ➤
2 Cylinder block (gearbox end)
2.1 Assembly overview - sealing flange and drive plate
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.
⇒ 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
❑ Must seat on dowel

itte
y li
rm
sleeves.
ab
pe
ility
❑ Do not damage or bend

ot
wit
, is n
when assembling.
h re
hole
❑ Is fitted onto sealing flange ⇒ page 30

spec
es, in part or in w
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 ➤
Sealing flange at gearbox end - tightening sequence

– Tighten bolts -1 to 8- in the sequence shown:
– 1. Screw in bolts hand-tight.
– 2. Tighten bolts to 9 Nm.
Installing intermediate plate

– Hook intermediate plate onto sealing flange and slide onto
dowel sleeves -arrows-.
2.2 Removing and installing drive plate

AG. Volkswagen AG d
agen oes
♦ Counterhold tool -VW 558- y Volksw not
gu
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rise nte
tho eo
au ra
ss c
ce
le
un
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
♦ Depth gauge
rrectness of i
♦ Hexagon bolt M8×40 and hexagon nut M8

l purpos
– Remove gearbox ⇒ Power transmission; Rep. gr. 37 ; Re‐

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

Amarok 2011 ➤
Preparing counterhold tool -VW 558- :

– Tighten hexagon bolt M8x40 -A- with hexagon nut on clutch
counter-hold tool -VW 558- .
Loosening and tightening drive plate:
– Insert counterhold -VW 558- in cylinder block and drive plate

as shown.
Installation position of counterhold: -A- to loosen, -B- to tighten.
Installing drive plate:

– Fit drive plate without swasher
wage
n AG-A- first.
. Volkswagen AG
does
k not
Vol gu
– Fit used securing
se
d b bolts -3- and tighten to 30 Nm.
y ara
nte
ri
utho eo
ra
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ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Check dimension between drive plate and cylinder block at

t to the co
three points and calculate average.

rrectne
Note
ss
Measure through hole in drive plate to milled surface of cylinder

o
cial p
f i
block. When measuring intermediate plate, plate thickness has to

nform
be taken into account.

mer
atio
om
n
c
• Specification measured without intermediate plate: 19.5…

i
or
n thi
21.1 mm
te
sd
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o
r
• Specification measured with intermediate plate: 18.8…

p
cum
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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.
2. Cylinder block (gearbox end) 31

Amarok 2011 ➤
If specification is not attained:

– Remove drive plate again and fit shim -A-. Tighten bolts -3-
again to 30 Nm.
– Repeat measurement. If the specification is not reached, re‐
place all securing bolts and tighten.
• Specified torque ⇒ page 29
2.3 Removing and installing needle bearing

in/from drive plate
♦ Pipe section -VW 418 A-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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aut ra
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nl
pt
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itte
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♦ Pipe section -VW 421-

erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
♦ Support -40 - 103-

atio
om
n in
or c
thi
te
sd
iva
o
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cu
o
m
f
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
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.
– Press in needle bearing using pipe section -VW 418 A- and

workshop press as far as stop.
• Installation position: closed side of needle bearing to engine.
– Install drive plate ⇒ page 30 .
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
♦ Hand drill with plastic brush attachment
wit
, is n
h re
♦ Eye protection
hole
spec
es, in part or in w
♦ Sealant ⇒ Electronic parts catalogue

t to the co
♦ Guide sleeve -T20097-
Removing
rrectness of i
• Gearbox removed.
l purpos
– Remove drive plate ⇒ page 30 .

nform
ercia
– Detach intermediate plate from sealing flange and dowel pins

-arrows-.
m
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
– Remove bolts -1 … 8-.

– Remove sealing flange at gearbox end.
Installing
• Specified torques
♦ Silicone sealant: ⇒ Electronic parts catalogue
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
plying the silicone sealant.

un
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
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
– Clean sealing surfaces. They must be oil and grease free.
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.
– Cut off nozzle on tube at front marking (∅ of nozzle approx.

2 mm).

Amarok 2011 ➤
– Apply silicone sealant onto clean sealing surface of cover, as

illustrated.
♦ Thickness of sealant bead: 2 ... 3 mm.
Note
♦ The sealing flange must be installed within 5 minutes after ap‐

plying the silicone sealant.
♦ The bead of sealant must not be thicker than specified, other‐
wise excess sealant can enter the sump and obstruct the
strainer in the oil intake pipe.
– Fit guide sleeve -T20097- onto crankshaft journal.

– Push sealing flange over guide sleeve -T20097- onto crank‐
shaft journal and tighten bolts immediately, tightening se‐
quence
Note
After 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.

Amarok 2011 ➤
3 Pistons and conrods
3.1 Assembly overview - pistons and conrods
1 - Conrod bolt
❑ Renew.
❑ Oil threads and contact agen
AG. Volkswagen AG d
oes
surface. olksw not
y V gu
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❑ 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
but not further.

itte
y li
rm
ab
pe
2 - Conrod bearing cap
ility
ot
wit
❑ Note installation posi‐
, is n
h re
tion.
hole
spec
❑ The conrod bearing cap
es, in part or in w
only fits in one position
t to the co
and only on the appro‐
priate conrod due to the
breaking procedure
rrectness of i
(cracking) separating
l purpos
the cap from the conrod.

❑ Mark with cylinder num‐
ber -A-.
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:
0.10…0.35 mm, wear
limit: 0.40 mm
❑ Measure radial clearance using Plastigage; new: 0.02…0.06 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 .

Amarok 2011 ➤
❑ Mark installation position and cylinder number.
❑ Arrow on piston crown points to belt pulley end.
❑ Install using piston ring clamp.
❑ Piston and cylinder dimensions
n AG. Volkswa⇒ page
gen AG do39 .
wage es n
❑ Checking cylinder
yV
olks bores ⇒ page 38 . ot g
u
b ara
ed
9 - Compression
ho
ris rings nte
eo
ut ra
❑ Offset
ss a gaps by 120°. c
ce
le
❑ Use piston ring pliers to remove and install.

un
pt
an
d
❑ „TOP“ or „R“ marking must face upwards towards piston crown.

itte
y li
erm
ab
❑ Checking ring gap ⇒ page 37 .
ility
ot p
❑ Checking ring-to-groove clearance ⇒ page 37 .
wit
is n
h re
ole,
10 - Oil scraper ring
spec
❑ 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
❑ Mark with cylinder number -A-.

i
or
n thi
e
❑ Installation position: Marking -B- faces towards pulley end.

t
sd
iva
o
pr
❑ Separating new conrod ⇒ page 39 .

um
r
fo
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 ring-to-groove clearance

– Clean annular groove of piston before check.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.06 … 0.09 0.20
2nd compression ring 0.03 … 0.06 0.15
Oil scraper rings Not measurable
3. Pistons and conrods 37

Amarok 2011 ➤
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

o
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.
The cylinder bore may not be worked on (reboring, honing,

grinding) may not be carried out using workshop tools! This will
damage the surface of the cylinder bore.
– Take measurements at 3 positions in both lateral direction

-A- and longitudinal direction -B-.
♦ Difference between actual and nominal diameter max. 0.08
mm.
Note
Cylinder bores must not be measured when cylinder block is

mounted on engine and gearbox support -VAS 6095- , as meas‐
urements may be incorrect.
Bearing shells - installation position

– Position bearing shells in centre of conrod and conrod bearing
cap when fitting.
Dimension -a- must be identical on both sides.

Amarok 2011 ➤
3.2 Separating new conrod

On a new conrod, it is possible that the breaking point has not
fully separated. Procedure if conrod bearing cap cannot be re‐
moved manually:
– Mark allocation of conrod to cylinder.
– Lightly clamp conrod in a vice using aluminium vice jaws, as
shown in illustration.
Note
♦ Only clamp the conrod lightly in order to avoid damaging it.

♦ Conrod is clamped below dashed line.
– Unscrew both bolts -arrows- approx. 5 turns.
– Using a plastic hammer, carefully knock against conrod bear‐

ing cap in -direction of arrow- until it is loose.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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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
The cylinder bore may not be worked on (reboring, honing,

, is n
h re
grinding) may not be carried out using workshop tools! This will
hole
spec
damage the surface of the cylinder bore.

es, in part or in w
t to the co
Piston ∅ Cylinder bore ∅

rrectness of i
Basic dimension mm 82.465 1) 82.51

l purpos
• 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.
3. Pistons and conrods 39

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
lksw not
4 Crankshaft Vo gu
by ara
d
rise nte
tho eo
au ra
ss c
4.1 Assembly overview - crankshaft
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
bearing shells (classifi‐

t
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.
shaft does not rest on

the sender wheel
❑ If the crankshaft is re‐
newed, the bearing
shells must be realloca‐
ted to bearing cap
⇒ page 41
❑ Axial clearance
⇒ page 43
❑ Radial clearance
⇒ page 43
❑ Do not rotate crankshaft
when checking radial
clearance.
❑ Crankshaft dimensions
⇒ page 42 .
4 - Bearing shell for bearing
cap
❑ Without oil groove.
❑ Do not interchange
used bearing shells (mark).
❑ Marking of crankshaft bearing shells (classification) ⇒ page 41
5 - Bolt
❑ Renew.
6 - Bearing cap
❑ Bearing cap 1: belt pulley end.
❑ Bearing shell retaining lugs in cylinder block and bearing caps must align.

Amarok 2011 ➤
7 - Bolt
❑ 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
1. Bolts -1 ... 10- and -arrows - - hand-tighten

2. Bolts -1 ... 10- - pre-tighten to 65 Nm
nform
ercia
3. Bolts -1 ... 10- - turn 90° further with fixed wrench

m
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.
4.2 Allocation of crankshaft bearing shells

(classification)
Bearing shells of the correct thickness are allocated to the cylin‐
der block at the factory. Coloured dots are used to identify the
thickness of the bearing shells.
Which bearing shell is to be inserted at each place in the cylinder
block (upper bearing shell) is marked by letters on the lower seal‐
ing surface or on the front side of cylinder block.
Which bearing shell is to be inserted at each place in bearing cap
(lower bearing shell) is marked by letters on the crankshaft.
The first letter is allocated to bearing cap 1, the second to bearing
cap 2, etc.
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
– Note letters and identify colour code to be installed based on

table.
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.
Marking on bearing shell for bearing cap:

Identification on crankshaft is allocated to lower bearing shell
(bearing shell for bearing cap).
– Note letters and identify colour code to be installed based on
table.
S = Black
R = Red
G = Yellow
B = Blue
W = White
4.3 Crankshaft dimensions

(Dimensions in mm)
Honing dimension Main journal ∅ Conrod journal ∅
1)
Basic dimension 58.00 47.80

Amarok 2011 ➤
1)No provision has yet been made to recondition worn crank‐

shafts.
4.4 Measuring axial clearance of crankshaft

♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge -VAS 6079-
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
– Press crankshaft against dial gauge by hand and set gauge to

erm
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
• New: 0.07 … 0.23 mm.

t to the co
• Wear limit: 0.30 mm

rrectness of i
4.5 Measuring radial clearance of crank‐

l purpos
shaft
nform
ercia

m
at
♦ Plastigage
om
ion
c
in t
or
Procedure
his
ate
do
priv
cum
for
Note
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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 ➤
– 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
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• New: 0.017 … 0.037 mm. byV
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• Wear limit: 0.15 mm utho tee
or
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ss
4.6 Pulling needle bearing out of and driving into crankshaft
ce
le
un
pt
an
d
itte
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ab
pe
ility
equipment required
ot
wit
, is n
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♦ Internal puller -Kukko 21/2-
hole
and internal puller -Kukko
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
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t.
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Cop py
t. rig
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pyri by
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by
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Prote AG.
Removing
Procedure
• Gearbox is separated from engine.

Amarok 2011 ➤
– Pull needle bearing out using commercially available internal

puller, e.g. KUKKO 21/2 and KUKKO 22/1, -A-.
Installing
Note
The lettering on the needle bearing must be visible when installed.
– Drive in needle bearing using drift -VW 207 C- or centring

mandrel -3176- .
– Drive needle bearing in carefully.
– Constantly measure insertion depth when driving in.
– Renew bearing, if driving depth is too deep.
olks
wage es n
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db ran
rise tee
tho or
s au ac
s
ce
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un
pt
an
d
itte
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ab
pe
ility
Installation depth dimension -a- = 1.5 to 1.8 mm.
ot
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
a
com
tion in
r
te o
thi
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iva
do
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cum
fo
en
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t.
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Cop py
t. rig
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pyri by
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by
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Prote AG.
4. Crankshaft 45
Amarok 2011 ➤
15 – Cylinder head, valve gear

1 Cylinder head
1.1 Assembly overview - cylinder head
Note
♦ Renew cylinder head bolts.

♦ During fitting work, renew self-locking nuts, bolts which have
been tightened further as well as oil seals and gaskets.
♦ The plastic protectors fitted to protect the open valves must
only be removed immediately before fitting the cylinder head.
♦ When fitting a new cylinder head or cylinder head gasket, drain
off all the old coolant and refill with new coolant.
1 - Cylinder head gasket

❑ Renew.
❑ Observe installation po‐
sition: Part number to
cylinder head
2 - Bolt
AG. Volkswagen AG d
❑ 25 Nm agen oes
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3 - Transport lug rised
nte
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ut
4 - Bolt ss a ra
c
❑ Tighten in 2 stages:
ce
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an
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itte
1. Tighten to 8 Nm
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ility
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2. Use fixed wrench to

turn 90° further wit
is n
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ole,
spec
5 - Cylinder head

t to the co
⇒ page 48 .
❑ Check for distortion
rrectne
⇒ page 48 .
6 - Cylinder head bolt
ss o
❑ Renew.
cial p
f in
❑ Note procedure when

form
mer
loosening ⇒ page 48 .
atio
m
❑ Note procedure when

o
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
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3. Use fixed wrench to
Prote AG.
turn 90° further
46 Rep. gr.15 - Cylinder head, valve gear

Amarok 2011 ➤
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.
11 - Plug
12 - To intake manifold.
13 - Heat shield
wage
14 - Bolt olks es n
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❑ 20 Nm ir se
d ran
tee
tho
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15 - Bolt ss
a ac
❑ 20 Nm
ce
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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
t to the co
19 - Seal
20 - Bolt rrectne
ss
21 - Crankcase breather
o
cial p
f inform
22 - Seal
mer
atio

om
n
c
23 - Seal
or
n thi
te
sd
a
❑ Renew if damaged.
iv
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pr
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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
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❑ 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 ➤
32 - Bolt
❑ 9 Nm
33 - Hall sender -G40-
34 - Partition
Crankcase breather system - tightening torque
Note
♦ Bolts are self-tapping. When renewing cylinder head, only

genuine bolts may be used since cylinder head is supplied
without thread to attach crankcase breather system.
♦ Threads may not be tapped with a thread tap.
– Tighten bolts for crankcase breather in the sequence

-1 … 10- to 11 Nm.
Checking cylinder head for distortion

AG. gen Volkswa
– Use straight edge and feeler gauge to measure agen cylinder headAG does
olksw not
for distortion at several points. ed by
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♦ Max. permissible distortion: 0.05
au
th mm. eo
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spec
es, in part or in w
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1.2 Removing and installing cylinder head

rrectness of i
♦ 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
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by
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Prote AG.

Amarok 2011 ➤
♦ Removal tool -T10352- and removal tool -T10352/1-
AG. Volkswagen AG d
agen oes
olksw not
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hole
spec
es, in part or in w
t to the co
rrectness of i
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♦ Locking pin -T40011-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
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t.
yi Co
Cop py
ht. rig
rig ht
py by
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by lksw
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Prote AG.
♦ Assembly pin -T40196-
1. Cylinder head 49
Amarok 2011 ➤
♦ Engine bung set -VAS 6122-
Removing
Note
♦ Fit cable tie in same place when installing.

♦ Always seal open channels of intake and exhaust system with
suitable plugs, for example from wengine
agen bung set -VAS
AG. Volkswagen AG d6122- .
oe
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Vol t gu
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or
WARNINGauth eo
ra
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ce
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Hot steam/hot coolant can escape - risk of scalding.

un
pt
an
d
itte
y li
♦ The cooling system is under pressure when the engine is

erm
ab
hot.
ility
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wit
♦ Cover filler cap on expansion tank with a cloth and open

is n
h re
carefully to dissipate pressure.

ole,
spec
t to the co

Engine guard .
rrectne

ss o
cial p
– Release brake servo vacuum line.

inform
mer
– Remove rear coolant hoses from cylinder head.

atio
om
n
c
i
or
Caution
thi
te
sd
iva
o
r
Danger of soiling fuel system.

p
cum
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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.

AG. Volkswagen AG d
lksw
agen oes
not Amarok 2011 ➤
o
d4-cylinder
by
V
injection engine (2.0 l directgu
ara injection engine, turbocharger) - Edition 02.2011
ise nte
or eo
h
– aut
Release and remove clip -2- for fuel return line -1-. ra
ss c
ce
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nl
pt
du
an
itte
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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
– 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.
– Disconnect electrical connectors -1 and 3- from air filter hous‐

ing.
– Release air intake hose -3- from air filter housing -1-.
– Pull off vacuum hose -2-.
– Unscrew securing bolt for air filter housing in area of coolant
expansion tank.
– Withdraw air filter housing upwards.
1. Cylinder head 51
Amarok 2011 ➤

pipe -2-.
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
2 - From knock sensor 1 -G61- and lay to one side.
y li
erm
ab
3 - From variable intake manifold valve -N316- , fuel pressure
ility
ot p
sender -G247- and Hall sender -G40- .
wit
, is n
h re
hole
4 - From injectors.
spec
es, in part or in w
5 - From throttle valve module -J338- .
t to the co
6 - From intake air temperature sender -G42- .
rrectness of i
l purpos
– Unplug electrical connections -1 and 2- and lay wiring to one
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.
– Unscrew bracket coolant line -arrow-.
Note
For reasons of clarity, following diagrams show installation posi‐

tion with engine removed.

Amarok 2011 ➤
– Remove intake manifold support (remove securing nut -1- and

bolt -2-).
– Disconnect coolant hose -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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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
– Remove ignition coils using puller -T40039- .

en
ng
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 ➤
– Disconnect crankcase breather hose -1-.

– Unscrew bolts -arrows-, remove crankcase breather system
and detach from hose -2- for crankcase breather system in
-direction of arrow-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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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
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.

side.

Amarok 2011 ➤
– Unscrew bolts -arrows- and remove support for turbocharger.
– Unscrew bolts -arrows- on oil return line.
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
t to the co
rrectne
– Detach connector from inlet camshaft control valve 1 -N205-

ss
-1-.
o
cial p
f inform
– Unscrew bolts -arrows- and remove inlet camshaft control

mer
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 ➤
– Unscrew bolts -1 to 5- and detach top cover for timing chain.
– Turn vibration damper to „TDC“ position -arrow- using coun‐

terhold -T10355- .
• Notch on vibration damper must align with arrow marking on
bottom cover for timing chains.
• Markings -1- on camshafts must face upwards.
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
The timing valve has a left-hand thread.

ot
wit
, is n
h re
hole
spec
– Depending on model, remove regulating valve using removal

es, in part or in w
tool -T10352- or removal tool -T10352/1- in

t to the co
rrectness of i
l purpos
– Remove bolts -arrows- and detach bearing saddle.

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.

Amarok 2011 ➤

terhold -T10355- .
cover for timing chains (bottom).
– Use a waterproof pen to mark drive chain/chain sprockets

-arrows-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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a ac
ss
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
– Insert scriber or suitable screwdriver in hole of chain tensioner

um
fo
en
g
in direction of -arrow 1- and lift locking element for chain ten‐

n
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
Inlet camshaft will move in direction of engine rotation.
1. Cylinder head 57
Amarok 2011 ➤
– Remove bolt -1- and guide tensioning rail -2- downwards.

– Use screwdriver to release catch and press off top guide rail
-3- forwards.
– Remove camshaft timing chain from camshaft sprockets.
Caution
Avoid damage to valves and piston crowns.

♦ Do not turn the crankshaft after the camshaft timing chain
has been removed from the cylinder head.
– Turn sealing plugs -arrows- 90° anti-clockwise -arrow- and re‐

move.
– Unscrew ball head -1 … 2-.
– Remove filler cap.
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
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.

Amarok 2011 ➤
– Unscrew bolts -arrows-.

– Unscrew cylinder head bolts in the sequence -1 … 5- with
special wrench, long reach -T10070- apart from 2 bolts.
Note
♦ If necessary, use spanner to turn camshafts before removing

cylinder head bolts.
♦ Make sure all hoses/pipes and wiring on component are re‐
moved.
♦ Ensure tensioning rail and guide rail are not damaged when
lifting off cylinder head.
– Remove cylinder head.

– Place cylinder head onto soft surface (foam plastic).
Installing
Caution
Avoid damage to sealing surfaces.

