Amarok 2.0 Biturbo

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
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15 - Cylinder head, valve gear ir se
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19 - Cooling
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23 - Mixture preparation - injection
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26 - Exhaust system
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28 - Glow plug system
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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 © 2013 Volkswagen AG, Wolfsburg D4B80260554

Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Safety precautions when working on injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Safety precautions when working on charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Safety precautions during road tests in which testing and measuring equipment is used . . 6
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 General notes on the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 General notes on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Rules for cleanliness when working on fuel supply system/injection system . . . . . . . . . . . . 8
3.4 Rules for cleanliness when working on charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Instructions for working on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6 To avoid any risk of injuries to persons and/or the destruction of the injection and glow plug
system, the following must be noted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.7 Instructions for hose connections with screw-type clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Securing engine on engine and gearbox support VAS 6095 . . . . . . . . . . . . . . . . . . . . . . 26
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.1 Removing and installing assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
13 - Crankshaft group
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1.2ss a Assembly overview - sealing flange, belt pulleyacend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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1.4 Assembly overview - poly V-belt drive, vehicles without A/C system . . . . . . . . . . . . . . . . . . 39
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1.5 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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1.6 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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1.7 Removing and installing ancillary bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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1.8 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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1.9 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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1.10 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2 Ancillary drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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2.1 Assembly overview - ancillary drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.2 Retrofitting preparation for ancillary drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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3 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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3.2 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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3.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

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4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

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4.2 Checking piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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4.4 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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4.5 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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Contents i
Amarok 2011 ➤
4.6 Bearing shells - installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4.7 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.4 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.5 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.2 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.4 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.5 Removing and installing injector seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.6 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.7 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.1 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3 Fresh air supply system, belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.1 Assembly overview - fresh air supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.2 Removing and installing blower for fresh air supply system . . . . . . . . . . . . . . . . . . . . . . . . 117
3.3 Removing and installing air filter housing for fresh air supply system . . . . . . . . . . . . . . . . 117
3.4 Removing and installing bracket for fresh air supply system . . . . . . . . . . . . . . . . . . . . . . . . 118
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.1 Assembly overview - valve gear . . . . a.g.e.n A .G. .. V.o.lk.s.w.ag. e.n.A.G. d.o. . . . . . . . . . . . . . . . . . . . . . . . . 119
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4.3 Measuring radial clearanceorof ise camshafts . . . . . . . . . . . . . . . . . . . . a.n.te. . . . . . . . . . . . . . . .
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4.4 Removing and installing acamshafts
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camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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4.6 Checking hydraulic compensation element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

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4.7 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

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5.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

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5.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

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5.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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1.1 Assembly overview - sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

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1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
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1.4 Removing and installing oil pump, vehicles with balancer shaft module . . . . . . . . . . . . . . 146
1.5 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
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1.6 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 147
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1.7 Removing and installing dipstick tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

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2 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

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2.1 Assembly overview - oil filter housing with engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . 150
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2.2 Removing and installing oil filter housing with engine oil cooler . . . . . . . . . . . . . . . . . . . . . . 151
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2.3 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.4 Checking oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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2.5 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
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2.6 Measure oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
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Amarok 2011 ➤
3 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

3.1 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4 Balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4.1 Assembly overview - balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4.2 Removing balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.3 Installing a new balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.4 Installing a previously used balancer shaft module again . . . . . . . . . . . . . . . . . . . . . . . . . . 168
5 Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.1 Removing and installing oil supply line to turbocharger, 120 kW and 132 kW engines . . . . 170
5.2 Removing and installing oil pressure line to turbocharger - 90 kW and 103 kW engine . . 172
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.1 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.2 Assembly overview - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.4 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.1 Assembly overview - coolant pump/ball thermostat (4/2-way valve) . . . . . . . . . . . . . . . . . . 187
2.2 Assembly overview - Continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . . . . . 188
2.3 Assembly overview - circulation pump V55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2.4 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.5 Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
2.6 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 196
2.7 Removing and installing coolant temperature sender at radiator outlet G83 . . . . . . . . . . 197
2.8 Removing and installing continued coolant . Vocirculation
lkswagen AG pump V51 . . . . . . . . . . . . . . . . . . 198
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2.9 Removing and installing Y-thermostat
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2.10 Removing and installingiserecirculation
db pump V55 . . . . . . . . .ua. r.an. . . . . . . . . . . . . . . . . . . . . 200
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3 Radiator, radiator fan ho
aut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a. . . . . . . . . . . . . . . . . . 202
3.1 Assembly overview ss - radiator/ radiator fan V7 . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . 202
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3.2 Assembly overview - radiator cowl and radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . 204

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3.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

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3.4 Removing and installing radiator cowl with radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . 207
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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

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1 Procedure when filling with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

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1.1 Procedure when filling with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

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1.2 Engine is not running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

1.3 Engine is running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
rrectness of i
2 Checking low-pressure fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

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2.1 Checking fuel low-pressure at high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

2.2 Checking flow rate at high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
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2.3 Checking fuel low-pressure ahead of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

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2.4 Checking flow rate ahead of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

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3 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

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3.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

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3.2 Assembly overview - fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

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3.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

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3.4 Removing and installing filler neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Co
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4 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
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4.1 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by c 236
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4.2 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
AG.
5 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

5.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Contents iii
Amarok 2011 ➤
5.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

5.3 Checking fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
6 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
6.1 Checking fuel delivery rate of fuel pump (fuel low pressure) . . . . . . . . . . . . . . . . . . . . . . . . 242
6.2 Checking voltage supply of fuel pump (fuel low pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . 245
7 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
7.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
7.2 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.3 Removing and installing intake air temperature sender G42 with charge air pressure sender
G31 . . . . . . . . . . . . . . . . . . . . . . . . k.s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
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1.4 Removing and installinglkexhaust swage gas flap valve N220 es n ............................ 255
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1.5 Checking charge air ed
bsystem
yV for leaks . . . . . . . . . . . . .
u a.ra. . . . . . . . . . . . . . . . . . . . . . . . . . 256
ris nt
2 Turbocharger uth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e.e o.r . . . . . . . . . . . . . . . . . . . . . . .
o 260
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2.1 Assembly overview
ss - turbocharger, 120 kW and 132 kW engines .................... 260
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2.2 Assembly overview - turbocharger, 90 kW and 103 kW engines . . . . . . . . . . . . . . . . . . . . 264

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2.3 Removing and installing turbocharger - 120 kW and 132 kW engines . . . . . . . . . . . . . . . . 267
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2.4 Removing and installing turbocharger - 90 kW and 103 kW engines . . . . . . . . . . . . . . . . . . 272
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2.5 Removing and installing charge pressure sender 2 G447 . . . . . . . . . . . . . . . . . . . . . . . . 277
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2.6 Removing and installing regulating flap potentiometer G584 and vacuum unit for
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turbocharger, 120 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
spec
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2.7 Removing and installing regulating flap potentiometer G584 and vacuum unit for
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turbocharger, 132 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
2.8 Removing and installing charge pressure control solenoid valve N75 . . . . . . . . . . . . . . . . rrectness of i 300
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

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1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

1.1 Schematic overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
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1.2 Fitting location overview - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

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1.3 Assembly overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

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1.4 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

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1.5 Filling/bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

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2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

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2.1 Schematic diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

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2.2 Testing vacuum system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3 Injectors and high-pressure accumulator (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
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3.1 Overview of injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
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3.2 Injector delivery calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
3.3 Removing and installing injectors (piezo injectors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
3.4 Removing and installing injectors (solenoid valves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
3.5 Removing and installing high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
3.6 Removing and installing high-pressure accumulator (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . 340
3.7 Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 343
4 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
4.1 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
4.2 Checking high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
5 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
5.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
5.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
5.3 Removing and installing throttle valve module J338 with throttle valve potentiometer G69 and
intake manifold flap motor V157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
iv Contents
AG. Volkswagen AG d
agen oes
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by Vol
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Amarok 2011 ➤
d
orise 4-cylinder diesel engine n(2.0
tee l engine, common rail) - Edition 04.2013
th or
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6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
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6.1 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
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6.2 Removing and installing exhaust pressure sensor 1 G450 . . . . . . . . . . . . . . . . . . . . . . . . 360
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6.3 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 362
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6.4 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
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6.5 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
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7 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
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7.1 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
7.2 Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
rrectness of i
8 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
8.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
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8.2 Renewing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374

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1 Exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
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1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
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1.2 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

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1.3 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

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2 Cleansing exhaust emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377

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2.1 Assembly overview - emission control (diesel particulate filter) . . . . . . . . . . . . . . . . . . . . . . 377
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2.2 Assembly overview - emission control (catalytic converter) . . . . . . . . . . . . . . . . . . . . . . . . 379
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2.3 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.4 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
3 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
3.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
3.2 Assembly overview - exhaust gas recirculation, 132 kW engine . . . . . . . . . . . . . . . . . . . . 391
3.3 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 392
3.4 Removing and installing exhaust gas recirculation cooler, 132 kW engine . . . . . . . . . . . . 398
3.5 Removing and installing exhaust gas recirculation valve N18 , 132 kW engine . . . . . . . . 400
3.6 Removing and installing changeover valve for exhaust gas recirculation cooler N345 . . . . 401
3.7 Checking exhaust gas recirculation cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
1.1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
1.2 Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
1.3 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
1.4 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Contents v
Amarok 2011 ➤
AG. Volkswagen AG d
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vi Contents
Amarok 2011 ➤
00 – Technical data
1 Identification
(VRL005497; Edition 04.2013)
⇒ “1.1 Engine number,n Aengine data”,
G. Volkswagen Apage 1
age G do
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1.1 ed by Engine number, engine data
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New afour
uth digit engine codes have been introduced since
or
ac model
yearss 2008. The first 3 digits refer to the mechanical configuration
of the engine. They are stamped onto the engine. The fourth digit
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denotes the power output of the engine and depends on the en‐
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gine control unit. The four digit engine code can be found on the
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identification plate, the vehicle data sticker and the engine control
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The engine number (“engine code” and “serial number”) can be
ole,
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found at the joint between engine and gearbox -arrow-.
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In addition, there is a sticker attached to the toothed belt guard
showing the “engine code” and “serial number”.
The engine code is also included on the vehicle data sticker.
rrectne
The engine number consists of up to nine characters (alphanu‐ s
meric). The first part (maximum 4 characters) makes up the
s o
“engine code”, and the second part (6 characters), the “serial