♦ Carefully remove sealant residue from cylinder head and
cylinder block.
♦ Ensure that no long scores or scratches are made on the
surfaces.
Avoid damage to cylinder block. AG. Volkswagen AG d
agen oes
ksw
♦ No oil or coolant must be allowed by
Vto remain in the blind
o l not
gu
holes for the cylinder head bolts
rise d in the cylinder block. ara
nte
ho eo
aut
Ensure that cylinder head gasket seals properly: ra
ss c
ce
le
♦ Carefully remove remains of emery and abrasives.

un
pt
an
d
itte
♦ Do not remove new cylinder head gasket from packaging

y li
rm
ab
until it is ready to be fitted.

pe
ility
ot
wit
♦ Handle the cylinder head gasket very carefully to prevent

, is n
h re
damage to the silicone coating or the indented area of the

hole
spec
gasket.
es, in part or in w
t to the co
Avoid damage to open valves.

♦ When installing an exchange cylinder head, the plastic
protectors fitted to protect the open valves should not be
rrectness of i
removed until the cylinder head is ready to be fitted.

l purpos
Avoid damage to valves and piston crowns after working on

valve gear.
nform
ercia
♦ Turn the engine carefully at least 2 rotations to ensure that

m
none of the valves make contact when the starter is op‐

a
com
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 ➤
Note

angle.
♦ Renew gaskets, oil seals and self-locking nuts.
♦ Please note different sealants for sealing surfaces, bolts and
cylinder head.
♦ Secure hose connections with hose clips corresponding to the
series equipment ⇒ Electronic parts catalogue .
♦ After fitting a new cylinder head or cylinder head gasket, the
engine oil and coolant must be changed.
– Position cylinder head gasket.

♦ Note centring pins in cylinder block -arrows-.
♦ Check installation position of cylinder head gasket. The part
number should be legible from the inlet side.
WARNING
When turning crankshaft, make sure that no components are

damaged by timing chain.
– If crankshaft is turned in the meantime, position piston of No.

1 cylinder at TDC and turn crankshaft back slightly. n AG. Volkswagen AG do
lkswage es n
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yV
– Fit cylinder head. d b ua
ran
ir se tee
tho
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a ac
ss
Note
ce
e
nl
pt
du
an
itte
To enable insertion of the cylinder head bolts, the inlet camshaft
y li
erm
ab
must be turned with a wrench.
ility
ot p
wit
, is n
h re
hole
– Insert bolts -1 … 8-.
spec
es, in part or in w
– Tighten bolts for cylinder head in sequence -1 … 8- in 3 stages

in total ⇒ page 46 . t to the co
– Tighten bolts -arrows- in 2 stages in total.

rrectness of i
l purpos
Note
nform
ercia
After repair work it is not necessary to retighten the cylinder head

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

Amarok 2011 ➤

terhold -T10355- .
• Notch on vibration damper must align with arrowemarking
n AG. Volkson
wagen AG
bottom cover for timing chains. olks
wag does
no
yV t gu
db ara
rise nte
tho eo
Note au ra
c
ss
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
must align -arrows-.
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.
– Insert bolts -1 … 2-.

– Tighten bolts for cylinder head in sequence -1 and 2- in 3
stages in total ⇒ page 46 .
Perform further assembly analogously in reverse order of remov‐
al. When doing this, observe the following:
– Install timing chain cover (top) ⇒ page 65 .
– Fill cooling system with fresh coolant ⇒ page 133 .
– Install catalytic converter ⇒ page 240 .
gine guard .
WARNING
Never use battery charging equipment for boost starting. There

is the risk of damaging the vehicle's control units.
1. Cylinder head 61
Amarok 2011 ➤
1.3 Checking compression

♦ Spark plug socket and extension -3122 B-
♦ Puller -T40039-
♦ Compression tester -V.A.G 1763-
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Test procedure
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Note
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♦ Engine oil temperature min. 30 °C.

l purpos
♦ Battery voltage at least 12.7 V

nform
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Prote AG.

Amarok 2011 ➤


– Unscrew spark plugs using spark plug socket and extension
-3122 B- .
– Check compression using compression tester -V.A.G 1763-
and adapter -V.A.G 1763/6- .
Note
Using compression tester: ⇒ Operating instructions .
– Operate starter until tester shows no further pressure in‐

crease.
Compression pressures:
New bar pressure Wear limit bar bar Difference between
pressure cylinders bar pres‐
sure
11.0 ... 14.0 7.0 max. 3.0
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– Install ignition coils with final output stages y⇒VolRep.
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Faults will have been stored in the memory because connectors

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erm
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memory after the test.

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– Read event memory of engine control unit.⇒ Vehicle diagno‐

hole
sis, testing and information system VAS 5051 in ”Guided fault

spec
finding” function .
es, in part or in w
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1.4 Removing and installing vacuum pump

rrectness of i
Removing
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– Remove high-pressure pump with »roller tappet«

⇒ page 226 .
nform
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1. Cylinder head 63
Amarok 2011 ➤
– Unbolt earth cable -1- and remove bolt.

– Remove vacuum hose -3- from vacuum pump -2.-
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– Unscrew bolts -arrows- and remove vacuum pump.
es, in part or in w
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Note
rrectness of i
The vacuum pump must not be dismantled.
l purpos
Installing:
nf
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atio
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Perform assembly in reverse order of removal. When doing this,

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observe the following:
thi
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– Clean sealing surfaces.
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– Place gasket on vacuum pump, insert 2 bolts and then fit on
en
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cylinder head. t. Cop py
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Prote AG.

Amarok 2011 ➤
2 Chain drive
2.1 Assembly overview - timing chain cover
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-
⇒ page 66 .
6 - Seal
ling.
7 - Bolt agen
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❑ Tightening sequence by Vo gu
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⇒ page 66 . rise
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8 - Timing chain cover (top) ss a ra
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⇒ page 66 . an
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9 - Seal ility
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10 - O-ring
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❑ Renew.
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ling.
rrectness of i
11 - Dowel pins
❑ For centring cover
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12 - Lower timing chain cover

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13 - Bolt
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❑ Renew.
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14 - Oil seal
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Co
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❑ Renewing ⇒ page 71 .
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15 - Plug
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❑ Renew.
2. Chain drive 65
Amarok 2011 ➤
Timing chain cover (top), tightening sequence

– Tighten bolts -1 to 5- in the sequence shown:
Timing chain cover (bottom), tightening sequence

– Tighten bolts -1 to 15- in two stages in the sequence shown:
– 2. Turn bolts 45° further agen
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2.2 Removing and installing inlet camshaft
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control valve 1 -N205- nform

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Removing
m

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-1-.
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• Specified torque Prote AG.
⇒ „2.1 Assembly overview - timing chain cover“, page 65 .
Note
Renew O-ring.
– Lubricate seal and O-ring with engine oil.

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2.3 Removing and installing upper timing ss c
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chain cover
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Removing
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valve 1 -N205- .
rrectness of i
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note the following:
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• Specified torque C py
ht. rig
⇒ „2.1 Assembly overview - timing chain cover“, page 65 . rig ht
py by
co Vo
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cted agen
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Note
Renew O-ring.
– Lubricate seal and O-ring with engine oil.

– Install timing chain cover (top), tightening sequence
⇒ Fig. “„Timing chain cover (top), tightening sequence““ , page
66 .
– Install inlet camshaft control valve 1 -N205- ⇒ page 66 .
2.4 Removing and installing timing chain

cover (bottom)
2. Chain drive 67
Amarok 2011 ➤
AG. Volkswagen AG d
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♦ Thrust piece -T10368-
t to the co
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Amarok 2011 ➤

terhold -T10355- .
• Notch on vibration damper must align with arrow marking onAG. Volkswagen AG d
bottom cover for timing chains. lksw
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– Remove bolt for vibration damper using counterhold
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– Remove vibration damper.
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Note
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Always use thrust piece -T10368- when fitting bolt for vibration
h re
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hole
spec
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– Screw bolt for vibration damper and thrust piece -T10368-
back in.
rrectness of i
Caution
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nform
ercia

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of „TDC“ position when bolt for vibration damper is re‐
om
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moved.
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– Remove guide roller -1-.
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– Remove bolts -arrows- and pull guide tube for oil dipstick out
C py
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of timing chain cover.
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2. Chain drive 69
Amarok 2011 ➤
– Lever off timing chain cover (bottom) (start at points

-1 and 2-).
Note AG. Volkswagen AG d

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To prevent damagingortheis timing chain cover, apply tool only atante
e
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the bolt holes. au
th ra
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Installing
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pe
⇒ „2.1 Assembly overview - timing chain cover“, page 65 .
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♦ Silicone sealant: ⇒ Electronic parts catalogue
h re
hole
spec
es, in part or in w
Note
t to the co
rrectness of i
♦ The cover must be installed within 5 minutes after applying the
l purpos
silicone sealant.
nform
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angle.
m
♦ Gaskets, oil seals and self-locking nuts must be renewed
a
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– Spray sealing surface with sealant remover and leave to act.
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Risk of eye injury.
AG.
– Mask oil seal on both sides with adhesive tape to make sure
the seal remains clean.
– Remove remaining sealant from cover, e.g. using rotating

plastic brush.
– Remove any oil and grease from sealing surfaces.
– Use old bolts when fitting cover and tighten to 8 Nm.
– Use feeler gauge to measure distance between cover and
crankcase (max. distance is 0.2 mm).
Note
♦ Renew cover if distance exceeds 0.2 mm.

♦ It is not possible to measure distance between cover and sump
(top section); check visually to ensure that sealing surface is
even.

Amarok 2011 ➤
– Check that both dowel pins are fitted in cover -arrows-.

3 mm).
– Apply silicone sealant onto clean sealing surface of cover, as

illustrated.
AG. Volkswagen AG d
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Note
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♦ The cover ut must be installed within 5 minutes after applying
ho e o the
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silicone
s sealant.
s a c
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nl

pt
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itte
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erm

ab
ility
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– Install cover immediately and tighten bolts, tightening se‐

h re
quence
hole
spec
⇒ Fig. “„Timing chain cover (bottom), tightening sequence““ ,

es, in part or in w
page 66 .
t to the co
Note
rrectness of i
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After fitting cover, let sealant dry for approx. 30 minutes. Only then
fill with engine oil.
nf
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or
– Install tensioner for poly V-belt ⇒ page 21 .

m
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atio
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n in
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thi
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2.5 Renewing oil seal for vibration damper

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t.
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Cop py
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rig ht
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Prote AG.
2. Chain drive 71
Amarok 2011 ➤

AG. Volkswagen AG d
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♦ Thrust piece -T10354- t to the co

rrectness of i
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nform
mercia
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tion in
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Prote AG.

Amarok 2011 ➤
♦ Puller hooks -T20143-

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es, in part or in w
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Removing
rrectness of i
Caution
l purpos

nform
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at
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p
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– Remove poly V-belt from pulley on vibration damper.
t. C rig
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Caution
agen
Prote AG.

of „TDC“ position when vibration damper is removed.

Engine guard .

terhold -T10355- .
– Remove bolt for vibration damper using counterhold -
T10355- .
2. Chain drive 73
Amarok 2011 ➤
– Remove vibration damper and screw on thrust piece -T10368-

in its place.
– Pull out oil seal using puller hooks -T20143/2- .
Installing
– Clean contact surface and sealing surface.
– Unscrew thrust piece -T10368- .
– Use thrust piece -T10354- and bolt for vibration damper to pull
in oil seal -arrow- onto stop.
Note
♦ Renew bolt for vibration damper.

♦ Renew O-ring.
wage e
Further assembly is basically Vol the reverse of the dismantling
ks s no
t guse‐
by
quence. In the process,
risenote
d the following: ara
nt ee
tho or
– Install vibrations adamper
u ⇒ page 27 . ac
s
ce
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nl
pt
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itte

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ab
gine guard .
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for
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Cop py
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Prote AG.

Amarok 2011 ➤
2.6 Camshaft timing chain - exploded view
1 - Bolt
❑ 9 Nm
AG. Volkswagen AG d
2 - Chain tensioner agen oes
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❑ Is spring-loaded rised ara
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❑ Before removing, lock in aut
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place using locking pin - ss c
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T40011-
nl
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3 - Tensioning rail for timing
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chain
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4 - Guide pins
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❑ 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
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remove using removal
orm
tool -T10352- or remov‐
m
atio
m
al tool -T10352/1- .
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7 - Bolt
thi
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❑ Renew.
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8 - Washer C py
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9 - Bearing saddle op Vo
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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 ➤
Crankshaft chain sprocket - installation position

• The two sections -arrows- must be aligned. olkswage es n
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2.7 Removing and installing camshaft tim‐
ing chain
rrectness of i
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nform
mercia
at
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ion
c
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for
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Cop py
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Prote AG.
♦ Removal tool -T10352- and removal tool -T10352/1-

Amarok 2011 ➤
AG. Volkswagen AG d
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olksw not
V gu
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Removing aut ra
c
ss
– Remove timing chain cover (top) ⇒ page 67 .
ce
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Caution
ility
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ole,
spec
t to the co
– Depending on model, remove regulating valve using removal
tool -T10352- or removal tool -T10352/1- in
rrectness o
cial p
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mer
atio
m

o
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c
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Engine guard .
thi
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t.
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Cop py
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Vo
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by c lksw
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Prote AG.
2. Chain drive 77
Amarok 2011 ➤

terhold -T10355- .
– Remove lower timing chain cover ⇒ page 67 .
AG. Volkswagen AG d
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au ra
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nl
pt
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– Press oil pump chain tensioner in direction of -arrow- and lock
erm
ab
in place using locking pin -T40011- .
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– Remove oil pump chain tensioner -1-.
h re
hole
spec
– Remove oil pump chain.
es, in part or in w
t to the co
rrectness of i
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nform
mercia

at
om
io

n
c
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sioner.
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do
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– Press tensioning rail for timing change in

p
cum
or
-direction of arrow 2- and secure with locking pin -T40011- .

f
en
ng
t.
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– Remove camshaft timing chain from cylinder head. t. Cop py
rig
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pyri by
Vo
co lksw
by
Note cted agen
Prote AG.

Amarok 2011 ➤
– Remove tensioning rail for timing chain -2-.

– Remove guide rail for camshaft timing chain -1-.
– Remove timing chain.
Installing
• Specified torque AG. Volkswagen
agen view“, pageAG
⇒ „2.6 Camshaft timing chain -oexploded 75do.es no
lksw t gu
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rrectness of i
Note
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♦ Following procedure must be carried out in a single operation.

This requires a 2nd mechanic.
nform
ercia
♦ Timing chain links with coloured markings must be positioned

m
at
om
at markings on chain sprockets.
ion
c
in t
or
♦ Continue to hold wrench until tensioning rail is installed.

his
ate
do
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or
– Fit timing chain onto exhaust camshaft.

f
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ng
t.
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– Fit timing chain onto crankshaft. Cop py
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– Use spanner to turn inlet camshaft in direction of -arrow- and p by
co Vo
fit timing chain.
by lksw
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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 ➤
– Attach bearing saddle and screw in bolts -arrows- hand-tight.

– Remove locking pin -T40011- .
– Tighten bolts -arrows- for bearing saddle ⇒ page 75 .
– Install regulating valve ⇒ Item 6 (page 75) .
Further assembly is basically the reverse of the dismantling se‐
quence. In the process, note the following:
– Install timing chain cover (bottom) ⇒ page 67 .
gine guard .
2.8 Assembly overview - balancer shaft timing chain
1 - Bolt
AG. Volkswagen AG d
❑ Renew. agen oes
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❑ 9 Nm rised ara
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2 - Balancer shaft aut ra
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❑ Exhaust side
ce
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❑ Must always be re‐
d
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newed if removed.
rm
ab
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ility
❑ Lubricate bearing with
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engine oil
, is n
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hole
spec
es, in part or in w
3 - Tube for balancer shaft
t to the co
⇒ page 81 .
rrectness of i
4 - Chain tensioner
l purpos
❑ 65 Nm
5 - Cylinder block
nform
ercia
6 - Balancer shaft
m
a
com
❑ Inlet side tion in

r
❑ Must always be re‐

te o
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newed if removed.
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❑ Lubricate bearing with

um
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engine oil
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7 - O-ring
op Vo
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❑ Lubricate with engine oil Prote AG.
8 - Bearing mounting
⇒ 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.

Amarok 2011 ➤
10 - Bolt
❑ Renew.
❑ 9 Nm n AG. Volkswagen AG do
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11 - Washer byV
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d ran
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12 - Bolt utho tee
or
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❑ If bolt has been loosened,ss intermediate shaft sprocket ⇒ Item 9 (page 80) willc need to be renewed.
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13 - Guide rail
erm
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ility
❑ For timing chain.
ot p
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14 - Guide pins
h re
ole,
spec
❑ 20 Nm
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
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19 - Guide rail
iv
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pr
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❑ For balancer shaft timing chain

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20 - Guide pins t. Cop py
rig
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❑ 20 Nm
ht
pyri by
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cted agen
Prote AG.
Tube for balancer shaft - installation position

• Lug on tube for balancer shaft must engage in slot -arrow-.
Bearing mounting - installation position

• Renew O-ring -1- and lubricate with oil.
• Dowel pin -arrow- for bearing mounting must engage in bore
in cylinder block.
• Lubricate bearing mounting.
2. Chain drive 81
Amarok 2011 ➤
Intermediate shaft sprocket - tightening sequence
Caution
The intermediate shaft sprocket must be replaced. Otherwise

no tooth backlash is set, engine damage.
The new intermediate shaft sprocket is coated with a solid film
lubricant that wears off after a short period and thus the tooth
backlash is automatically set.
AG. Volkswagen AG d
agen oes
lksw not
– With new bolt tighten d byas
V follows.
o gu
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1. Tighten withutorque
tho wrench initially to 10 Nm. eo
ra
s a c
2. Turn intermediate
s shaft sprocket.
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pt
du
There must be no play in intermediate shaft sprocket; otherwise
an
itte
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loosen bolt and tighten again.
erm
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ility
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3. Tighten with torque wrench to 25 Nm.
wit
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4. Use fixed wrench to turn 90° further.
hole
spec
es, in part or in w
2.9 Removing and installing balancer shaft
t to the co
module
rrectness of i
Removing
l purpos

nf
ercia
Engine guard .
orm
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atio

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– Remove camshaft timing chain ⇒ page 76 .

thi
te
sd
iva
– Remove guide rail for camshaft timing chain -1-.

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en
– Remove chain tensioner for camshaft timing chain -3-.

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

Amarok 2011 ➤
– Remove chain tensioner for balancer shaft timing chain -1-.

– Remove tensioning rail -2-.
– Remove guide rail -3-.
– Remove guide rail -4-.
– Remove timing chain.
Installing
• Specified torque
⇒ „2.8 Assembly overview - balancer shaft timing chain“, page
80 . wage
es
ks not
Vol gu
d by ara
e nte
ris
– Turn intermediate shaft sprocket/balancer
tho shaft to markings eo
-arrows-. ss au ra
c
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un
pt
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Note
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erm
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ility
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Timing chain links with coloured markings must be positioned at
wit
is n
markings on chain sprockets.
h re
ole,
spec
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 ➤
– Check adjustment again.
– Check markings on intermediate shaft sprocket/balancer shaft

-arrow-.
Note
For illustration purposes, the markings on intermediate shaft

sprocket/balancer shaft are shown with the chain removed.

– Install camshaft timing chain ⇒ page 76 .
gine guard . en AG. V
olkswagen AG
wag does
olks not
yV gu
2.10 Renewing balancer shaft for inlet cam‐
b ara
ed nte
ris
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shaft ss
au
t ra
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nl
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an
itte
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♦ Puller -T10394-
erm
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ility
ot p
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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te
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t.
yi Co
Cop py
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rig ht
py by
co Vo
by lksw
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Prote AG.

Amarok 2011 ➤
♦ Puller -T10055-
Removing

agen oes
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The balancer shaft for the inlet camshaft must always b be renewed
y ara
d
ise nte
after removing. thor eo
au ra
ss c
– Remove toothed belt for coolant pump ⇒ page 146 .
ce
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nl
pt
du
an
itte
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erm
ab
ility
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Engine guard .
wit
, is n
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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
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o
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f
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ng
t.
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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 ➤
– Insert shell half -T10394/1- from puller -T10394- and turns up‐
wards in direction of arrow.
– Insert puller -T10394- and push locking collar in

– 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
an
itte
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erm
ab
80 .
ility
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wit
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– Place new balancer shaft in freezer compartment for 30 mi‐

h re
nutes, if necessary, or spray with commercially available cool‐

hole
spec
ing spray.
es, in part or in w
t to the co
– Lubricate balancer shaft bearing with engine oil.
– 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
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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 ➤
– Renew O-ring -1- and lubricate with engine oil.

– Lubricate bearing mounting with engine oil and install; dowel
pin -arrow- for bearing mounting must engage in bore in cyl‐
inder block.
Caution
The intermediate shaft sprocket must be replaced. Otherwise

no tooth backlash is set, engine damage.
The new intermediate shaft sprocket is coated with a solid film
lubricant that wears off after a short period and thus automat‐
ically sets the tooth backlash.
– Mark faces of gear teeth of intermediate shaft sprocket with

paint -arrows-.
n AG. Volkswagen AG
– Insert intermediate shaft wage
olks sprocket; marking on balancer
does
not shaft
must be positionedd bbetween markings on faces of gear
y V gu teeth.
ara
e nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Tighten bolt -1- for intermediate shaft sprocket: tightening se‐

t to the co
quence ⇒ page 82 .
– Check markings on intermediate shaft sprocket/balancer shaft
rrectness of i
-arrow-.
l purpos
Assembly is performed analogously in the reverse order of re‐

moval. In the process, note the following:
nf
ercia
– Install balancer shaft module ⇒ page 82 .

orm
m

atio
om
n in
c

or
thi
te
sd
a

iv
o
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rp
cu
o

f
en
ng
t.
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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.

gine guard .
2.11 Renewing balancer shaft for exhaust

camshaft
2. Chain drive 87
Amarok 2011 ➤
♦ Puller -T10394-
♦ Puller -T10055-
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,

spec

t to the co
Engine guard .
rrectne

ss
– Remove balancer shaft timing chain ⇒ page 82 .

o
cial p
f in
– Unscrew bolt -1- for exhaust camshaft balancer shaft.

form
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.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte Amarok 2011 ➤
tho eo
4-cylinder injection engine
s au (2.0 l direct injection engine, turbocharger) - Edition ra
c 02.2011
s
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
– Insert puller -T10394- and push locking collar in

m
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.
80 .
– Check installation position of tube for balancer shaft -arrow-.

Lug -arrow- must engage in slot.
– Place new balancer shaft in freezer compartment for 30 mi‐
nutes, if necessary, or spray with commercially available cool‐
ing spray.
– Lubricate balancer shaft bearing with engine oil.
2. Chain drive 89
Amarok 2011 ➤
– Install balancer shaft for exhaust camshaft.

– Before tightening bolt -1-, check that balancer shaft rests flat
against crankcase.
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
itte
y li
erm
ab
– Install balancer shaft module ⇒ page 82 .
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

gine guard .
nform
ercia
2.12 Checking valve timing

m
at
om
ion
c

in t
or
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.

bottom cover for timing chains (use a mirror).
– Measure the distance from the outer edge of web -A- to mark‐
ing -B- on the inlet camshaft.
• Specification: 61…64 mm.

Amarok 2011 ➤
– If the specified value is achieved, measure the distance be‐

tween the marking on the inlet camshaft -B- and the marking
on the exhaust camshaft -C-.
• Specification: 124…126 mm
Note
Offset of one tooth means a deviation of approx. 6 mm from the

specified value. If an offset is found, the timing chain must be re-
fitted.
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
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Chain drive 91
Amarok 2011 ➤
3 Valve gear
3.1 Assembly overview - 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
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erm
ab
4 - Valve stem seal
ility
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wit
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❑ Renew: with cylinder
h re
head fitted
hole
spec
⇒ page 109 , with cylin‐
es, in part or in w
der head removed
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
❑ Oil contact surface.

thi
te
sd
iva
9 - Exhaust camshaft
o
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rp
cu
o

f
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
12 - O-ring
❑ Renew.

Amarok 2011 ➤
13 - Plug
14 - Inlet camshaft
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
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❑ 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
– Undo and remove cylinder head cover in the sequence 1 … 6.
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
Take care to keep cylinder head cover level.
3. Valve gear 93
Amarok 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
∅a mm 33.85 ± 0.10 28.0 ± 0.1

un
pt
an
d
itte
∅b mm 5.98 ± 0.01 5.96 ± 0.01
y li
rm
ab
pe
ility
c mm 104.0 ± 0.2 101.9 ± 0.2
ot
wit
, is n
α ∠° 45 45
h re
hole
spec
es, in part or in w
3.2 Removing and installing camshafts
t to the co
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
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pyri by
Vo
co lksw
by
♦ Removal tool -T10352/1- Prote
cted AG.
agen

Amarok 2011 ➤
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
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erm
ab
ility
ot p
♦ Assembly pin -T40196-
wit
is n
h re
ole,
spec
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 ➤
Removing
Note
♦ Sealing surfaces at bottom of cylinder head cover and top of

cylinder head must not be machined.
♦ Camshaft bearings are integrated into cylinder head and cyl‐
inder head cover. Camshaft timing chain must be relieved of
tension before you remove cylinder head cover.
♦ Renew sealing cap if cylinder head cover has been detached.
♦ Fit cable tie in same place when installing.
– Disconnect electrical connectors -1 and 3- from air filter hous‐

ing.
– Release clip -4- and detach hose.
– Release air intake hose -3- from air filter housing -1-.
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

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.

Amarok 2011 ➤
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
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r
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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.
valve 1 -N205- .
3. Valve gear 97
Amarok 2011 ➤
Caution
– Remove regulating valve using removal tool -T10352/1- in di‐

rection of -arrow-.

Engine guard .
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
terhold -T10355- .
ot
wit
, is n

h re
hole

spec
es, in part or in w
t to the co
Note
rrectness of i
Engine must be at „TDC“ again.

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.

lkswage es n Amarok 2011 ➤
Vo ot g
4-cylinder injection engine (2.0 l direct d injection engine, turbocharger) - Edition
by ua
ran 02.2011
ir se tee
tho
o
– Use a waterproof pen to mark drive chain au
ss at marks on chain
ra
c
sprockets -arrows-.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectnes
– 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.

sioner.
– Turn crankshaft in opposite direction to normal rotation
-arrow 2- and lock in place using locking pin -T40011- .
3. Valve gear 99
Amarok 2011 ➤
Note
– Remove bolt -1- and guide tensioning rail -2- downwards.

– Use screwdriver to release catch and press off top guide rail
-3- forwards.
– Remove camshaft timing chain from camshaft sprockets.
Caution
Avoid damage to valves and piston crowns.

♦ Do not turn the crankshaft after the camshaft timing chain
has been removed from the cylinder head.
– Remove high-pressure pump⇒ Rep. gr. 24 .

– Remove vacuum pump ⇒ Rep. gr. 47 .
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es, in part or in w
t to the co
rrectness of i
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Prote AG.

Amarok 2011 ➤
– Undo and remove cylinder head cover bolts in the sequence

-1 … 6-.
– Remove cylinder head cover.
– Detach camshafts.
n AG. Volkswagen AG do Caution

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Danger of soiling
hor lubrication system and bearings.
is tee
ut or
♦ Coverssopen parts of engine.
a ac
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Installing
erm
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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
valve stem ends.
nform
ercia
– Remove sealant remaining on cylinder head with flat scraper.

m
at
om
ion
WARNING
c
in t
or
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ate
do
Risk of eye injury.

priv
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for

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by
Caution cted agen
Prote AG.
Danger of soiling lubrication system and bearings.

♦ Cover open parts of engine.
– Remove sealant left in groove of cylinder head cover and on

sealing surfaces, e.g. using a rotating plastic brush.
– Clean sealing surfaces. They must be oil and grease free.
– Oil running surfaces of both camshafts.
3. Valve gear 101

Amarok 2011 ➤
WARNING
Risk of eye injury.

AG. Volkswagen AG d
agen oes
lksw not
– Lock camshaft with spacers -T40191- d by V as shown; if necessary,
o gu
ara
slide forked sleeves into correct orisposition.
e nte
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Note
nl
pt
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If available, use 2nd set of spacers -T40191- or reuse -T40191/1- .
erm
ab
ility
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wit
, is n
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– 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
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sd
a
– Check alignment -arrows- of camshafts.

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Prote AG.

2 mm).

AG. Volkswagen AG d
agen oes
olksw not
d by
V gu
ara Amarok 2011 ➤
e nte
4-cylinder injectionthengine
oris
(2.0 l direct injection engine, turbocharger)eo - Edition 02.2011
au ra
ss c
– Apply silicone sealant onto clean sealing surface of cylinder
ce
e
nl
head cover, as illustrated -arrows-.
pt
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Note hole
spec
es, in part or in w
♦ The cylinder head cover must be installed within 5 minutes
t to the co
after applying the silicone sealant.
rrectness of i
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♦ Observe expiry date of sealing compound.
nform
ercia
Sealant ⇒ Electronic parts catalogue .

m
at
om
i
– Fit cylinder head cover onto cylinder head.
on
c
in t
or
– Renew bolts for cylinder head cover.
his
ate
do
priv
c
– Tighten bolts in several stages, tightening sequence
um
for
⇒ page 92 .
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by c lksw
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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

terhold -T10355- .
Note
The timing chain links with markings must be positioned at the

markings on the chain sprockets.
3. Valve gear 103

Amarok 2011 ➤
– Fit camshaft timing chain: the drive chain/sprocket markings

must align -arrows-.
– Use spanner to turn inlet camshaft in direction of -arrow- and
fit timing chain.
AG. Volkswagen AG d
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olksw not
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– Attach bearing saddle and screwho rise in bolts -arrows- hand-tight. nte
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– Remove locking pin -T40011-
ss . c
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– Tighten bolts -arrows- for bearing saddle.
pt
du
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– Install regulating valve.
erm
ab
ility
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– Turn crankshaft 4 times in direction of engine's rotation.
wit
, is n
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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
l purpos
gine guard .
nf
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Amarok 2011 ➤
3.3 Renewing valve stem sealsagwith cylinder

en AG. V
olkswagen Ahead
Gd installed
w oes
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Special tools and workshop ho
ris nte
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equipment required au
t ra
c
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♦ Spark plug socket and ex‐
ce
le
un
pt
tension -3122 B-
an
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ab
♦ Valve stem seal puller
ility
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-3364-
wit
is n
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♦ Valve stem seal fitting tool
ole,
-3365-
spec
t to the co
♦ Adapter -T40012-
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
l FSI engine -VAS
atio
m
5161/19B-
o
n
c
i
or
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.
Removing valve stem oil seals

– Remove camshafts ⇒ page 94 .
– Mark allocation of roller rocker fingers and hydraulic compen‐
sation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and place down on a clean surface.
– Unscrew spark plugs using spark plug socket and extension
-3122 B- .
3. Valve gear 105

Amarok 2011 ➤
– 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“.
– Screw adapter -T40012- into spark plug thread.

– Connect compressed air with pressure rating of at least 6 bar.
– Strike tight valve cotters with drift -VAS 5161/3- and a plastic
hammer.
For inlet side

– Screw retainer -VAS 5161/6- with guide fork -VAS 5161/5- into
centre thread of guide plate for 2.0 ltr. and 3.0 ltr. FSI engine
-VAS 5161/19B- . en AG. V
olkswagen AG
ag does
lksw not
– Insert assembly cartridge -VAS 5161/8-yV
o into guide plate for 2.0 gu
db ara
ltr. and 3.0 ltr. FSI engine -VAS
or
ise 5161/19B- . nte
h eo
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– Attach pressure fork -VAS
ss 5161/2- to retainer -VAS
a 5161/6- . c
ce
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un
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rm
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pe
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For exhaust side

hole
spec
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
knurled screw of installation cartridge -VAS 5161/8- to right

l purpos
until tips engage in valve cotters.

– Move knurled screw back and forth slightly to press apart valve
nform
ercia
cotters and capture them in the assembly cartridge.

m
– Release pressure fork -VAS 5161/2- .

a
com
tion in
– Remove installation cartridge -VAS 5161/8- .

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Prote AG.

Amarok 2011 ➤
– Pull off valve stem seals using valve stem seal puller -3364- .
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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
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t.
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– Place lower part of valve stem seal puller -3364- onto valve Cop py
. rig
stem seal.
t
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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
– To prevent damage to new valve stem seals -B-, attach plastic

sleeve -A- to valve stem.
– Lubricate sealing lip of valve stem seal -B-, place it in the valve
stem oil seal fitting tool -3365- and push carefully onto valve
guide.
– Remove plastic sleeve -A-.
– Insert valve spring and valve spring plate.
– Install removal and installation device for valve cotters -VAS
5161- as shown.
3. Valve gear 107

Amarok 2011 ➤
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
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o
into the insertion device t gu
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-VAS 5161/18- . o
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h
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♦ Press assembly cartridge
ss
a -VAS 5161/8- onto insertion device c
from above and pick up valve cotters.
ce
le
un
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an
d
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– Press installation cartridge -VAS 5161/8- down with pressure

rm
ab
fork -VAS 5161/2- , and turn installation cartridge knurled

pe
ility
ot
screw back and forth whilst pulling upwards.

wit
, is n
h re
– Relieve pressure fork -VAS 5161/2- whilst pulling on knurled

hole
spec
screw.
es, in part or in w
t to the co
– Remove removal and installation device -VAS 5161- .

Perform assembly analogously in reverse order of removal. When
rrectness of i
doing this, observe the following:

l purpos
– Install camshafts ⇒ page 94 .

nform
mercia
a
com
tion in
r
te o
thi
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Cop py
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Prote AG.

Amarok 2011 ➤
3.4 Renewing valve stem seals with cylinder head removed

equipment required
♦ Valve stem seal puller
-3364-
♦ Valve stem seal fitting tool
-3365-
♦ Dismantling and assem‐
bling device for valve cot‐
ters -VAS 5161-
♦ Guide plate for 2.0 l and 3.0
l FSI engine -VAS
5161/19B-
♦ Engine and gearbox sup‐
port -VAS 6095- agen
AG. Volkswagen AG d
oes
olksw not
♦ Cylinder head tensioning byV gu
ara
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device -VAS 6419- horis nte
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un
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an
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erm
ab
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wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
a
Procedure
iv
o
pr
cum
r
fo
– Remove camshafts ⇒ page 94 .

en
ng
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.
3. Valve gear 109

Amarok 2011 ➤ AG. Volkswagen AG d
4-cylinder injection engine (2.0 l direct injection engine, agen
ksw turbocharger) - Edition
oes 02.2011
ol not
V gu
by ara
ed nte
– Use lever -arrow- to slide air cushion under combustion
oris cham‐ eo
th
ber from which valve stem seal is to be removed.
ss au ra
c
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
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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
5161/19B- with knurled screws -VAS 5161/12- to cylinder

head as shown.
nform
ercia
– Set piston of respective cylinder to „bottom dead centre“.

m
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
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cum
fo
en
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
For inlet side
centre thread of guide plate for 2.0 ltr. and 3.0 ltr. FSI engine
-VAS 5161/19B- .
– Insert assembly cartridge -VAS 5161/8- into guide plate for 2.0
ltr. and 3.0 ltr. FSI engine -VAS 5161/19B- .
– Attach pressure fork -VAS 5161/2- to retainer -VAS 5161/6- .
For exhaust side

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
knurled screw of installation cartridge -VAS 5161/8- to right
until tips engage in valve cotters.
– Move knurled screw back and forth slightly to press apart valve
cotters and capture them in the assembly cartridge.
– Release pressure fork -VAS 5161/2- .
– Remove installation cartridge -VAS 5161/8- .

Amarok 2011 ➤
– Pull off valve stem seals using valve stem seal puller -3364- .
Installing valve stem seals
Caution
Risk of damage when installing valve stem seals.

♦ Place plastic sleeve -A-, enclosed with new valve stem
seals -B-, onto valve stem.
– Lightly oil sealing lip of valve stem seal.

– Push valve stem oil seal onto plastic sleeve.
AG. Volkswagen AG d
agen oes
– Carefully press valve stem oil seal ontoyV
olksvalve guide using
w not
gu
valve stem seal fitting tool -3365-
ise
d. b ara
nte
r
ho eo
– Remove plastic sleeve. aut ra
c
ss
– Insert valve spring and valve spring plate.
ce
e
nl
pt
du
an
itte
– Remove removal and installation device for valve cotters -VAS
y li
erm
ab
5161- as shown.
ility
ot p
wit
, is n
h re
hole
Inlet side 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
riv
Exhaust side
p
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
3. Valve gear 111

Amarok 2011 ➤
Note
♦ If the valve cotters have been removed from the installation

cartridge, they must first be inserted into the insertion device
-VAS 5161/18- .
♦ Press assembly cartridge -VAS 5161/8- onto insertion device
from above and pick up valve cotters.
– Press installation cartridge -VAS 5161/8- down with pressure

fork -VAS 5161/2- , and turn installation cartridge knurled
screw back and forth whilst pulling upwards.
– Relieve pressure fork -VAS 5161/2- whilst pulling on knurled
screw.
– Remove removal and installation device for valve cotters -VAS
5161- .
– Install camshafts ⇒ page 94 .
olkswagen AG
en AG. V
3.5 Checking valve
does
not
yV
gu olks guides
wag
edb ara
horis equipment required nte
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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
♦ Dial gauge -VAS 6079-

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
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

agen oes
olksw not
V gu
by
♦ If the wear limit is exceeded, repeat ised the measurement with ara
nte
new valves. If the wear limit is exceeded
ut
hor
again, renew the cyl‐ eo
inder head. ss a ra
c
ce
le
♦ If the valve is to be renewed as part of a repair, use a new

un
pt
an
d
valve for the calculation.

itte
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rm
ab
pe
ility
ot
wit
3.6 Checking axial clearance of camshafts
, is n
h re
hole
spec
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.
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♦ Dial gauge -VAS 6079- t. Cop py
rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
3. Valve gear 113

Amarok 2011 ➤
Test procedure
AG . Volkswagen AG
– Take measurements with retaining frame removed.
ksw
agen does
not
Vo l
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– 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
• Axial clearance: 0.05 … 0.17 mm.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
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
1.1 General notes on the lubrication system
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
shaft bearings or conrod bearings are damaged. To avoid any
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
1.2 Engine oil

nform
ercia
Oil capacities:
m
With oil filter change: 7.5 l

com
tion in
r
Without oil filter change: 7.2 l

te o
thi
s
iva
do
Engine oil specifications:

r
rp
cum
fo
⇒ Maintenance ; Booklet 11
en
ng
t.
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op py
Checking oil level: t. C rig
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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.
1. Parts of lubrication system 115

Amarok 2011 ➤
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-.
1.3 Assembly overview - sump, oil pump
1 - Bolt
❑ Renew.
⇒ page 117 .
2 - Lower part of sump
⇒ 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
❑ Moisten with oil.

erm
ab
ility
ot p
7 - Oil pump
wit
, is n

h re
hole
⇒ page 119 .
spec
es, in part or in w
8 - Centring sleeve
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9 - O-ring
❑ Renew.
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10 - Oil pressure control valve

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-N428-
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⇒ page 128 .
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11 - Bolt
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or
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116
agen
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Rep. gr.17 - Lubrication
Amarok 2011 ➤
14 - Bolt
❑ 9 Nm
15 - Seal
❑ Renew.
16 - Coarse oil separator
17 - Bolt wage
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❑ Tightening
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❑ Removing
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20 - Bolt
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21 - Bolt
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❑ 20 Nm
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22 - Seal
23 - Bolt
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25 - Non-return valve
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Tightening sequence for sump (bottom section)
AG.
– Tighten bolts in sequence -1 to 19- in 2 stages as follows:

2. Turn bolts 45° further

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Tightening sequence for sump (top section)
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1.4 Removing and installing coarse oil sep‐

arator
♦ Support bracket -10 - 222 A-
Removing
– Support engine.
118 Rep. gr.17 - Lubrication

Amarok 2011 ➤

pipe -2-.
Engine guard .
– Remove left engine support ⇒ page 17 .
– Release vacuum hoses ⇒ Item 17 (page 141) and
⇒ Item 13 (page 141) from coolant pump.
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– Remove coarse oil separator
oris -1 ... 9-. tee
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– Check oil level and top up, if necessary ⇒ page 115 .
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1.5 Removing and installing oil pump
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♦ Assembly tool -T10118- orm

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Removing
– Remove sump (bottom section) ⇒ page 120 .
– Remove baffle plate -arrows-.
Note
The following procedure must be performed in one operation. A

2nd mechanic is required to assist.

Amarok 2011 ➤
– Unscrew bolts -arrows- and remove oil pump.
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– Pull chain tensioner back ausing
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Installation is carried out analogously in the reverse order; note
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the following:
hole
spec
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– Check that both centring sleeves for centring oil pump are
present.
rrectness of i
– Renew baffle plate.
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Note
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Plastic ribs that are permanently deformed during tightening are
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located on the baffle plate. The plastic rips ensure that the baffle
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plate rests without play and does not rattle. For this reason, the
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1.6 Removing and installing lower part of Cop py
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AG.
♦ Used oil collection and extraction unit -V.A.G 1782-

Amarok 2011 ➤
♦ Support bracket -10 - 222 A-
♦ Hand drill with plastic brush

♦ Eye protection
♦ Silicone sealant -D 174 003 A2-
Removing
Note
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To remove the sump lower part the engine has to bed bsupported
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Engine guard .
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– Drain off engine oil.
rrectness of i
Note
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Observe environmental regulations for disposal.

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– Unscrew bolts -1 … 20-. au
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– Remove sump; if necessary, loosen using light blows with a
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rubber-headed hammer.
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Installing
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Note
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♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
ss o
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– Remove sealant residues from sump upper part with a flat
f in
scraper.
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WARNING
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Risk of eye injury.

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– Remove sealant residue from bottom part of sump, e.g. with
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rotating plastic brush.
AG.
– Clean sealing surfaces until they are all oil- and grease-free.

3 mm).

Amarok 2011 ➤
– Apply the bead of silicone sealant -D 174 003 A2- to the clean
sealing surface of the sump (lower part), as illustrated.
Note
♦ The sump must be installed within 5 minutes of applying sili‐

cone sealing compound.
♦ Thickness of sealant bead: 2…3 mm.
– Fit sump lower part immediately and tighten bolts -1 to 20- in

3 stages as follows:
1- Tighten bolts hand tight.
2- Tighten bolts to 8 Nm.
3- Turn bolts 45° further
Note
Let sealing compound dry for. approx. 30 minutes after installing

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Assembly
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Amarok 2011 ➤
1.7 Removing and installing upper part of sump

equipment required
♦ Assembly tool -T10118-
♦ Brake lining wear gauge -
VW 136-
1331-
♦ Silicone sealant -D 174 003
A2-
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Removing
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– Remove gearbox ⇒ Rep. gr. 34 .

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– Remove oil pump ⇒ page 119 . C py
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– Remove sealing flange on gearbox side ⇒ page 33 .
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– Unscrew bolts -arrows-.
Prote AG.
DANGER!
Injury risk! When removing upper part of sump, spring of chain

tensioner for oil pump drive jumps from upper part of sump to
lower timing chain cover. When removing upper part of sump,
do not grip between upper part of sump and lower timing chain
cover.

Amarok 2011 ➤
– Remove bolts -1 to 14- and lever off upper part of sump.
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
Note

♦ The sump upper part must be installed within 5 minutes of ap‐
plying silicone sealing compound.
– Use assembly tool -T10118- to pull spring of chain tensioner

for oil pump drive in direction of guide rail -arrow-.
– Secure spring by inserting brake lining wear gauge -VW 136- ,
as shown in illustration, into hole of guide rail.
per.
WARNING
Risk of eye injury.

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– Remove ut
horemaining sealant on upper part of sump and e olower
ra
timing
ss achain cover e.g. using rotating plastic brush. c
ce
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Note
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Check timing chain cover for deformation. To do this, fit sump

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upper part first without sealant and check gap between cover and
h re
ole,
sump upper part. Renew cover if deformation is found which can‐

spec
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
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mer
atio
om
n
c
i
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Cop py
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Vo
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by c lksw
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Prote AG.

Amarok 2011 ➤

3 mm).
– Apply silicone sealant -D 174 003 A2- onto clean sealing sur‐
face of upper part of sump, as illustrated -arrow-.
• Thickness of sealant bead: 2…3 mm
Note
♦ The sump upper part must be installed within 5 minutes of ap‐

plying silicone sealing compound.
AG. Volkswagen AG d
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• Sump upper part and crankcase must be flush on gearbox
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– Fit sump upper part immediately and tighten bolts
ss -1 to 14- in c
3 stages as follows:
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1- Tighten bolts hand tight.
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2- Tighten bolts to 15 Nm.
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3- Turn bolts 90° further.
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– Install bolts -arrows-. Specified torque.

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Cop py
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Prote AG.

Amarok 2011 ➤
– 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.
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Amarok 2011 ➤
2 Oil filter bracket, oil pressure, engine

oil cooler and oil supply line
2.1 Assembly overview - oil filter, engine oil cooler
1 - Bracket for ancillaries

⇒ page 24 .
2 - Seal
❑ Renew.
3 - O-ring
❑ Not replacement part.
Include in items sup‐
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5 - Valve unit
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❑ With O-rings
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6 - Oil filter
h re
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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
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❑ Renew.
8 - Oil pressure switch -F22- nf
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or
❑ Blue insulation
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⇒ page 130 .
or
thi
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❑ Check ⇒ Vehicle diag‐

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nostic tester.
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❑ 20 Nm
t.
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Cop py
9 - Bolt ht. rig
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❑ 23 Nm
co Vo
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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.
13 - Seal
❑ Renew.

Amarok 2011 ➤
14 - Bolt
2.2 Removing and installing engine oil cool‐

er
olkswagen AG
en AG. V
♦ Drip tray for workshop hoist -VAS 6208-olkswag does
not
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es, in part or in w
t to the co
Removing
rrectness of i
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WARNING
nform
ercia
Hot steam/hot coolant can escape - risk of scalding.

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♦ The cooling system is under pressure when the engine is
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hot.
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♦ Cover filler cap on expansion tank with a cloth and open
s
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carefully to dissipate pressure. do

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– Drain coolant ⇒ page 133 . t. C rig
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– Remove bracket for ancillaries ⇒ page 24 .
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by c lksw
cted agen
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– Unscrew bolts -4 and 5- and remove engine oil cooler -3- to‐
gether with seal -2-.
Installing
note the following:
Note
♦ Renew gaskets and seals.

♦ Secure all hose connections with hose clips corresponding to
the series equipment ⇒ Electronic parts catalogue .
2. Oil filter bracket, oil pressure, engine oil cooler and oil supply line 129
Amarok 2011 ➤
– Install engine oil cooler -3- with new seal -2-.

– Install bracket for ancillaries ⇒ page 24 .
2.3 Removing and installing agenoil pressure

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switch -F22- ed by Vol not
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Removing ho eo
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caping engine oil.
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spec
es, in part or in w
t to the co
– Unscrew oil pressure switch -F22- -2-.
Installing
rrectness of i
note the following:
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Note
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♦ Insert new oil pressure switch -F22- immediately in bore to

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avoid loss of oil.

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Cop py
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2.4 Removing and installing oil supply line
op Vo
by c lksw
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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.
2.5 Checking oil pressure


Amarok 2011 ➤
♦ Oil pressure tester -V.A.G 1342-
Test prerequisites
• Oil level OK.
• Engine oil temperature at least 80 °C (radiator fan must have
run once) wage
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Test procedure ed by ara
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caping engine oil.
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– Detach connector -2- from oil pressure switch -F22- -1-, un‐
h re
ole,
screw oil pressure switch -F22- .
spec
– 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
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Note
c
i
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During the first 1000 km the oil pressure could be 3.0 to 4.0 bar
i
o
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cum
at 2000 rpm.
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t.
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op py
Reassembly t. C rig
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pyri by
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Prote AG.
– Install oil pressure switch.
2. Oil filter bracket, oil pressure, engine oil cooler and oil supply line 131
Amarok 2011 ➤
19 – Cooling
1 Cooling system
General notes on cooling system ⇒ page 132 .
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1.1 General notes eon
d b cooling system
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WARNING ss
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an
Steam may escape when expansion tank is opened. Wear eye
d
itte
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protection and protective clothing to avoid eye injuries and
erm
ab
scalding. Cover cap with cloth and open carefully.
ility
ot p
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ole,
spec
Caution
t to the co
rrectne
tions:
ss
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nform
sitions.
mer
atio
m
♦ To avoid damage to lines, ensure sufficient clearance from

o
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all moving or hot components.

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Note t. Cop py
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♦ When the engine is warm, the cooling system is under pres‐
cop Vo
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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.
132 Rep. gr.19 - Cooling

AG. Volkswagen AG d
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Amarok 2011 ➤
ris
4-cylinder uinjection
tho engine (2.0 l direct injection engine, eturbocharger)
eo
ra
- Edition 02.2011
s a c
s
1.2 Draining and filling coolant
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
equipment required
wit
, is n
h re
hole
♦ Refractometer -T10007-
spec
es, in part or in w
♦ Drip tray for workshop hoist
t to the co
-VAS 6208-
rrectness of i
♦ Cooling system charge unit
l purpos
-VAS 6096-
♦ Adapter for cooling system
nform
ercia
tester -V.A.G 1274/8-

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tion in
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Procedure:
Draining
WARNING
Steam may escape when expansion tank is opened. Wear eye

protection and protective clothing to avoid eye injuries and
scalding. Cover cap with cloth and open carefully.
1. Cooling system 133

Amarok 2011 ➤
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agen oes
olksw not
– Open filler cap -2- on expansion tank -1-. db
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ara
rise nte
– Remove engine guard, if fitted ⇒ Body, front; Rep. gr.uth50
o ; eo
ra
Engine guard . ss a c
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un
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d
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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
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rp
cum
fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
– Remove spring-type clip -2 and detach bottom coolant hose

-1- from radiator -3-.
Note
Observe environmental regulations for disposal.
Filling
Note
♦ G 13 is used as the anti-freeze in series production.

♦ Only G 13 and G 12 plus-plus in accordance with TL VW 774
G may then be used as coolant additive.
♦ G 13 Plusplus prevents frost and corrosion damage and scal‐
ing and also raises the boiling points. Therefore, the cooling
system must be filled all year round with coolant additive.
♦ Because of its higher boiling point, the coolant improves en‐
gine reliability under heavy loads, particularly in countries with
tropical climates.
♦ Frost protection is required down to about -25°C (in countries
with arctic climates down to about -35°C).
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The
coolant additive concentration must be at least 40%.
♦ If a stronger anti-freeze mixture is necessary due to harsher
weather conditions, the percentage of G 13 and G 12 sPlusplus
wage
es n
can be increased. But only to 60% (frost protectionby
V to approx.
olk ot g
ua
-40°C), otherwise frost protection and cooling
ris
edeffectiveness ran
tee
are reduced again. utho
or
sa ac
♦ If radiator, heat exchanger, cylinder head
s
or cylinder head
ce
e
gasket is renewed, do not reuse old coolant.

nl
pt
du
an
itte
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♦ The refractometer -T10007- is recommended for determining

erm
ab
the current anti-freeze density.

ility
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, is n
h re
Recommended mixture ratios:

hole
spec
es, in part or in w
Frost protection Anti-freeze G 13 and Demineral‐

t to the co
to ratio G 12 Plus‐ ised / distil‐

plus1) led water
to standard
rrectness of i
VDE
05101)
l purpos
-25°C 40% 5.0l 7.5l

-35°C 50% 6.25l 6.25l
nf
ercia
orm
m
1) The quantity of coolant can vary depending upon vehicle equipment.

atio
om
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
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Unscrew filler cap -2- from expansion tank -1-.

– Detach coolant hose -3 from expansion tank -1.
– Fill expansion tank -1 to capacity and reconnect coolant hose
-3.
– Seal expansion tank -1- with cap -2-.
– Start engine and keep engine speed at approx. 2000 rpm until
radiator fan starts up.
– Check coolant level and top up if necessary. When engine is

at normal operating temperature, the coolant level must be at
the upper mark; when engine is cold, in the middle of the sha‐
ded field.
1.3 Checking cooling system for leaks

♦ Cooling system tester -V.A.G 1274 B-
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
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au ra
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ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
♦ Adapter for cooling system tester -V.A.G 1274/8-

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.

Amarok 2011 ➤
4-cylinder injection engine (2.0 l direct injection engine,
. Volkswage
turbocharger) - Edition 02.2011
AG n AG d
agen oes
olksw not
♦ Adapter for cooling system tester -V.A.G d b 1274/9-
yV gu
ara
rise nte
tho eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
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
cloth over cap and open with caution.

iv
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
– Clamp connector -V.A.G 1274 B/1- into adapter for cooling

system tester -V.A.G 1274/8- .
– Join connection piece -V.A.G 1274 B/1- to cooling system
tester -V.A.G 1274 B- using connecting hose supplied.
– Using hand pump on tester, build up a pressure of approx. 1.0
bar.
DANGER!
Risk of scalding! Before the cooling system tester -V.A.G 1274

B- is disconnected from the connecting hose or the connector
-V.A.G 1274 B/1- it is essential that the pressure is first re‐
lieved. To do this, press pressure relief valve on cooling system
tester -V.A.G 1274 B- until pressure gauge displays value of
»0«.
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- .

Amarok 2011 ➤
– Join connection piece -V.A.G 1274 B/1- to cooling system

tester -V.A.G 1274 B- using connecting hose supplied.
– Operate hand pump.
• The pressure relief valve should open at a pressure of 1.4 …
1.6 bar. en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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.

Amarok 2011 ➤
2 Coolant hose schematic diagram
2.1 Coolant hose schematic diagram for vehicles with heat exchanger
1 - Heat exchanger for heater

unit
2 - Cylinder head connection
3 - Circulating pump V 55 (only
for Climatronic)
4 - Auxiliary heater
AG. Volkswagen AG d
♦ Depending on equipment. agen oes
olksw not
y V gu
d b ara
5 - Circulating pump V 51 orise nte
th eo
u ra
6 - Radiator ss a c
ce
e
nl
♦ Renew coolant after replac‐
pt
du
an
ing.
itte
y li
erm
ab
♦ Removing and installing
ility
ot p
⇒ page 152 .
wit
, is n
h re
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. Coolant hose schematic diagram 139

Amarok 2011 ➤
2.2 Coolant hose schematic diagram for vehicles with 2nd heat exchanger
1 - Connecting pipes for 2nd

heat exchanger
2 - Heat exchanger for heater
unit
3 - Shut-off valve
4 - Circulating pump V 55 (only
for Climatronic)
5 - Auxiliary heater
♦ Depending on equipment.
6 - Radiator
♦ Renew coolant after replac‐
ing.
♦ Removing and installing
⇒ page 152 .
7 - Circulating pump V 51
9 - Turbocharger
10 - Cylinder head
11 - Thermostat n AG. Volkswagen AG do
lkswage es n
12 - Coolant pump d byV
o ot g
ua
ran
ir se tee
13 - Cylinder head connection
utho
or
a ac
ss
14 - Expansion tank
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.

Amarok 2011 ➤
3 Parts of cooling system, engine side

wage es n
3.1 Assembly overview - coolant pipes and continued coolant circulation pump olks ot g
byV ua
d ran
-V51- utho
ir se tee
or
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ss
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
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
8 - Continued coolant circula‐ yi

t.
Co
tion pump -V51- t. Cop py
rig
gh
ht
pyri by
Vo
⇒ page 142 .
co lksw
by
cted agen
Prote AG.
9 - Coolant hose
❑ To water connection
10 - Coolant pipe with coolant
hose
11 - Coolant hose
❑ To supplementary water
pump
12 - Retainer
13 - Coolant pipe with coolant
hose
❑ To coolant pump.
14 - Coolant hose
15 - Coolant hose
❑ Radiator top
16 - Coolant hose
❑ To radiator
❑ Top left
17 - Coolant hose
❑ From radiator to coolant pump
18 - Retainer
3. Parts of cooling system, engine side 141

Amarok 2011 ➤
19 - Coolant pipe
20 - Bracket for continued coolant circulation pump -V51- .
21 - Coolant pipe
❑ Return line
22 - Seal
23 - Coolant pipe
❑ Supply
24 - Coolant hose
25 - Coolant hose
❑ To expansion tank
3.2 Removing and installing continued cool‐

ant circulation pump -V51-
♦ Hose clips up to 25 mm -3094-
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.

Amarok 2011 ➤
Removing
Note
Place a cloth under coolant pipe to absorb escaping coolant.

Engine guard .
– Clamp off coolant hoses -arrows- using hose clamps to 25 mm
-3094- and remove.
– Disconnect electrical connector -2-.
– Remove bolt -1- and detach continued coolant circulation
pump -V51- .
Installing
Installation is carried out in the reverse order; note the following:
Note
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
♦ In order to be able to attach the air ducts on their connections,
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
– Check coolant level ⇒ page 133 .
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.

Amarok 2011 ➤
3.3 Coolant pump and thermostat - exploded view

AG. Volkswagen AG d
1 - Bolt agen oes
olksw not
yV gu
❑ Tightening sequence rised b ara
nte
⇒ page 145 . ut
ho eo
ra
s a c
2 - O-rings s
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
❑ Check for secure seat‐
t to the co
ing.
5 - Coolant temperature send‐
rrectness of i
er -G62-
l purpos

⇒ page 145 .
nform
ercia
6 - O-ring
m
❑ Renew.
a
com
tion in
7 - Coolant pump
r
te o
thi
s
iva
do
⇒ page 149 .
r
rp
cum
fo
❑ New coolant pump: re‐

en
ng
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.
⇒ page 146 .
11 - Toothed belt guard
12 - Bolt
❑ 9 Nm
13 - Bolt
❑ Left-hand thread.
❑ Renew.
14 - Toothed belt drive sprocket
❑ Note installation position.
15 - Oil seal
16 - Balancer shaft
17 - Thermostat

Amarok 2011 ➤
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
– Tighten bolts for coolant pump in the sequence -1 … 5- to 9
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
ature sender -G62-
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
AG.
pipe -2-.
– Disconnect electrical connector -1- at throttle valve module -

J338- .
– Remove bolts -arrows- and detach throttle valve module -
J338- .

Amarok 2011 ➤
– Remove support for intake manifold (remove nut -2- and bolt
-1-).
– Disconnect electrical connector -1- at coolant temperature
sender -G62- .
– Detach retaining clip (press release tabs -arrows-).
Note
Place a cloth underneath to absorb escaping coolant.
– Remove coolant temperature sender -G62- -2-.

AG. Volkswagen AG d
agen
Installing Volksw
oes
not
by gu
d ara
orise nte
eo
note the following: aut
h
ra
ss c
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
es, in part or in w
t to the co
♦ 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

m
a
com
tion in
♦ In order to be able to securely attach the air ducts on their

r
te o
connections, the screws of the used hose clips have to be

thi
s
iva
sprayed with penetrating spray before installing.

do
r
rp
cum
fo
en
g
– Install intake manifold support ⇒ Rep. gr. 24 .

n
t.
yi Co
Cop py
t.
– Install throttle valve module -J338- ⇒ Rep. gr. 24 .
rig
gh ht
pyri by
Vo
o
by c
lksw
cted agen
Prote AG.
3.5 Removing and installing toothed belt for

coolant pump

Amarok 2011 ➤
♦ 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
– Remove short coolant pipe ⇒ page 141 .
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
Risk of damage to thread.

♦ The drive sprocket bolt has a left-hand thread.

Amarok 2011 ➤
AG. Volkswagen
n AG do
wage es n
olks ot g
– Use torque wrench -V.A.G 1331- and socket ed
by -T10360- to re‐
V ua
ran
move bolt on coolant pump drive sprocketoris -1- (counterhold at tee
vibration damper. th or
au ac
ss
– Detach drive sprocket -1- and toothed belt -2-.
ce
e
nl
pt
du
an
itte
Installing
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
note the following:
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Replace bolt for drive sprocket.
l purpos
♦ Renew seals and O-rings.

♦ Note installation position of V-belt pulley ⇒ page 144 .
nform
mercia
– Install short coolant pipe ⇒ page 141 .
at
om
ion
c
in t
or
his
ate
do
riv
3.6 Renewing oil seal for coolant pump drive

p
cum
for
en
ng
t.
yi
Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Procedure
– Remove short coolant pipe ⇒ page 141 .
– Press screwdriver -1- firmly onto section -2- of oil seal
-arrow B-.
– Lever out oil seal -arrow A-.
– Clean contact surface and sealing surface.

Amarok 2011 ➤
– Lubricate sealing surface of balance shaft -2- with gear oil.

– Fit oil seal -1- onto balance shaft.
agen
AG. Volkswagen AG d
o w es n
olks o
• The marking „Luftseite“
d b („Outside“) -arrow- should be legible
yV t gu
ara
from the outside. rise nte
ho e t or
au ac
ss
Caution
ce
e
nl
pt
du
an
itte
y li
Risk of damage to thread.
erm
ab
ility
ot p
♦ The drive sprocket bolt has a left-hand thread.
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
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
3.7 Removing and installing coolant pump

t.
yi Co
Cop py
t. rig
Removing
gh ht
pyri by
Vo
o
by c lksw
– Remove short coolant pipe ⇒ page 141 . cted agen
Prote AG.

– Disconnect electrical connector -1- at throttle valve module -
J338- .
– Remove bolts -arrows- and detach throttle valve module -
J338- .
– Disconnect electrical connector -1- at coolant temperature

sender -G62- .
Note
-Item 2 and arrows- can be disregarded.

Amarok 2011 ➤
– Disconnect coolant hoses. To do so, raise retaining clips -1-

and -2- and lay coolant hoses to one side.
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
– 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

m
note the following:
at
om
ion
c
in t
or
his
te
Note
a
do
priv
cum
for
Renew seals and O-rings. en

ng
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.
– Tighten bolts for coolant pump.
Note
Remove protective cap -arrow- if a new coolant pump has been

fitted.

– Install throttle valve module -J338- ⇒ Rep. gr. 24 .

Amarok 2011 ➤
3.8 Removing and installing thermostat

Removing AG. Volkswagen AG d
agen oes
lksw not
– Remove engine by guard, if fitted ⇒ Body, front; Rep.
Vo gu
ara gr. 50 ;
Engine guard rised
. nte
ho eo
ut
– Drainss coolant ⇒ page 133 .
a ra
c
ce
e
– Disconnect coolant hose ⇒ Item 17 (page 141) arrow from en‐

nl
pt
du
an
gine mounting.
itte
y li
erm
ab
– Remove engine mounting (left-side) ⇒ page 17 .
ility
ot p
wit
, is n
– Unscrew continued coolant circulation pump -V51- with brack‐
h re
et.
hole
spec
es, in part or in w
– Remove coarse oil separator ⇒ page 118 .
t to the co
– Unscrew bolts -arrows- and remove connection.
– Detach thermostat.
rrectness of i
Installing
l purpos

note the following:
nform
ercia

m
at
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Renew seals and O-rings.

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– Clean sealing surface for O-ring.
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– Coat O-ring with coolant, Coolants ⇒ Electronic parts cata‐
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Prote AG.
– Insert thermostat -4- in coolant pump housing -5- and swivel

forwards slightly -arrow-.
– Fit connection -3- carefully (insert centralising pin -2- in guide
-1-).
– Install coarse oil separator ⇒ page 118 .
– Install left engine mounting ⇒ page 17 .

Amarok 2011 ➤
4 Parts of cooling system, body side
4.1 Assembly overview - parts of cooling system, body side
1 - Radiator upper mounting

2 - Radiator
❑ Renew coolant after re‐
placing.
⇒ page 155 .
3 - Charge air cooler
4 - Upper cowling
5 - Condenser (only for vehi‐
cles with air conditioning sys‐
tem)
6 - Cap
❑ Check using cooling
system tester -V.A.G
1274- and adapter for
cooling system tester -
V.A.G 1274/9- .
❑ Test pressure 1.4…1.6 n AG. Volkswagen AG do
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7 - Connector o
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9 - Expansion tank
pt
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ing system tester -

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V.A.G 1274- and adapt‐

h re
er -V.A.G 1274/8-
hole
spec
⇒ page 136 .
es, in part or in w
t to the co
❑ With coolant tempera‐

ture display sender -
G32- .
rrectness of i
10 - Bolt, 5 Nm
l purpos
11 - Cowling with radiator fan -V7-

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12 - Bolt, 4 Nm
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13 - Breather line
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❑ Coolant hose schematic diagram ⇒ page 139 .

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❑ Secured to radiator at top.

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14 - Spring-type clip
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15 - Bolt, 1.2 Nm
agen
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16 - Retainer
❑ For continued coolant circulation pump -V51-

Amarok 2011 ➤
17 - Bolt, 4.5 Nm
18 - Continued coolant circulation pump -V51-
19 - Coolant hose
20 - Retainer
21 - Radiator outlet coolant temperature sender -G83-
22 - Retainer
❑ Hose clip pliers -VAS 6362- are recommended to install spring-type clips.
24 - Radiator lower mounting
4.2 Assembly overview - air ducting with radiator fan -V7-
1 - Radiator
2 - Radiator fan -V7-
3 - Bolt, 5 Nm
4 - Bolt, 5 Nm
5 - Locking lug
❑ Must be engaged in ra‐ n AG. Volkswagen AG do
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6 - Cowling o
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⇒ page 154 .
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4. Parts of cooling system, body side 153

Amarok 2011 ➤
4.3 Removing and installing cowling lksw

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– Unclip coolant hose -1- from brackets -2-.
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– Unscrew securing bolts -3- for cowling -4-.
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– Separate connector -1- at cowling -2-.
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– Remove bolts -1-.

– Detach retaining clips-3- with water hose -4- from cowling
-2-.

Amarok 2011 ➤
– Disengage cowling -2- at left and right. To do this, press re‐

taining lever -1- forwards using a screwdriver and raise cowl‐
ing -2- slightly.
– Remove cowling.
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– Unscrew bolts -arrows- and remove radiator fan -V7- -1-.
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Installing
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Install in reverse order.
Specified torque -arrows- 6 Nm
rrectness of i
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Amarok 2011 ➤
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 .
Engine guard .
– Remove cowling ⇒ page 154 .
Observe instructions for hose connections with screw-type clips
⇒ page 184 .
– Remove coolant hose -1- at radiator -3- and remove connect‐

ing hose -2-.
– Remove right connecting hose leading to turbocharger from
charge air cooler and place to one side.
– Remove air duct mounting ⇒ page 154 .
AG. Volkswagen AG d
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– Unclip left radiator fastening
ised b -2- at condenser -3-. ara
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– Unclip right radiator
s aut fastening as well and pull condenser -3- ra
c
off radiator -1-.s
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– Support condenser, e.g. with cable ties.

t to the co
Caution
rrectne
• During further removal work, make sure that the refriger‐

ant lines are not bent or stretched excessively.
ss o
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mer
– Do not bend or stretch the refrigerant lines excessively.

atio
m
– Carefully remove radiator upwards together with charge air

o
n
c
i
or
cooler. When doing so, take the radiator -2- past the refrigerant
thi
e
lines.
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Amarok 2011 ➤
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♦ If the radiator -1- is to be replaced, undo bolts of chargecair
ss
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cooler and remove it from radiator.

un
pt
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♦ Undo and remove bolt -2- on right and left (not shown in illus‐
y li
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tration) at radiator.
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– Install in reverse order. In the process, note the following:
es, in part or in w
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Note
l purpos
Before installing radiator, check that radiator mountings -1- are

correctly seated on front part of car -2- and, if necessary, reposi‐
nform
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tion:
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90".
Prote AG.
– Insert top radiator mountings -1- on right and left into the
mounting on radiator -2- appropriately.

Amarok 2011 ➤
– 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.
⇒ page 184 .
Caution
The screw-type clips on the charge air lines must always be

tightened to 5.5 Nm. If the torque is too low or too high, the
charge air hose may slip off the charge air pipe during vehicle
operation.
– Fit condenser -3- on radiator -1- on left and right so that it en‐
gages securely in the catches -2-.
Caution
– Install cowling ⇒ page 154 .

For vehicles with air conditioning AG. Volkswagen AG d
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– Install lock carrier ⇒ General body repairs, exterior; Rep. gr. d by
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Amarok 2011 ➤
20 – Fuel supply system

1 General notes on fuel system
General notes on fuel system ⇒ page 159
Observe safety precautions ⇒ page 160 .
Observe rules for cleanliness ⇒ page 183 .
1.1 General notes on fuel system

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When doing any repair ut
h work, especially in the engine compart‐
or eo
ment, pay attentionss to the following due to the cramped condi‐
a ra
c
tions:
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♦ Ensure that there is sufficient clearance to all moving or
spec
hot components.
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cted AG.
agen
♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ When installing or removing spring-type clips, we recommend
using spring-type clip pliers -VAS 6340- or
♦ … hose clip pliers -VAS 6362- .
♦ 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 on the ends of the hoses
must be aligned with each other.
1. General notes on fuel system 159

AG. Volkswagen AG d
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4-cylinder horiinjection
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1.2 Safety precautions when working on
ce
le
un
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fuel supply system
an
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Caution
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tions:
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sitions.
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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
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♦ The fuel system is also under pressure! Before opening
s
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the system, place cloths around the connections. Then
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carefully loosen connection to release the pressure!
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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!
1.3 Rules for cleanliness

When working on the fuel supply and injection system, pay careful
attention to the following „6 rules“ for cleanliness:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes or similar).
♦ When system is open, do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
160 Rep. gr.20 - Fuel supply system

Amarok 2011 ➤
1.4 Releasing pressure in high-pressure

area
WARNING
The injection system consists of a high-pressure section (max‐

imum approx. 120 bar) and a low-pressure section (approx. 6
bar).
Prior to opening the high-pressure area, e.g. when removing
the fuel pressure sender -G247- , the fuel pressure in the high-
pressure area must be reduced to a residual pressure of
approx. 6 bar. The appropriate procedure is described as fol‐
lows.
– Connect vehicle diagnostic tester and then carry out Guided

Fault Finding, „Reducing high fuel pressure“.
– Switch off ignition.
WARNING
The fuel lines are pressurized! Wear eye protection and pro‐
tective clothing to avoid eye injuries and skin contact. Before
opening the high-pressure section, wrap a cloth around the
connection.
– Now place a clean cloth around the connection and carefully

open the connection to release the residual pressure of ap‐
prox. 6 bar. Catch the escaping fuel.
AG. Volkswagen A gen G do
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– After completingby
Volwork, read fault memory of engine
k not
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and clearrisall
ed fault entries.
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If the fault memory was cleared, the readiness code must be gen‐
erm
ab
erated ⇒ vehicle diagnosis tester „Guided functions“.

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1. General notes on fuel system 161

Amarok 2011 ➤
2 Fuel pump
2.1 Checking fuel pump
Note
When replacing fuel delivery unit, check fuel tank for heavy soiling
and clean if necessary.

equipment required
♦ Pressure gauge -VAS
6550-
♦ Remote control -V.A.G
1348/3A-
♦ Test instrument adapter/
DSO (5-pin) -VAS 5565-
♦ Multimeter -V.A.G 1715-
♦ Special wrench -T10202-
♦ Measuring container, ca‐ n AG. Volkswagen AG do
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Checking function and voltage supply ⇒ page 162

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Checking holding pressure ⇒ page 165 .
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2.1.1 Checking function and voltage supply

• Battery voltage at least 11.5 V
• Fuse for fuel pump on fuse holder OK ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.

Amarok 2011 ➤
• Fuel pump control unit -J538- OK.

Test sequence:
Note
Function of fuel pump is checked using final control diagnosis.
– Connect vehicle diagnostic tester as follows:

– Connect diagnosis cable connector to diagnostic connection
in driver footwell.
– Switch ignition on.
– Press one after the other in. Vthe
olksdisplay
wagen AGthe buttons for Vehicle
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self-diagnosis ks,
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– Press au right arrow button ► on display to final control diagnosis
th or
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for sfuel pump electronics.
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The fuel pump must now run slowly up to maximum speed.
an
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The fuel pump runs very quietly. spec

es, in part or in w
t to the co

If fuel pump does not run:
rrectness of i
– Lower fuel tank until connectors on fuel delivery unit are ac‐
l purpos
cessible.
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2. Fuel pump 163

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Amarok 2011 ➤ byV ua
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th injection engine, turbocharger) - Edition 02.2011
o tee
or
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– First ensure that 5-pin wiring connection -1- is secure by pull‐
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
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– 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
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Voltage supply not OK:
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– Locate and eliminate open circuit referring to current flow di‐
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Voltage supply OK: Prote AG.
– Remove fuel delivery unit ⇒ page 172 .

– Check that electrical wires between flange and fuel pump are
connected.
If no open circuit can be found:
– Fuel pump is defective, renew fuel delivery unit ⇒ page 172 .
2.1.2 Checking fuel pressure

Test prerequisites
• Function of fuel pump has been checked ⇒ page 162 .
Test procedure
Note
Check fuel pressure using final control diagnosis.
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.

Amarok 2011 ➤
– Release clip -2- and detach fuel pressurisation line -3- from
high-pressure pump -1-. Collect escaping fuel with a cloth.
– Connect pressure tester -VAS 6550- to fuel supply line with

adapter -VAS 6550/1- and -VAS 6550/2- .
– Make sure that drain tap is closed and cut-off taps are open.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– Read off fuel pressure on pressure gauge.
• Specification: 4.0…7.0 bar
Fuel pressure OK, check holding pressure ⇒ page 165 .
If the specification is exceeded:
– Pressure limiting valve in fuel delivery unit is defective.
Note
The pressure limiting valve is integrated in the fuel delivery unit

and cannot be renewed separately. AG. Volkswagen
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If the specification is not attained:ed
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– Fuel pump is defective,aurenew
th fuel delivery unit ⇒ page 172 . or
ac
ss
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un
2.1.3 Checking holding pressure

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Test prerequisite
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• Fuel pressure OK and pressure tester -VAS 6550- connected.

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Check fuel pressure ⇒ page 164 .

hole
spec
Test sequence:
es, in part or in w
t to the co

pressure.
rrectness of i
– Read off fuel pressure on pressure gauge.

l purpos
• Specification: 4.0…7.0 bar

– End self-diagnosis and switch ignition off.
nform
ercia
– Observe pressure drop on pressure gauge. After 10 minutes,

m
pressure must not drop below 3.0 bar.

com
tion in
r
If the pressure drops further:

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pressure.
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Prote AG.
2. Fuel pump 165

Amarok 2011 ➤
– 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
Leak must be sought on engine side. Repeat holding pressure

test. This time, close shut-off tap -A- to check whether leak ac‐
tually is on engine side.
– Check fuel pipe to high-pressure pump for leaks.

If no fault is found:
– Renew high-pressure pump ⇒ page 226 .
If the pressure drops again:
Leak must be sought on fuel tank side; proceed as follows:
– Check fuel line leading to flange for leaks.
– Open fuel delivery unit flange -1- ⇒ page 172 .
– Check that all hose connections are connected.

AG. Volkswagen AG d
agen
– Renew fuel delivery unit. Volksw
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2.1.4 Checking fuel delivery rate

es, in part or in w
t to the co
– Checking fuel delivery rate ⇒ Vehicle diagnostic tester.

rrectness of i
l purpos
nform
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tion in
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Amarok 2011 ➤
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4-cylinder injection
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Assembly overview - fuel tank ⇒ page 167 .
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Removing and installing fuel tank ⇒ page 169 .
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Removing and installing fuel delivery unit ⇒ page 172 .
spec
Removing and installing fuel gauge sender -G- ⇒ page 173 .
t to the co
3.1 Assembly overview - fuel tank
rrectne
1 - Union nut, 110 Nm
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❑ Remove and install us‐
cial p
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ing union nut tool
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-3217- .
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2 - Seal
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❑ Moisten with fuel when

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⇒ page 168 .
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❑ To remove, first remove

fuel tank ⇒ page 169 .
fuel gauge sender
⇒ page 173 .
4 - Connecting hose
6 - Spring nut
7 - Filler neck
8 - Weld bolt with cap nut
9 - Filler cap with retaining
strap
10 - Seal
11 - Slotted pan head screw
12 - Control unit for fuel pump
J538
13 - Fuel tank
❑ When removing, sup‐
port using engine and gearbox jack -V.A.G 1383 A- .
❑ Drain fuel tank using fuel extractor -VAS 5190-
14 - Breather line
❑ Check for secure seating.
15 - Quick-release coupling
❑ Must audibly engage
16 - Activated charcoal filter
3. Fuel tank 167

Amarok 2011 ➤
17 - Slotted pan head screw

18 - Rear securing strap
19 - Hexagon bolt
20 - Protective cover
❑ For bottom of fuel tank.
❑ Depending on equipment.
21 - Securing nuts
❑ 20 Nm
22 - Double flange bolt
23 - Centre securing strap
24 - Heat shield for fuel filter
25 - Fuel filter with pressure regulator
26 - Return line
❑ Blue or with blue marking.
❑ Clipped onto fuel tank.
❑ To pull off flange, press release button on connecting piece.
27 - Supply line
❑ To fuel filter ⇒ page 167 .
❑ Clipped onto fuel tank.
❑ Black
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❑ To pull off flange, press gen AG button on
arelease connecting
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28 - Breather line sedb ran
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29 - Breather line
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Installation position of fuel gauge sender

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Arrow on sender flange -1- must align with mark on fuel tank
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Connections for blue or blue-marked return line and black supply

spec
line are marked with arrows on fuel gauge sender flange.

es, in part or in w
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Note
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After installing fuel gauge sender, check whether fuel supply and
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return lines are still clipped onto fuel tank.

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Amarok 2011 ➤
3.2 Removing and installing fuel tank

equipment required
♦ Union nut tool -3217-
1331-
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Fuel extractor -VAS 5190-
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Removing
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Note
Fuel tank must be drained. Use the fuel extractor -VAS 5190- to
ss o
do this.
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mer
– Note safety precautions before starting installation work

atio
m
⇒ page 160 .
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– Observe rules for cleanliness ⇒ page 160 .

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Before carrying out further work, disconnect battery earth strap.
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For this reason, first check whether a coded radio is fitted. Obtain
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anti-theft coding first if necessary.
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3. Fuel tank 169

Amarok 2011 ➤
– 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- .
– Disconnect supply line -3- and return line -2-.
Note
Press in buttons on hose couplings to do this.
– 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
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– Unscrew bolt -arrow- for rear securing strap -2- for fuel tank
-1-.
rrectness of i
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Amarok 2011 ➤
– 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-.
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Immediately seal all openings on fuel tank with clean cloths. s
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– Continue lowering fuel tank with engine and gearbox jack -
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.
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– Unclip fuel lines -2 and 3- from fuel delivery unit -1-.

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– Carefully lower fuel tank.

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Installing ht. rig
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Install in reverse order. In the process, note the following: by c lksw
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3. Fuel tank 171

Amarok 2011 ➤
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- .
– Push on breather line -3- and engage securely.

♦ Connections for breather and fuel lines must engage audibly
when joined.
♦ Clip fuel lines onto fuel tank.
♦ Push connector onto fuel pump flange and clip wire onto fuel
tank.
♦ Ensure that fuel hose connections are tight.
Vehicles with lower protective cover
– Bolt protective cover to bottom of fuel tank .
3.3 Removing and installing fuel delivery

unit
♦ Union nut tool -3217- AG. Volkswagen AG d
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Removing
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– Remove fuel tank ⇒ page 169 .

l purpos
– Unclip fuel lines -2 and 3- from fuel delivery unit -1-.

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Cop py
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Amarok 2011 ➤
– Unscrew union nut with union nut tool -3217- .

– Take fuel delivery unit out of the fuel tank.
Installing
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– Install fuel delivery unit so that mark on flange of fuel delivery
an
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unit -1- is aligned with mark on fuel tank -arrows-.
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3.4 Removing and installing fuel gauge

m
sender -G-
a
com
tion in
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Removing
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– Remove fuel delivery unit ⇒ page 172 .

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– Free lines -2- and unclip fuel gauge sender -G- to side
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– Remove fuel gauge sender -G- -1- in -direction of arrow-.

– Release connectors on fuel gauge sender -G- .
Installing
– Insert fuel gauge sender -G- into guides on fuel pump and
press downwards until it engages.
3. Fuel tank 173

Amarok 2011 ➤
3.5 Removing and installing filler neck

AG. Volkswagen AG d
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♦ Hose clip pliers -VAS 6362- Volksw not
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♦ Torque wrench -V.A.G 1410-
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Removing by c lksw
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– Unscrew bolt -2- for filler neck -1- on underbody.
– Open tank flap and clean inside tank flap unit thoroughly.
– Unscrew cap.
– Unscrew bolt -2- from tank flap unit.

– Unclip tank flap unit and remove completely.

Amarok 2011 ➤
– Unscrew nuts -2- from filler neck -1- at top of tank flap unit cut-
out.
– Remove filler neck -1- from below; filler neck must be turned
when doing this.
Installing
Install in reverse order.
– Thread filler neck -1- in through wheel housing and position at

top of tank flap unit cut-out with nuts -2-.
– Tighten nuts -2- to 5 Nm.
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– Tighten bolt -2- to 2 Nm.
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– Installing fuel tank:
wit
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spec
es, in part or in w
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mercia
– Push hose -1- of filler neck onto connection on fuel tank -3-.
at
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c
– Position clamp -2- at assembly markings -arrows- using hose

in t
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clip pliers -VAS 6362- .

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3. Fuel tank 175

Amarok 2011 ➤
– Push on breather line -3- and engage securely.

♦ Connections for breather and fuel lines must engage audibly
when joined.
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♦ Clip fuel lines onto fuel tank. agen oes
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♦ Push connector onto fuel pump flange and clip wire onto
orise fuel nte
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♦ Ensure that fuel hose connections are tight.
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3.6 Assembly overview - fuel filter with attachments
spec
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
nform
⇒ page 177 .
mer
atio
m
❑ Installation position: pin

o
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c
on filter housing must
i
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engage in notch of guide
te
sd
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in filter bracket
iv
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pr
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⇒ page 177 .
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2 - Retaining clip
Co
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❑ For fuel pressure regu‐ gh ht
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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.

AG. Volkswagen AG d
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4-cylinder injection engine (2.0 l direct d binjection engine, turbocharger) - Edition
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9 - 3 Nm ss au ra
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10 - Retainer
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❑ For fuel filter.
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❑ Secured to fuel tank.
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3.7 Removing and installing fuel filter
es, in part or in w
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rrectness of i
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Cop py
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♦ Container cop Vo
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Removing
AG.
Note
♦ Note safety precautions before starting installation work

⇒ page 160 .
♦ Observe rules for cleanliness.
– Place container under fuel filter.
WARNING
Fuel system is under pressure! Wear eye protection and pro‐

tective clothing to avoid eye injuries and skin contact. Before
loosening hose connections, wrap a cloth around the connec‐
tion. Then release pressure by carefully pulling hose off con‐
nection.
– 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
Direction of flow is indicated with an arrow on filter housing.
– Bleeding fuel system
3. Fuel tank 177

Amarok 2011 ➤
Installation position
Pin -2- on filter housing must engage in notch of guide -1- in filter
bracket.
Specified torque:
Component Nm
Retaining clamp for fuel filter 3
3.8 Removing and installing fuel pump con‐

trol unit -J538-
Note
The fuel pump control unit -J538- is installed on the fuel tank.
– Lower fuel tank until control unit is accessible.

AG. Volkswagen AG d
agen oes
– Detach connector from fuel pump control unit -J538-
Vol .
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– Loosen securing nuts. rise nte
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Installing: ss c
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– Installation is performed in the reverse sequence.
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Prote AG.

Amarok 2011 ➤
4 Electronic power control (EPC)

Assembly overview - accelerator module ⇒ page 179 .
Removing and installing accelerator module ⇒ page 179 .
wage
4.1 Assembly overview - accelerator module lks es n
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Assembly overview utho tee
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1 - Connector
pt
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2 - Securing nuts
erm
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ility
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❑ 10 Nm
wit
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3 - Accelerator with electronic
hole
module
spec
es, in part or in w
❑ The accelerator position
t to the co
sender passes the posi‐
tion of the accelerator
on to the engine control
rrectness of i
unit.
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4.2 Removing and installing accelerator

module
Removing
– Disconnect connector -1-.
– Unscrew nuts -2-.
– Remove accelerator module -3- towards the front.
4. Electronic power control (EPC) 179

Amarok 2011 ➤
AG. Volkswagen AG d
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Installing
Specified torque:
Component Nm
Accelerator module to body 10

Amarok 2011 ➤
5 Activated charcoal
agen
AG.filter system
Volkswagen AG
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1 - Breather line tho
ris eo
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❑ Check for ssecure
s seat‐ c
ing.
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2 - Activated charcoal filter
itte
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❑ Location: on fuel tank,
ility
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left.
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only with fuel tank re‐
spec
moved
es, in part or in w
t to the co
3 - Breather line
rrectness of i
ing.
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4 - Quick-release coupling
ing.
nform
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5 - Fuel line
at
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6 - Clip
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for
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7 - Activated charcoal filter sol‐

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op
enoid valve 1 -N80- C py
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❑ Valve closed with igni‐ yri
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tion switched off.
by c lksw
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❑ When engine is warm,
valve will be activated
(pulsed) by engine con‐
trol unit.
5.1 Checking fuel tank breather

♦ Hand vacuum pump -VAS 6213-
5. Activated charcoal filter system 181

AG. Volkswagen AG d
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Amarok 2011 r➤ ise
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4-cylinder ainjection
ut
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engine (2.0 l direct injection engine, turbocharger)
eo
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ss c
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♦ Adapter set -V.A.G 1318/17-
un
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Test prerequisite
form
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• Ignition must be switched off.
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• Fuel tank must be lowered.
i
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Test procedure
iv
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– Detach bleeder line ⇒ Item 3 (page 181) .
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To do this, press release button.
– Connect hand vacuum pump -VAS 6213- with adapter set -

V.A.G 1318/17- to breather line.
– Operate hand vacuum pump -VAS 6213- several times. Vac‐
uum must not build up.
If vacuum builds up:
– Check breather line ⇒ Item 1 (page 181) on activated charcoal
filter for soiling and clean if necessary.
If vacuum does not build up:
– Hold breather line ⇒ Item 1 (page 181) shut and operate vac‐
uum pump again several times. Vacuum must build up.
If vacuum does not build up:
– Renew activated charcoal filter.

Amarok 2011 ➤
wage es n
21 – Turbocharging/supercharging
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1 Charge air system ss
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1.1 Safety precautions
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WARNING
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tions:
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sitions.
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Note the following if testers and measuring instruments have to
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be used during a road test:
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♦ Test equipment must always be secured on the rear seat and . Cop py
operated by a 2nd person.
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If test and measuring instruments are operated from front pas‐
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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.
1.2 Rules for cleanliness

When working on the charge air system, pay careful attention to
the following rules for cleanliness:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes or similar).
♦ Existing transport and protective packaging and sealing caps
must only be removed immediately prior to installation.
♦ When making repairs, remove oil from connection and hose
ends.
♦ Do not use substances containing oil, silicone or grease when
assembling.
♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
1. Charge air system 183

Amarok 2011 ➤
1.3 Instructions for hose connections with

screw-type clips
Caution

operation.
Normal screw-type clips are used on the hose connections on the

„intake side“.
On the hose connections on the „delivery side“, there are screw-
type clips with „barbs“ -arrows-.
AG. Volkswagen AG d
agen oes
lksw not
Caution d by Vo gu
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• Do not loosen a these screw-type clips and pull back over
u t ra
s c
the delivery shose. Risk of damage to the hose!
ce
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nl
pt
du
• If a clip has been removed, it must be renewed together
an
itte
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with the hose.
erm
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ility
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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
Hose and clip are supplied together as one part.

l purpos
– Do not use substances containing oil, silicone or grease when

assembling. Only use clean water.
nf
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1.4 Assembly overview - charge air cooling

f
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– Observe rules for cleanliness ⇒ page 183 .
t. C rig
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Prote AG.
184 Rep. gr.21 - Turbocharging/supercharging

Amarok 2011 ➤
1 - Charge air cooler

⇒ page 186 .
Note
2 - Seal
3 - Hose clip
❑ Reinforced.
❑ 5.5 Nm
4 - Pressure hose
❑ To turbocharger.
❑ Must be free of oil and
grease before installing.
5 - Hose clip
❑ Reinforced.
❑ 5.5 Nm
6 - Hose clip
❑ Reinforced.
❑ 5.5 Nm
wage es n
7 - Pressure hose yV
olks ot g
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❑ 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
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erm
❑ Reinforced.
ab
ility
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❑ 5.5 Nm
wit
is n
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9 - Securing bolt
ole,
spec
10 - Pressure sensor
t to the co
11 - Bolt
12 - Rubber grommet
rrectne
13 - Pressure pipe
s
❑ Must be free of oil and grease before installing.

s o
cial p
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
❑ Must be free of oil and grease before installing.

p
cum
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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.

Amarok 2011 ➤
1.5 Removing and installing pressure pipe

Removing
– Detach connector from charge pressure sender -G31- .
– Release clip -3- from charge air hose -4-.
– Loosen bolt -1- of pressure pipe -2-.
– Unclip water hose from pressure pipe.
– Release lower clip ⇒ Item 8 (page 185) from socket to throttle
valve module -J338- .
– Remove pressure pipe.
Installing
1.6 Removing and installing charge pres‐

sure sender -G31-
Removing
olkswagen AG
en AG. V
– Disconnect electrical connector -4- from charge pressure olks
wag does
not
sender -G31- . ed
byV gu
ara
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– Unscrew bolts -2- and pull charge pressure sender a-G31-
ut
ho / eo
ra
-3- out of air duct -1-. ss c
ce
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nl
Installing
pt
du
an
itte
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erm
ab
note the following:
ility
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spec
es, in part or in w
t to the co
Note
Renew O-ring.
rrectness of i
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1.7 Removing and installing charge air cool‐

er
nf
ercia
orm
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om
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c

or
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Cop py
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Prote AG.

Amarok 2011 ➤
♦ Socket set 1/4", 22-piece -VAS 5528-
Removing
Engine guard .
– Undo and remove bolts -2- that fasten radiator to lock carrier
-1-.
– Remove lock carrier ⇒ General body repairs, exterior; Rep.
gr. 50 ; Lock carrier .
– Remove cowling ⇒ page 153 .
⇒ page 184 .
– Remove coolant hose -1- and pressure hose -2-.

– Remove right pressure hose
. Voleading toGturbocharger from
lkswagen A
gen AG
charge air cooler
olkand
swa place to one side.does no
t V gu
by ara
– Removeorair
ise duct mounting ⇒ page 154 .
d
nte
h eo
ut ra
Vehicles
ss with air conditioner
a c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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n in
or c
thi
te
sd
iva
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m
f
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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 ➤
– Squeeze left and right catches -2- together and detach con‐
denser -3- from radiator -1-.
Caution
– Support condenser, e.g. with cable ties.
Caution
• During further removal work, make sure that the refriger‐

ant lines are not bent or stretched excessively.
– Do not bend or stretch the refrigerant lines excessively. AG. Volkswagen AG d

agen oes
lksw not
Continuation for all vehicles d by
Vo gu
ara
ise nte
r
– Carefully remove radiator upwards together withut charge air
ho eo
ra
cooler. When doing so, take the radiator -2- past
ss the
a refrigerant c
lines.
ce
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nl
pt
du
an
itte
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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
Before installing radiator, check that radiator mountings -1- are

do
priv
correctly seated on front part of car -2- and, if necessary, reposi‐

um
for
en
tion:
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Insert radiator mounting into lock carrier -2- at bottom -1-, do‐
ing so transversely to the direction of travel, and then turn it
90".
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
itte
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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
mounting on radiator -2- appropriately.

iv
o
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rp
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f
en
ng
t.
⇒ page 184 .
yi Co
Cop py
t. rig
– Install cowling ⇒ page 154 .
gh ht
pyri by
Vo
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by c lksw
– Replenish coolant ⇒ page 133 . cted agen
Prote AG.
Only for vehicles with air conditioning

– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
50 ; Lock carrier .
Caution

operation.
Hose connections with screw-type clips ⇒ page 184 .
1.8 Checking charge air system for leaks


Amarok 2011 ➤
♦ Charge air system tester -V.A.G 1687-

. Volkswage n AG n AG d
wage oes
Volks not
gu
by ara
ed nte
oris eo
th
au ra
c
ss
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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.
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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.
Prepare charge air system tester -V.A.G 1687- as follows:

– Unscrew pressure control valve -2- completely, close valves
-3- and -4-.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.

Amarok 2011 ➤
– Connect charge air system tester -V.A.G 1687- to compressed

air -1- via commercial adapter.
Note
If there is water in inspection glass, drain via drain screw -6-.
– Open valve -3-.
Caution
Risk of damage because pressure is set too high.

♦ The pressure must not exceed 0.5 bar!
– Adjust pressure to 0.5 bar with pressure control valve -2-.

– Open valve -4- and wait until test circuit is full. If necessary,
readjust pressure to 0.5 bar.
– Check charge air system for leaks by hearing, touching, with
commercially available leak detector spray or using ultrasonic
tester -V.A.G 1842- .
lkswage es n
o ot g
byV ua
d ran
Note ir se tee
tho
u or
a ac
ss
♦ A small amount of air escapes through the valves and enters
ce
e
nl
the engine. Therefore a holding pressure test is not possible.
pt
du
an
itte
y li
♦ How to use the ultrasonic tester -V.A.G 1842- ⇒ operating
erm
ab
instructions
ility
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♦ Before removing the adapters, depressurise the test circuit by
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.
rrectness of i
l purpos
♦ In order to be able to securely attach the air ducts on their

connections, the screws of the used hose clips have to be
sprayed with penetrating spray before installing.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
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
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♦ 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
♦ Charge air system must be free of leaks.
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
are recommended for installation of spring-type clips.
spec
es, in part or in w
♦ Fill turbocharger with engine oil at oil supply line connection.
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
♦ Observe rules for cleanliness ⇒ page 183 .
nform
ercia
2.1 Assembly overview - turbocharger

m
a
com
Part I
tion in
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te o
Part II ⇒ page 194

thi
s
iva
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.

Amarok 2011 ➤
Part IV ⇒ page 196
1 - Turbocharger
❑ Can only be renewed to‐
gether with exhaust
manifold and vacuum
unit as one unit
⇒ page 197 .
2 - Hose
3 - Vacuum unit for turbocharg‐
er
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
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9 - Hose ut
ho eo
ra
s a c
10 - Turbocharger air recircu‐ s
ce
le
lation valve -N249-

un
pt
an
d
itte
❑ Note installation posi‐
y li
erm
ab
tion ⇒ page 193 .
ility
ot p
wit
11 - Bolt
is n
h re
ole,
❑ 7 Nm
spec
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
Installation location of turbocharger air recirculation valve -N249-

iva
o
pr
cum
r
– Note installation position -arrows-.

fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
2. Turbocharger 193
Amarok 2011 ➤
Part II
Part I ⇒ page 192
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
ce
le
un
⇒ page 197 .
pt
an
d
itte
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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
7 - Oil supply line

m
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8 - Bolt
ion in
r
❑ 9 Nm
te o
thi
s
iva
do
9 - Bolt
r
rp
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❑ 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.

Amarok 2011 ➤
20 - Oil return line

21 - Seal
❑ Renew.
Part III
Part I ⇒ page 192
1 - Seal
❑ Renew.
2 - Nut
❑ Renew.
⇒ 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
5 - Coolant return line

pe
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

gether with exhaust
manifold and vacuum
rrectness of i
unit as one unit

l purpos

⇒ page 197 .
nform
ercia
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 ➤
❑ 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
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
Part IV
Part I ⇒ page 192
nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
1 - Turbocharger
cum
for
en
g

n
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
Prote AG.
⇒ page 197 .
2 - Vacuum unit for turbocharg‐
er
⇒ 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

Amarok 2011 ➤
4-cylinder injection engine (2.0olkl sdirect
w
injection engine, turbocharger) - Edition 02.2011
AG. V agen AG
agen does
lksw not
Further specified torques d by Vo gu
ara
e nte
ris
Component tho Nm eo
au ra
c
ss
Right air duct to sump 10
ce
e
nl
pt
Air duct to bracket du 10
an
itte
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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

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
– Release clip -3-, unclip vacuum line -5- from guideway -2-.
– Unclip line -1- for air mass meter -G70- .
2. Turbocharger 197
Amarok 2011 ➤
– Detach intake hose -4- from turbocharger.

– Disconnect coolant hose from turbocharger.
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
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rp
cu
o
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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.

Amarok 2011 ➤
– Release hose clip -1- and detach pressure hose -3- from tur‐
bocharger -2-.

side. AG. Volkswagen A
agen G do
es n
ksw
y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– 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 ➤
– Remove nuts -arrows-.

– Remove turbocharger with exhaust manifold upwards.
Installing
note the following:
Note
♦ Renew seals, gaskets, O-rings and self-locking nuts.

♦ Fill turbocharger with engine oil at oil supply line connection.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
G. Volkswage
♦ Secure all hose connections with hose clips corresponding
lksw
agen
A
to n AG does n
the series equipment ⇒ Electronic parts y Vcatalogue .
o ot g
ua
db ran
rise tee
tho
– Install catalytic converter ⇒ page
s au 240 .
or
ac
s
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
2.3 Checking vacuum unit for turbocharger

nf
ercia

orm
m
atio
m

o
n in
or c
thi
te
sd
iva
o
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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.

Amarok 2011 ➤
Procedure:
– Connect hand vacuum pump -VAS 6213- to vacuum unit
-arrow-.
– Move slide ring -1- on hand vacuum pump -VAS 6213- to po‐
sition -B- for „pressure“.
Caution
The pressure must not exceed 750 mbar! If the pressure is

exceeded, the vacuum unit can be damaged.
– Operate hand vacuum pump -VAS 6213- repeatedly, observ‐

ing linkage.
The linkage -A- should start to move at a pressure of approx.
300 mbar and be at its limit stop at a pressure of approx.
700 mbar.
The stroke of the linkage is approx. 10 mm.
Note
If no pressure can be built up using the hand vacuum pump

AG -VAS
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6213- or the pressure drops immediately again, agen
ksw check the hand
does
ol not
vacuum pump -VAS 6213- and connecting d b hoses for leaks. If no
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fault is found: renew vacuum unit ⇒hopage
ris
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200 . nte
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Amarok 2011 ➤
AG. Volkswagen AG d
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24 – Mixture preparation - injection
oes
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Safety precautions and rules for c
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cleanliness
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General notes on self-diagnosis ⇒ page 202
ab
ility
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Releasing pressure in high-pressure area
wit
is n
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Safety precautions ⇒ page 160 .
spec
Rules for cleanliness ⇒ page 202 .
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
spring-type clips. The use of clamp or screw-type clips is not
atio
m
permissible.
o
n
c
i
or
♦ For trouble-free operation of electrical components, a voltage n thi

te
sd
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of at least 11.5 volts is necessary.

i
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pr
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♦ Do not use sealants containing silicone. Particles of silicone

en
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t.
yi
drawn into the engine will not be burnt in the engine and dam‐
Co
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age the Lambda probe.
t. rig
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pyri by
Vo
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♦ Vehicles are fitted with a crash fuel shut-off circuit. This is in‐
c by lksw
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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 .
202 Rep. gr.24 - Mixture preparation - injection

Amarok 2011 ➤
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
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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
Renew Teflon seal on injector ⇒ page 219
y li
erm
ab
Cleaning injectors ⇒ page 221
ility
ot p
wit
, is n
Removing and installing fuel pressure sender -G247-
h re
hole
⇒ page 222
spec
es, in part or in w
Removing and installing throttle valve module -J338-
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
ulating valve -N276- ⇒ page 225

Removing and installing high-pressure pump ⇒ page 226 .
nf
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orm
m
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n in
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2. Injection system 203

Amarok 2011 ➤
2.1 Overview of fitting locations
1 - Intake manifold pressure

sender -G71-
2 - Air mass meter -G70-
⇒ page 209 .
3 - Lambda probe -G39- and
Lambda probe heater -Z19-
4 - Vacuum pump
5 - High-pressure pump
⇒ page 226 .
6 - Engine speed sender -G28-
⇒ page 252 .
❑ 4.5 Nm
8 - Activated charcoal filter sol‐
enoid valve 1 -N80-
9 - Intake air temperature
sender -G42-
10 - Throttle valve module -
J338-
❑ Throttle valve drive an‐
gle sender -G187- and
throttle valve drive angle
sender 2 -G188-
❑ Each time after remov‐ AG. Volkswagen AG d
ing, installing or renew‐ agen oes
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ing throttle valve module d by V gu
ara
-J338- it must be re- oris e nte
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adapted to engine con‐ aut
h
ra
trol unit -J623- . s s c
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nl

pt
du
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11 - Wiring harness to engine control unit

erm
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12 - Charge air pressure sender -G31-

wit
, is n
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hole
spec
13 - Coolant temperature sender -G62-

es, in part or in w
t to the co

14 - Fuel pressure sender -G247-
rrectness of i

l purpos
15 - Oil pressure switch -F22-

16 - Knock sensor 1 -G61-
nform
ercia
17 - Intake manifold flap potentiometer -G336-

m
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io
18 - Ignition coils with final output stage

n
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or
❑ Pull all ignition coils out of cylinder head using puller -T40039- .
his
ate
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riv

p
cum
for
en
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19 - Inlet camshaft control valve 1 -N205-

n
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204
agen
Prote AG.
Rep. gr.24 - Mixture preparation - injection
Amarok 2011 ➤
20 - Turbocharger air recirculation valve -N249-

21 - Charge pressure control solenoid valve -N75-
22 - Lambda probe after catalytic converter -G130- and Lambda probe heater 1, after catalytic converter -Z29-
2.2 Assembly overview - air filter
1 - Air duct
❑ Check for secure en‐
gagement.
2 - Rubber bush
❑ Clipped into lower part
of air filter agen
AG. Volkswagen AG d
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3 - Air filter lower part d by gu
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4 - 8.5 Nm auth eo
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❑ Rubber bush clipped in‐ s
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nl
to lower part of air filter.
pt
du
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5 - Water drainage pipe
erm
ab
⇒ page 207
ility
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❑ Clipped onto lower part
, is n
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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
❑ Replacing air filter:

clean and replace filter
element ⇒ Mainte‐
nform
ercia
nance ; Booklet 11
m
at
❑ Replacing air filter: with

om
ion
saturation indication in
c
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or
Combi instrument
his
ate
⇒ Maintenance ; Book‐
do
priv
let 11
um
for
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7 - Air filter upper part
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8 - 2 Nm
ht
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9 - O-ring
cted agen
Prote AG.
10 - Intake manifold pressure sender -G71-
11 - 1.6 Nm
12 - Retainer
❑ For coolant hose mounting.
13 - O-ring
14 - Air mass meter -G70-

Amarok 2011 ➤
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
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too low or too high, the d by ara
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charge air hose may slip thor eo
off the charge air pipe s au ra
c
during vehicle operation. s
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17 - Intake hose
erm
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❑ It is essential that the marks on intake hose be in line with the webs on the turbocharger.
wit
, is n
❑ Clean oil from ends of hoses before installing.
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
The screw-type clips on

m
the charge air lines must
at
om
io
always be tightened to
n
c
in t
r
5.5 Nm. If the torque is

o
his
e
too low or too high, the

at
do
riv
charge air hose may slip

p
cum
or
off the charge air pipe

f
en
ng
t.
during vehicle operation.
yi Co
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19 - Vacuum hose
c by lksw
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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

Amarok 2011 ➤
Water drainage pipe on lower part of air filter

– Water drainage pipe -1- is clipped into lower part of air filter
-arrow-.
lkswage es n
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byV ua
2.3 Removing and installing air filter hous‐
d ran
ir se tee
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ing u or
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ss
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le

un
pt
an
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itte
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erm
ab
ility
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is n
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spec
t to the co
rrectness o
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f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
r
fo
en
ng
t.
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Cop py
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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-.

Amarok 2011 ➤
– Disconnect electrical connectors -1 and 3-.

– Loosen screw-type clip -4- and remove intake hose from air
mass meter -G70- .
Note
Item 2 can be disregarded.
– Unscrew securing bolt -2- for air filter housing -1- in area of
coolant expansion tank.
– Pull air filter out of mountings. n AG. Volkswagen AG do
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Installing byV
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Install in reverse order. In the process, note
uth the following:
o
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pt
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an
itte
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ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
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co lksw
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Prote AG.

Amarok 2011 ➤
2.4 Removing and installing air filter ele‐

ment
Removing
– Disconnect electrical connector from air mass meter G 70 and
intake manifold pressure sender G 71 -1 and 3-.
– Open hose clip on air duct -4- and remove from air mass meter.
– Detach vacuum hose.
Note
Item 2 can be disregarded.
– Unscrew all bolts from air filter upper part and remove upper
part.
– Remove air filter insert upwards.
Installing
Note
♦ Always use genuine part for air filter element.

♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
agen Do not use lubricants
AG. Volkswagen AG d
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containing silicone during installation.
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♦ Air filter housings musthobe
ris clean. tee
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au
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original equipment: ⇒ Parts catalogue .
ce
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un
pt
an
d
♦ To prevent malfunctions, cover all critical engine air ducting

itte
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erm
ab
components such as air mass meter, intake pipes, etc. with a

ility
clean cloth when blowing out the air filter housing with com‐
ot p
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pressed air.
is n
h re
ole,
♦ Observe environmental regulations for disposal.

spec
t to the co
– Check for salt residue, dirt and leaves in air mass meter and
intake hose (engine intake side).
rrectne
– Check air intake hose of air ducting for contamination.

– Further installation is carried out in the reverse order.
ss o
cial p
f in
2.5 Removing and installing air mass meter

form
mer
-G70-
atio
om
n
c

or
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t.
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Cop py
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pyri by
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by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
Removing
– Pull off connector -3- for air mass meter -G70- .
– Loosen screw-type clip -4- and remove intake hose from air
mass meter -G70- .
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
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rm
To ensure the proper function of the air mass meter -G70- , it is ab

pe
important to observe the following notes and instructions. ility

ot
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
♦ Always use genuine part for air filter element.

♦ Use a lubricant (silicon) to amount the air intake hose.
nform
mercia
a
com
– Check for salt residues, dirt and leaves in air mass meter -G70-
ion in
and air intake hose (pure air side).

r
te o
thi
s
iva
– Check intake channel for contamination as far as air filter el‐

do
r
rp
ement. If contamination is found, remove salt residues, dirt

um
fo
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.

Amarok 2011 ➤
2.6 Assembly overview - intake manifold

AG. Volkswagen AG d
agen oes
olksw not
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1 - Screw for intake air temper‐ ise d b ara
nte
ature sender -G42- ut
hor eo
a ra
❑ 9 Nm ss c
ce
e
nl
pt
2 - Intake air temperature
du
an
sender -G42- itte
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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
cle diagnostic tester.
t to the co
4 - Intake manifold
rrectness of i
⇒ page 213 .
l purpos
5 - Vacuum unit for air flow

control flaps (intake manifold
nform
ercia
flaps)
m
6 - Bolts for high-pressure
at
om
io
pump
n
c
in t
or
❑ 20 Nm
his
ate
do
riv
7 - Connection for fuel supply

p
cum
or
line
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ng
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❑ From fuel tank t. Cop py
rig
gh ht
yri
8 - Fuel pressure regulating p by
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by c
valve -N276-
lksw
cted agen
Prote AG.
❑ 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.
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

Amarok 2011 ➤
15 - Intake manifold support
16 - Bolt for intake manifold support
❑ 23 Nm
17 - Nut for intake manifold support
❑ 10 Nm
18 - Bolts for throttle valve module -J338-
❑ 10 Nm
19 - Throttle valve module -J338- , throttle valve drive for electric throttle operation -G186-
❑ Throttle valve drive angle sender 1 for electric throttle -G187- and throttle valve drive angle sender 2 for
electric throttle -G188-
❑ After removing, installing or renewing throttle valve module -J338- it must be re-adapted to engine control
unit -J623- . See „Guided functions“.
20 - Seal
❑ Renew. AG. Volkswagen AG d
agen oes
olksw not
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2.7 Assembly overview - fuel rail or eo
th
au ra
ss c
ce
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nl
pt
du
1 - Injector
an
itte
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❑ 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
⇒ page 217 .
rrectness of i
2 - Support ring
l purpos
3 - Fuel rail
nform
ercia
⇒ page 213 .
m
at
om
on
c
in t
or
❑ With fuel pressure regu‐

his
te
lating valve -N276- .

a
do
priv

um
for
en
g

n
t.
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pumps fuel to mechani‐ Cop py
t. rig
cal high-pressure pump. opyri
gh by
Vo
ht

c by lksw
cted agen
high-pressure pump, it Prote AG.
is essential to ensure
that no dirt enters the
fuel system.
❑ The fuel system must
not be under pressure
when installing the high-
pressure pump; proce‐
dure for reducing fuel
pressure ⇒ page 161
❑ Fuel lines must be free
of tension when instal‐
led.
⇒ page 226 .

. VolkswageAmarok 2011 ➤
gen AG n AG d
swa oes
4-cylinder injection engine (2.0 l direct injection engine,
y Volk turbocharger) - Edition n02.2011
ot g
ua
edb ran
ris tee
5 - Roller tappet autho
or
ac
ss
6 - Fuel pressure regulating valve -N276-
ce
le
un
pt
an
d
7 - Bolts for high-pressure pump
itte
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erm
ab
❑ 20 Nm
ility
ot p
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8 - Connection for fuel pressurisation line to fuel rail
is n
h re
ole,
❑ Renew.
spec
❑ 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

o
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
2.8 Removing and installing intake manifold

After fuel rail has been removed or renewed, intake manifold flap
potentiometer -G336- must be adapted to engine control unit -
J623- . Use vehicle diagnostic tester for this.

Amarok 2011 ➤
♦ Hose clip pliers -V.A.G 1921-
♦ Special wrench, long reach -T10347-
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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pt
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itte
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Removing
erm
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ility
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Note
h re
hole
spec
es, in part or in w
♦ The injectors can only be accessed after removal of the intake

t to the co
manifold and fuel rail.

♦ Combustion chamber ring seal (Teflon) and O-ring must al‐
rrectness of i
ways be renewed.
♦ Assembly overview - intake manifold ⇒ page 211 .
l purpos
♦ Assembly overview - fuel rail ⇒ page 212 .

nform
mercia
at
om
WARNING
ion
c
in t
or
his
e
Fuel system is under pressure! The fuel pressure in the high-

at
do
riv
pressure part of the injection system must be reduced to a

p
cum
or
residual pressure prior to opening; for procedure see

f
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 ➤
– Disconnect battery from negative terminal.

– Remove pressure pipe ⇒ page 184 .
– Remove throttle valve module ⇒ page 223 .
– Disconnect coolant hose ⇒ Item 19 (page 141) from intake
manifold.
– Disconnect coolant hose at front ⇒ Item 14 (page 141) and
rear from coolant pipe ⇒ Item 10 (page 141) .
– Unclip wiring harness for oil pressure switch -F1- from intake
manifold.
– Disconnect vacuum line -arrow- to activated charcoal filter.
– Unplug following electrical connectors.
1 - Activated charcoal filter solenoid valve 1 -N80-
2 - For knock sensor 1 -G61- AG. Volkswagen AG d
agen oes
lksw not
3 - From variable intake d bymanifold valve -N316- , fuel pressure
Vo gu
ara
sender -G247- andorHallise sender -G40- nte
h eo
ut ra
4 - From injectors
ss a c
ce
e
nl
5 - Throttle valve module -J338-
pt
du
an
itte
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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-.
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Cop py
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pyri by
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cted agen
Prote AG.

Amarok 2011 ➤
4-cylinder injection engine (2.0 l direct injection engine, gturbocharger)
en AG. V
olkswage-nEdition
AG d 02.2011
wa oes
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– Detach vacuum hose -1- at disconnection point -2-. ed
b ara
nte
ris
ho eo
– Remove crankcase breather hose -3-. au
t ra
c
ss
ce
le
un
pt
an
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itte
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erm
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ility
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ole,
spec
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
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t.
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Cop py
t. rig
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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.
– Loosen union nut of high-pressure fuel line -lower arrow- at

high-pressure pump.
Note
♦ Fuel system must be depressurised.

♦ Collect escaping fuel with a clean cloth.
♦ Seal open connections with clean caps. It is essential to en‐
sure that no dirt enters the fuel system.
– Disconnect connector from coolant temperature sender -

G62- .
– Unclip wiring harness from support.
– Loosen securing nut -1- and unscrew bolt -2- completely.

Amarok 2011 ➤
– 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
To unscrew inaccessible bolts without socket -T10347- , throttle

valve module -J338- has to be removed.
– Carefully pull intake manifold withgefuel

AGrail
. Volkslightly
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a n
cylinder head. Volksw es n
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Note au ra
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♦ Injectors can remain in fuel rail.
an
d
itte
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♦ Seal intake ports with a clean cloth.
erm
ab
ility
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wit
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– Disconnect intake manifold from fuel rail ⇒ page 213 .
h re
ole,
spec
Installing
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
mer
atio
• Specified torque: assembly overview - intake manifold
om
⇒ page 211 .
c
i
or
n thi
te
• Specified torque: assembly overview - fuel rail ⇒ page 212 .

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2.9 Removing and installing injectors
t. C rig
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Special tools and workshop equipment required Prote
cted AG.
agen
♦ Tool case with puller -T10133-
Note
Puller tool T10133/2 has been modified and is now designated

puller T10133/2 A . If new tool is not yet available, you can carry
out modification yourself.

Amarok 2011 ➤
Rework puller tool T10133/2 to make puller tool
olks
T10133/2
wage A. es n
ot g
byV ua
– File out a semicircle as illustrated. The ris recess allows the tool
ed ran
tee
to be pushed further onto the injectoruth so the contact surface is
o
or
increased. ss
a ac
ce
e
nl
– For identification purposes, mark the modified tool with the
pt
du
an
letter „A“ after the tool number.
itte
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spec
es, in part or in w
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rrectness of i
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♦ Round file approx. 6 mm

m
at
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ion
c
Removing
in t
or
his
ate
– Remove intake manifold and fuel rail ⇒ page 211 .
do
priv
cum
or
Remove injectors if these are still in fuel rail.

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t.
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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
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Injector (old version)
Prote AG.
1 - Combustion chamber ring seal (Teflon ring seal), renew; when

fitting, do not grease ring or use any other lubricant.
2 - The support ring must be replaced with an intermediate ring.
See next figure ⇒ page 218
3 - Injector
4 - Spacer (renew if damaged)
5 - O-ring (renew; to install, lightly lubricate with clean engine oil).
6 - Support ring (via this support ring, the fuel rail exerts force
which secures injector in cylinder head)
Injector (new version)

1 - Replace intermediate ring
2 - Support
3 - Combustion chamber ring seal (Teflon ring seal), renew; when
fitting, do not grease ring or use any other lubricant.
4 - Injector
5 - Spacer (renew if damaged)
6 - O-ring (renew; to install, lightly lubricate with clean engine oil).
7 - Support ring (via this support ring, the fuel rail exerts force
which secures injector in cylinder head)
– Cover open intake ports with a clean cloth.
– Detach electrical connector from injector that is to be removed.

Amarok 2011 ➤
– Insert puller -T10133/2A- into groove in injector.

– Then position removal tool -T10133/16- and pull injector out
by turning bolt -1-.
Note
The combustion chamber seal must always be renewed prior to

reinstallation of the injector ⇒ page 219 .
2.10 Renewing Teflon seal on injector
AG. Volkswagen AG d
Note agen oes
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The combustion chamber horiseal
s
must always be renewed prior to nte
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reinstallation of the injector ra
ss c
ce
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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
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that groove and continuous ridge in groove surface are not
wit
is n
damaged.
h re
ole,
spec
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
The figure shows an injector with an „angled connector“. This can

i
or
n thi
be ignored in the subsequent procedure since it is not important

te
sd
va
when renewing the combustion chamber ring seal.

i
o
pr
cum
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ng
t.
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– Place assembly cone -T10133/5- with a new Teflon ring -1- on
Co
op py
injector -2-. t. C rig
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pyri by
Vo
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cted agen
Prote AG.

lkswage es n
Amarok 2011 by➤
Vo ot g
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4-cylinderhor injection engine (2.0 l direct injection engine,
is tee turbocharger) - Edition 02.2011
ut or
a ac
ss
– Push Teflon ring with assembly sleeve -T10133/6- further on
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
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erm
ab
ility
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wit
Note
, is n
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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
calibration sleeve -T10133/7- .
nf
ercia
– Using a twist (approx. 180°) and slight pressure, slide calibra‐
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
Step 2 of calibration (adaptation) of Teflon ring is carried out with
thi
e
calibration sleeve -T10133/8- .

t
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pyri by
Vo
co lksw
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cted agen
Prote AG.
– Using a twist (approx. 180°) and slight pressure, slide calibra‐

tion sleeve -T10133/7- over injector until stop is reached. Turn
calibration sleeve -T10133/7- in opposite direction.
– Renew O-ring on injector. Before installing, lightly moisten O-
ring with clean engine oil.
– Teflon ring must not be oiled.
– Before installing injectors, thoroughly clean injector bores in

cylinder head with nylon brush provided. -T10133/4- .
Note
♦ The Teflon seal on the injector must not be oiled or greased.

♦ There must be no cleaning fluid or oil in the bores in the cyl‐
inder head when installing the injector.
– Push injector by hand as far as it will go into cylinder head bore

(free of oil and grease). Ensure injectors are positioned cor‐
rectly in cylinder head.

AG. Volkswagen AG d
agen oes
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2011 ➤
aut r a Amarok
s c
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pt
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itte
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Note
ility
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♦ 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
– Install analogously in reverse order.
nf
ercia
or
Important: It is essential to observe following points
m
m
atio
om
• Moisten O-rings of high-pressure injectors with clean engine
n in
or c
oil to aid insertion into fuel rail.
thi
te
sd
iva
• Renew all gaskets.
o
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rp
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m
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ng
• Fuel rail must be placed on injectors and evenly pressed in.

t.
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Cop py
• Install intake manifold with fuel rail ⇒ page 211 .
t. rig
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pyri by
Vo
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cted
2.11 Cleaning injectors
agen
Prote AG.

♦ Ultrasonic cleaner -VAS 6418-
♦ Mounting plate for injection modules -VAS 6418/1-
♦ Cleaning fluid -VAS 6418/2-
Cleaning
– Remove injectors ⇒ page 217 .
Note
Observe ultrasonic unit safety regulations and operating instruc‐

tions.
– Ultrasonic unit must be filled with cleaning fluid -VAS 6418/2- .
Note
Ultrasonic unit must be filled with cleaning agent up to upper edge

of holes (see expanded view).
– Insert injectors-1- into mounting plate for injection modules -

VAS 6418/1- as far as stop -2-.

Amarok 2011 ➤
– Dip injectors together with mounting plate for injection mod‐

ules -VAS 6418/1- into cleaning fluid.
– Set a temperature of 50 degrees with rotary knob -4-.
– Set rotary knob -5- to a cleaning time of 30 minutes.
– Press button -3- to switch ultrasonic unit on.
Note
As soon as the cleaning temperature is 50 degrees, the set time

will begin to elapse.
– Each time after cleaning injector, renew combustion chamber

ring seal (Teflon ring seal) ⇒ page 219 .
– Then reinstall injectors ⇒ page 217 .
2.12 Removing and installing fuel pressure

sender -G247-
If fuel pressure sender -G247- fails, fuel pressure regulating valve
-N276- is switched off, electric fuel pump is is fully actuated, and
engine is operated with available fuel pressure. Engine torque is
drastically reduced as a result.
AG. Volkswagen AG d
agen oes
♦ Assembly tool -T10118- olksw not
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ara
ed
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aut ra
ss c
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un
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itte
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ab
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ole,
spec
t to the co
♦ Double hexagon socket, 1/2, 27mm -VAS 5301/7- or commer‐

rrectne
cially available 27 mm socket

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

Amarok 2011 ➤
Removing
WARNING
The fuel system is pressurised! The fuel pressure in the high-

pressure part of the injection system must be reduced to a
residual pressure prior to opening; for procedure see
⇒ page 161 .
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
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rm
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
– Disengage connector from fuel pressure sender -G247- with
rrectness of i
assembly tool -T10118- .
l purpos
– Unscrew fuel pressure sender -G247- using double hexagon

socket, 1/2, 27mm -VAS 5301/7- .
nform
ercia
Installing
m
a
com
t
ion in
r
te o
– Check tightening torque of connection before installing fuel
thi
s
iva
pressure sender -G247- .
do
r
rp
cum
fo
• Specified tightening torque of connection: assembly overview
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.
2.13 Removing and installing throttle valve

module -J338-
Removing
– Open hose clip -arrow- of air duct and detach this downwards
from throttle valve module -J338- .
– Detach electrical connector -1- from throttle valve module -
J338- .

Amarok 2011 ➤
– Unscrew 4 bolts -arrows- of throttle valve module -J338- and

remove throttle valve module -J338- .
Installing
– Clean sealing surface for O-ring.
– Renew seal.
• Specified torques: assembly overviewen- Aintake
G. Volksmanifold
wagen AG
⇒ page 211 . olks
wag does
no
V t gu
by ara
– After renewing throttle valve
ris module -J338- it must be re-
ed nte
adapted to engine control
au
tho unit -J623- using vehicle diagnostic eo
ra
tester. ss c
ce
le
un
pt
an
d
2.14 Cleaning throttle valve module -J338-

itte
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
– Remove throttle valve module -J338- ⇒ page 223 .

– Open throttle valve by hand and lock it in open position using
nform
ercia
a suitable object (e.g. wood or plastic wedge) -arrow-.

m
a
com
tion in
WARNING
r
te o
thi
s
iva
do
Acetone is highly inflammable. Observe accident prevention

r
rp
cum
regulations and safety notes when handling highly inflammable

fo
en
g
fluids. Do not use compressed air when cleaning throttle valve.

n
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.
– Thoroughly clean throttle valve connection, especially around

closed throttle valve -arrows- using commercially available
acetone to DIN 53247 and a brush.
– Wipe out throttle valve housing with a lint-free cloth.
– Allow acetone to vent completely and reinstall cleaned throttle
valve module.
– Clear learned values and adapt engine control unit -J623- to
throttle valve module, using vehicle diagnostic tester.

Amarok 2011 ➤
2.15 Assembly overview - high-pressure

pump
WARNING
Fuel system is under high pressure! It is essential to reduce

fuel pressure before opening system. For procedure, please
see ⇒ page 161
1 - Roller tappet
❑ Can remain inserted in
vacuum pump after re‐
moval of high-pressure
pump
2 - O-ring
❑ Renew.
pumps fuel to mechani‐
cal high-pressure pump.
high-pressure pump, it
is essential to ensure
that no dirt enters the AG. Volkswagen AG d
fuel system. olksw
agen oes
not
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❑ 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
dure for reducing fuel

un
pt
an
d
pressure ⇒ page 161

itte
y li
rm
ab
❑ Fuel lines must be free
pe
ility
of tension when instal‐
ot
wit
, is n
led.
h re
hole

spec
⇒ page 226 .
es, in part or in w
t to the co
4 - Fuel pressure regulating
valve -N276-
rrectness of i
5 - Bore in vacuum pump for

high-pressure pump
l purpos
6 - Injectors
nform
ercia
❑ Renew O-ring and Tef‐

lon ring
m
a
com
ti
❑ Check installation location is correct

on in
r
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thi
s
iva
do

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rp
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fo
en
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8 - Inlet camshaft control valve 1 -N205-

n
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yi Co
Cop py
9 - Bolts for high-pressure pump ht. rig
rig ht
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❑ 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.

Amarok 2011 ➤
❑ Connection: 40 Nm
❑ Specified tightening torque for union nut of fuel pressurisation line: 27 Nm
❑ Fuel pressurisation line must not be under tension when installed (ensure cleanliness)
2.16 Removing and installing high-pressure

pump
WARNING
Fuel system is under high pressure! It is essential to reduce

fuel pressure before opening system. For procedure, please
see ⇒ page 161
Note
♦ Engine must be cold before high-pressure pump is removed.

♦ When installing the high-pressure pump, it is essential to en‐
sure that no dirt enters the fuel system.
♦ Collect escaping fuel with a cleaning cloth.
♦ O-ring must always be renewed.
♦ Always ensure that high-pressure fuel line is free of tension
when installed.
Removing
– Detach connector from fuel pressure regulating valve
AG. Volks-N276-
wagen AG
agen does
-1-. V olksw not
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ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Open fuel lines -arrows-.

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.

Amarok 2011 ➤
– Remove 2 bolts -arrows-.

– Carefully pull out high-pressure fuel pump. Sleeve can remain
inserted in vacuum pump.
Installing
– Renew high-pressure pump O-ring.
– Insert roller tappet in vacuum pump (first check roller tappet
for damage).
Note
♦ Roller tappet must be at bottom dead centre to enable high-

pressure pump to be installed.
♦ If same or a used high-pressure pump is installed, connection
for fuel pressurisation line (high-pressure side) must be re‐
newed. See assembly overview - high-pressure pump item 11
⇒ page 225
– Turn crankshaft until roller tappet is at bottom dead centre.

– Insert high-pressure pump into vacuum pump and tighten.
– Tighten bolts hand tight.
– Renew high-pressure pump connection.
• Specified torque: assembly overview - high-pressure pump
⇒ page 225 .
– Now tighten bolts in diagonal sequence to specified torque,
see assembly overview - high-pressure pump ⇒ page 225 .
– Tighten union nut of high-pressure line hand-tight. Align free
of tension.
AG. Volkswagen
• Specified torque for fuel wapressurisation
gen line (union
AG do
es n nut): as‐
olks
sembly overviewd b-yintake manifold ⇒ page 213 . ot gua
V
e ran
ris tee
tho or
– Reattach sconnector
au to fuel pressure regulating valve -N276- ac
-1-. s
ce
e
nl
pt
du
– Put back fuse if it has been removed.

an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
spec
Check fuel system for leaks.

es, in part or in w
t to the co
rrectness of i
l purpos
2.17 Removing and installing engine control

unit
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.

Amarok 2011 ➤
AG. Volkswagen AG d
Removing lksw
agen oes
not
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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

nl
pt
du
an
itte
y li
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .
erm
ab
ility
ot p
– Remove shear bolts -1- and remove bow -4-.
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
rrectness of i
– Insert engine control unit.
l purpos
– Insert and lock connectors -2- and -3-.
nform
mercia
at
om
ion
c
in t
or
his
te
– Fit bow -4- and new shear bolts -1-.

a
do
priv
cum
or
– Connect battery ⇒ Electrical system; Rep. gr. 27 .

f
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.

Amarok 2011 ➤
3 Checking components
3.1 Check fuel holding pressure upstream

of high-pressure pump
♦ K-Jetronic pressure tester -V.A.G 1318-
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
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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
• Fuel filter OK.

• Fuel tank at least 1/4 full.
nform
ercia
• Fuel pump control unit -J538- OK.

m
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.
♦ A clean cloth must then be wrapped around the connec‐

tion and the residual pressure dissipated by carefully loos‐
ening the connection.
– Release clip -2- and detach fuel line -3- from high-pressure
pump -1-.
3. Checking components 229

Amarok 2011 ➤
– Connect double connection -V.A.G 1318/23- and adapter AG. Volkswagen AG d

adapter set -V.A.G 1318/17A- to K-Jetronic pressure tester - lkswagen oes
not
V.A.G 1318- . db
yV
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e ran
ris tee
– Attach adapter adapter set -V.A.G 1318/17A- to detachedtho fuel or
pressurisation line. s au ac
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nl
– Screw adapter -V.A.G 1318/11- to K-Jetronic pressure tester
pt
du
an
-V.A.G 1318- .
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– Attach auxiliary hose -arrow- to pressure tester and hold it in
ility
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collecting container.
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– Close pressure tester shut-off valve.
nl
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• Lever is at right angle to direction of flow -arrow-.
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– Connect vehicle diagnosis tester.
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– Select „Engine electronics“ in the self-diagnosis program.
hole
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– 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
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Note
This function actuates fuel pump.
nf
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– Read off fuel pressure at K-Jetronic pressure tester -V.A.G
om
1318- .
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• Specification: 5 to 8 bar
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– Stop procedure once fuel pressure no longer rises at K-Jet‐
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ronic pressure tester -V.A.G 1318- .

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– Checking fuel pump delivery rate ⇒ Rep. gr. 20
by lksw
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Checking holding pressure
– Check for leaks and check holding pressure by observing
pressure drop at K-Jetronic pressure tester -V.A.G 1318- .
• After 10 minutes, there must be a residual pressure of at least
3 bar.
If the holding pressure drops below 3 bar:
♦ Check threaded connection between pressure gauge and fuel
line for leaks.
♦ Check pressure gauge for leaks.
♦ Check fuel lines and their connections for leaks.
♦ Checking fuel pump delivery rate ⇒ Rep. gr. 20
♦ Renew fuel filter with integrated fuel pressure regulator ⇒ Rep.
gr. 20 .
♦ Fuel pump non-return valve is defective ⇒ Rep. gr. 20 .
Assembly is carried out in the reverse order. When installing, note
the following:
Note
Fuel pressure must be reduced by opening shut-off valve before

removing pressure tester. Hold collecting container at connection
as you do so.

Amarok 2011 ➤
– Reconnect fuel pressurisation line -3- to high-pressure pump

-1- and attach clip -2- (ensure cleanliness).
Note
lkswage es n
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Check fuel system for leaks. d byV ua
ran
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pt
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3.2 Checking intake manifold change-over
h re
hole
spec
Perform check only if there is a loss of torque. This means when
es, in part or in w
there is a lack of elasticity or a lack of pulling power.
t to the co
rrectness of i
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nform
mercia
at
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ion
c
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ate
do
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Test prerequisite cted agen
Prote AG.
♦ Variable intake manifold valve -N316- has been checked with

a vehicle diagnostic tester .
If the intake manifold flap valve -N316- is OK, perform the follow‐
ing tests:
– Start engine and run at idling speed.
– Have second person abruptly increase engine speed (throttle
burst). Observe intake manifold changeover vacuum actuator.
• Actuator must move -arrow-.
If changeover does not operate as indicated:
– Check vacuum system for leaks.
– Check changeover mechanism for ease of movement . To do
this, operate rods by hand.
– Check that vacuum lines are correctly connected.
– Check vacuum hoses for porosity.

Amarok 2011 ➤
– Remove vacuum hose -1- leading to actuator for intake mani‐

fold valve flap -N316- from intake manifold flap valve -N316-
-2-.
sition -A- for "vacuum".
– Connect hand vacuum pump -VAS 6213- to actuator for intake

manifold flap valve -N316- .
– Operate hand vacuum pump -VAS 6213- several times.
Vacuum actuator -arrows- must move.
. Volkswag
– If vacuum actuatorkdoes
swa not move, renewdit.
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es, in part or in w
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rrectness of i
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AG. Volkswagen
Amarok 2011 ➤ ksw
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Vol ot g
4-cylinder injection
d b engine (2.0 l direct injection engine,
y ua
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e nte
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3.3 Checking
ss fuel pressure sender -G247-
au ra
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nl
pt
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equipment required
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♦ Deep hexagon socket,
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
♦ Test adapter -VAS 5570-

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♦ Vehicle diagnosis tester
om
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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.

agen
AG. Volkswagen AG d
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4-cylinder injectionbyengine
Vol
(2.0 l direct injection engine,gu turbocharger)
ara
- Edition 02.2011
d
rise nte
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– Unscrew plug -2- andauscrew
th
fuel pressure sender -G247- into ra
tester -VAS 6394/1-s . Specified torque 27 Nm.
s c
ce
le
un
pt
– Connect pressure line of tester -VAS 6394/1- to adapter -VAS
an
d
itte
6394/2- .
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pe
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es, in part or in w
t to the co
rrectness of i
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– Connect fuel pressure sender and electrical connector of fuel

pressure sender using test instrument adapter -VAS 5570- .
nform
mercia
a
com
tion in
r
te o
thi
s
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AG. Volkswagen AG d
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Amarok 2011 by V➤
ol
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4-cylinder
orise injection engine (2.0 l direct injection engine,
nte
eo
turbocharger) - Edition 02.2011
th
au ra
ss tester -VAS 6394/1- by briefly pressing the -A- but‐ c
– Switch on
ce
le
ton once.
un
pt
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ab
pe
ility
Note
ot
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♦ 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
– Switch ignition on.
nform
ercia
– Press following buttons on display of diagnostic tester one af‐

m
ter the other:
a
com
tion in
r
Vehicle self-diagnosis
te o
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Self-diagnosis ►
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01 - Engine electronics ►
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– Select measured value block 1 4 0 and acknowledge with
co Vo
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The actual fuel pressure value is shown in display zone 3, meas‐

ured by the fuel pressure sender -G247- .
– Start engine.
– Compare pressure on tester -VAS 6394/1- with actual value
displayed on vehicle diagnostic tester .
• A maximum pressure deviation of 5 bar is permissible.
– If deviation is greater than 5 bar, renew fuel pressure sender
-G247- .
WARNING
Tester -VAS 6394- is under high fuel pressure! With engine

running, detach connector from fuel pressure sender -G247- .
This reduces fuel pressure to approx. 6 bar. Switch off ignition.
Place a cleaning cloth around fuel pressure sender -G247- ,
then reduce residual pressure by carefully loosening fuel pres‐
sure sender -G247- .
– 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 .
3.4 Checking double non-return valve


Amarok 2011 ➤
. Volkswagen AG
♦ Hand vacuum lkpumpgen AG
swa -VAS 6213- does
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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
• Activated charcoal filter solenoid valve 1 -N80- has been

checked with vehicle diagnostic tester and is OK.
nform
ercia
– Detach connector -1- and breather hose -3- from activated

m
at
charcoal filter solenoid valve 1 -N80- -2-.
om
ion
c
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or
his
ate
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cted agen
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sition -A- for "vacuum".

Amarok 2011 ➤
– Connect hand vacuum pump -VAS 6213- to activated charcoal

filter solenoid valve 1 -N80- .
– Connect contacts of solenoid valve to battery using auxiliary
leads -1-. This opens the activated charcoal filter system sol‐
enoid valve 1 -N80- .
Then operate hand vacuum pump -VAS 6213- several times.
• Vacuum must build up.
AG. Volkswagen AG d
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– Disconnect battery again
Vol (cut power).
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If ise up:
vacuum does nothbuild
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– Renew double
ss non-return valve -1-. c
ce
le
un
Double non-return valve, activated charcoal filter solenoid valve
pt
an
d
itte
1 -N80- and plastic hoses form a single component. To replace
y li
rm
ab
it, the intake manifold must be removed.
pe
ility
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wit
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es, in part or in w
t to the co
rrectness of i
l purpos
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Amarok 2011 ➤
AG. Volkswagen AG d
agen
26 – Exhaust system
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1 Assembly overview - parts of the exhaust system
s a c
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1 - Seal
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❑ Renew.
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2 - Catalytic converter
ole,
spec
❑ Protect catalytic con‐
verter from damage by
t to the co
knocks and impact
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
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sd
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5 - Nut
i
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❑ 40 Nm
en
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❑ Renew. Cop py
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❑ Coat studs of turbo‐
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charger with high-tem‐ by c lksw
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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
❑ 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 .
❑ Tighten bolted connections evenly.
10 - Bolt
❑ 20 Nm
11 - Retainer
12 - Front clamp
❑ Align exhaust system free of tension before tightening ⇒ page 243 .
1. Assembly overview - parts of the exhaust system 239

Amarok 2011 ➤
AG. Volkswagen AG d
4-cylinder injection engine agen l direct injection
w(2.0 engine,
oes turbocharger) - Edition 02.2011
olks no t gu
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❑ Tighten bolted connections
rise evenly. nte
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Installation position of front clamp un
pt
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– Install clamp in illustrated angle position.
rm
ab
pe
ility
• Bolt connections point to the right.
ot
wit
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• Nuts point upwards.
hole
spec
es, in part or in w
• α = approx. 20°
t to the co
rrectness of i
l purpos
nform
ercia
Installation position of rear clamp

m
– Install clamp so that ends of bolts do not protrude beyond bot‐
a
com
tio
tom of clamp.
n in
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te o
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• Bolt connections point downwards.
s
iva
do
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t.
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Cop py
t. rig
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co lksw
by
cted agen
Prote AG.
1.1 Removing and installing catalytic con‐

verter
Removing
– Detach connector for Lambda probe 1 heater, downstream of
catalytic converter -Z29- -arrow- and lay leads to one side.
– Detach connector -1- for Lambda probe downstream of cata‐

lytic converter -G130- from bracket -2- and lay leads to one
side.
Engine guard .
240 Rep. gr.26 - Exhaust system

Amarok 2011 ➤
– Unscrew securing bolts -1- for catalytic converter -2-.
AG. Volkswagen AG d
agen oes
olksw not
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– Unscrew bolts -2- from
ut
ho bracket -1-. eo
ra
s a c
s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
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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
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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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by c lksw
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Prote AG.
– Unscrew nuts -arrows- and remove catalytic converter up‐
wards.
Installing
note the following:
Note
Renew seals, gaskets and self-locking nuts.
1.2 Removing and installing exhaust mani‐

fold
Exhaust manifold and turbocharger are one component; remov‐
ing and installing ⇒ page 197 .

Amarok 2011 ➤
1.3 Removing and installing centre silencer

AG. Volkswagen AG d
Procedure agen oes
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♦ Engine and gearbox jack -V.A.G 1383ss A-
a c
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
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rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Release double clip -2- to rear silencer; to do so, loosen se‐

curing nuts -1-.
– Release clip -2- to catalytic converter.
– Remove centre silencer downwards.

Installing

Amarok 2011 ➤
– 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 .
1.4 Removing and installing rear silencer

Removing
– Release double clip -2- to rear silencer; to do so, loosen se‐
curing nuts -1-.
AG. Volkswagen AG d
agen oes
olksw not
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aut ra
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un
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an
d
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erm
ab
ility
ot p
wit
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ole,
– Detach rubber connector -2- in -direction of arrow- from brack‐

spec
et -1-.
– Remove rear silencer downwards. t to the co
Installing
rrectne

s

s o
cial p
f in
– Aligning exhaust system ⇒ page 243 .

form
mer
atio
om
n
c
i
or
n thi
te
sd
va
1.5 Checking exhaust system for leaks

i
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.
1.6 Aligning exhaust system free of stress


Amarok 2011 ➤
♦ Torque wrench (5…50 Nm) -V.A.G 1331-
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
lencer -1- in such a way that dimension -a- is 8 mm.

or
thi
te
sd
a
– Tighten double clamp bolts -3- to 31 Nm.

iv
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.

Amarok 2011 ➤
AG. Volkswagen AG d
1.7 Installation position and specified torque Vol
ksw
agen oes
not
of the clamp by gu
ara
ed nte
ris
tho eo
s au ra
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s
Note
ce
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nl
pt
du
an
itte
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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
Specified torque: 35 Nm.

Installation dimensions -a- 8.5 mm (only for front clamp)
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
Installation dimension -a- for vehicles with marking on front ex‐
o
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haust pipe
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en
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t.
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1 - Clamp Cop py
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gh ht
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2 - Front exhaust pipe p by
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a - Installation dimension Prote AG.
A - Marking
Installation position of front clamp

– Install clamp so that end of bolt -arrow- does not extend be‐
yond lower edge of clamp.
• Threaded connection faces right

Amarok 2011 ➤
Installation position of rear clamp

– Install clamp so that end of bolt -arrow- does not extend be‐
yond lower edge of clamp.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
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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.

Amarok 2011 ➤
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 .
1.1 General notes on ignition system

♦ The battery must be disconnected only with ignition switched
off. If a coded radio is installed, ascertain code before discon‐
necting battery.
♦ Observe required procedures after connecting battery ⇒ Elec‐
trical system; Rep. gr. 27 ; Disconnecting and reconnecting
battery.
♦ For trouble-free operation of electrical components,gean voltage
AG. Volkswagen AG d
of at least 11.5 V is necessary. Volksw
a oes
not
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♦ After completing work, read fault memory ris of engine control
e nte
tho been created during
unit, clear all fault entries which mayahave eo
u ra
checks and repairs. If the fault memory
ss was cleared, the read‐ c
iness code must be generated ⇒ vehicle diagnosis tester
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
may be that the immobilizer is blocking the engine control unit.
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
♦ Switch off ignition before connecting or disconnecting injection

orm
and ignition system wiring as well as test instrument cables.

m
atio
om
n in
♦ If the engine has to be turned over at starting speed without it

or c
starting (e.g. compression test), first unplug the connectors

thi
te
sd
a
from the ignition coils and the injectors. Read and clear fault
iv
o
r
rp
cu
memory after completion of work.

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m
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t.
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♦ Always switch off ignition before cleaning engine.
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♦ Disconnecting and connecting the battery must only be done
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with the ignition switched off, otherwise the engine control unit
o Vo
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cted
could be damaged.
agen
Prote AG.
Note the following if testers and measuring instruments have to

be used during a road test:
♦ Test and measuring instruments must always be secured to
the rear seat and operated by a second person from this lo‐
cation.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
1. Repairing ignition system 247

Amarok 2011 ➤
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
1.3 Assembly overview - ignition system

1 - Knock sensor 1 -G61- olkswage es n
ot g
yV
❑ On front of cylinder d b head ua
ran
ir se
under intake ho manifold
tee
aut or
ac
❑ Removing ss and installing
⇒ page 252 .
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,
the knock sensor.
spec
t to the co
3 - Ignition coil with output
stage -(N70, N127, N291,
N292)-
rrectne
⇒ page 248 .
ss
4 - Spark plug, 25 Nm
o
cial p
f in
❑ If a spark plug is re‐
form
mer
placed, regrease igni‐

tion coil with final output atio
om
stage ⇒ page 249

n
c
i
or
n thi
e
❑ Type and electrode gap

t
sd
va
⇒ page 253 .
i
o
pr
cum
r
fo
❑ Remove and install with

en
ng
t.
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spark plug socket and
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extension -3122 B- . t. C rig
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5 - O-ring
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❑ Renew.
AG.
6 - Engine speed sender -G28-

❑ At lower left of front cyl‐
inder block, next to
coarse oil separator
⇒ page 118
⇒ page 252 .
7 - 10 Nm
❑ In cylinder head cover at front.
❑ Gold-plated contacts.
1.4 Removing and installing ignition coils

with output stage
248 Rep. gr.28 - Ignition system

Amarok 2011 ➤
♦ Puller -T40039-
AG. Volkswagen AG d
♦ Lubricating paste -G 052 141 A2- olksw
agen oes
not
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b
Removing rise
d ara
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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
– Pull all ignition coils approx. 30 mm out of spark plug recess

using puller -T40039- .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
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cted agen
Prote AG.
– Release connectors and simultaneously detach all connectors

from ignition coils -arrows-.
Installing
Note
♦ When fitting new spark plugs, the ignition coil must be re‐
greased using lubricating paste -G 052 141 A2- This will stop
the ignition coil sealing hose from »sticking« to the spark plug.
The lubricating paste must be distributed on the spark plug
when inserting on the ignition coil.
♦ New ignition coils with output stage are lubricated when de‐
livered.

Amarok 2011 ➤
– Apply a thin line of lubricating paste -G 052 141 A2- around

the ignition coil sealing hose -arrow-. The bead must be 1…2
mm thick.
– Insert all spark plugs loosely into spark plug recess.
– Align ignition coils with connectors -arrows- and push all con‐
nectors simultaneously onto ignition coils.
– Evenly push ignition coils onto spark plugs by hand.
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
Observe disposal regulations.

ot
wit
, is n
h re

hole
spec
es, in part or in w
♦ Torque wrench -V.A.G 1331/-

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
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co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
♦ Spark plug socket and extension -VAS 3122B-
♦ Puller -T40039-
AG. Volkswagen AG d
agen oes
olksw not
V gu
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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

r
te o

thi
s
iva
do
– Remove ignition coil with final output stage

r
rp
cum
fo
en
g
– Unscrew spark plugs with spark plug spanner -VAS 3122B- .

n
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.

Amarok 2011 ➤
– Align ignition coil plus final output stages with connectors

-arrows- and push on simultaneously.
wage
e ks s no
Vol t gu
d by ara
e nte
ris
Note tho eo
au ra
c
ss
Do not strike with a hammer or similar tool.
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
– Detach connector -2- from knock sensor I -G61- .
nform
ercia
– Remove coolant pump ⇒ page 149 .

m
at
om
ion
c
Note
in t
or
his
ate
do
riv
The knock sensor I -G61- is located under the intake manifold

p
cum
or
behind the coolant pump.

f
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.
1.7 Removing and installing engine speed

sender -G28-
♦ Hexagon key extension, 4 mm -T10370-

Amarok 2011 ➤
Removing
– Detach connector -2- from engine speed sender -G28- at right
below coarse oil separator -1-.
Note
To release electrical connector without assembly tool -T10118- ,

press connector on engine speed sender -G28- in with a screw‐
driver and at the same time raise release tab with a thin wire hook.
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
, is n
h re
hole
• Specified tightening torque of fastening bolt for engine speed
spec
sender -G28- 5 Nm.
es, in part or in w
t to the co
rrectness of i
l purpos
1.8 Test data, spark plugs

nform
mercia
Engine codes CFPA

a
com
tion in
Firing order 1-3-4-2

r
te o
thi
Spark plugs
s
iva
do
r
rp
VW/Audi 06H 905 601 A

um
fo
en
ng
t.
Electrode gap 1.0…1.1 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.

Amarok 2011

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Service

4-cylinder injection engine (2.0 l direct injection

Service Department. Technical Information

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Copyright © 2011 Volkswagen AG, Wolfsburg D3E8037FAC2

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.2 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.2 Allocation of crankshaft bearing shells (classification) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.4 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.6 Pulling needle bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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

1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1.3 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

1.4 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2.10 Renewing balancer shaft for inlet camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

1.2 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

3 Parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 spec

3.4 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 145

3.7 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

3.8 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

4 Parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

4.1 Assembly overview - parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . 152

4.2 Assembly overview - air ducting with radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

4.3 Removing and installing cowling with radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

1.1 General notes on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

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

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

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

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

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

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

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

3.1 Check fuel holding pressure upstream of high-pressure pump . . . . . . . . . . . . . . . . . . . . . . 229

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

1.6 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

1.7 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

1.1 Engine number

1.2 Engine data

Torque Nm at rpm 300 Nm at 1600

Capacity cm3 1984 cm3

Valves per cylinder 4

Fuel according to DIN EN 228

Firing order 1-3-4-2

Catalytic converter yes

Exhaust gas recirculation yes

Charge air cooler yes

Camshaft timing control yes

2 Rep. gr.00 - Technical data

10 – Removing and installing engine

1.1 Removing engine

Special tools and workshop

1. Removing and installing engine 3

♦ Torque wrench -V.A.G

4 Rep. gr.10 - Removing and installing engine

♦ Drip tray for workshop hoist

♦ Before carrying out further work, remove the battery. Check

whether a coded radio is fitted. Obtain anti-theft coding be‐

♦ The engine is removed upwards.

♦ The gearbox remains installed.

is removed must be renewed/replaced in the same position