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number”. If more than 999,999 engines were produced with the

form
mer
same code letters, the first of the six digits is replaced by a letter.
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Engine code CDCA CDBA CNFA

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Manufactured from 01.10 ►

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Emissions fulfil yri
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EU 3 standard EU 3 standard
EU 4 standard EU 4 standard EU 4 standard
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Capacity l 2.0 2.0 2.0
Output kW at 120/4000 90/3750 90/3750
rpm
Torque Nm at 400/ 340/ 340/
rpm 1500 - 2000 1750 - 2250 1600 - 2000
Capacity cm3 1968 1968 1968
Bore ∅ mm 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5
Valves per cylinder 4 4 4
Compression ratio 16.5 16.5 16.0
Fuel accord‐ DIN EN 590 DIN EN 590 DIN EN 590
ing to
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Balancer shaft module no no no
Catalytic converter yes yes yes
Exhaust gas recirculation yes yes yes
Turbocharging/supercharg‐ yes yes yes
ing
Charge air cooler yes yes yes
Particulate filter yes, in the case of EU 5 yes, in the case of EU 5 yes, in the case of EU 5
1. Identification 1
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
Engine code y Volksw CDCA notCDBA
gu CNFA
d b ara
Particulate filter orise No; on vehicles compli‐ No; on vehicles nte compli‐
eo No; on vehicles compli‐
auth
ant with EU 3 and EU 4 ant with EU 3 andr a EU 4 ant with EU 3 and EU 4
c
ss
standards. standards. standards.
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Selective catalytic reduction no no no
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(SCR system)
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1) Present in the case of engines compliant with EU 5 standard and/or in conjunction with dual clutch gearboxes.
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Engine codes CNEA CSHA CNFB
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Manufactured from 01.10 ►
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Emissions fulfil EU 4 standard EU 4 standard EU 4 standard
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Capacity l 2.0 2.0 2.0

Output kW at 132/4000 132/4000 103/3500
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rpm
m
at
Torque Nm at 400/ 420/ 340/
om
io
rpm 1500 - 2250 1750 1600 - 2250
n
c
in t
or
Capacity cm3 1968 1968 1968
his
ate
do
riv
Bore 81.0 ∅ mm 81.0 81.0

p
cum
for
en
g
Stroke 95.5 mm 95.5 95.5

n
t.
yi Co
op
Valves per cylinder 4 4 4
C py
t. rig
gh ht
yri
Compression ratio 16.5 16.0 16.0
p by
co Vo
by lksw
cted
Fuel accord‐ DIN EN 590 DIN EN 590 DIN EN 590
agen
Prote AG.
ing to
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Balancer shaft module no yes no
Catalytic converter yes yes yes
Exhaust gas recirculation yes yes yes
Turbocharging/super‐ yes yes yes
charging
Charge air cooler yes yes yes
Particulate filter yes, in the case of EU 5 yes, in the case of EU 5 yes, in the case of EU 5
Particulate filter No; on vehicles compli‐ No; on vehicles compli‐ No; on vehicles compli‐
ant with EU 3 and EU 4 ant with EU 3 and EU 4 ant with EU 3 and EU 4
standards. standards. standards.
Selective catalytic reduc‐ no no no
tion
(SCR system)
2) Present in the case of engines compliant with EU 5 standard and/or in conjunction with dual clutch gearboxes.
2 Rep. gr.00 - Technical data

Amarok 2011 ➤
2 Safety instructions
⇒ “2.1 Safety precautions when working on fuel supply system”,
page 3
⇒ “2.2 Safety precautions when working on injection
AG. Vosystem”,
lkswagen AG
agen does
page 4 Volksw not
g y ua
db ran
⇒ “2.3 Safety precautions when working
ris
e
on charge air system”, tee
ho
page 5 au
t or
ac
ss
⇒ “2.4 Safety precautions when working on cooling system”, page
ce
e
nl
pt
5
du
an
itte
y li
erm
⇒ “2.5 Safety precautions during road tests in which testing and
ab
ility
measuring equipment is used”, page 6
ot p
wit
, is n
2.1 Safety precautions when working on
h re
hole
spec
fuel supply system
es, in part or in w
t to the co
Caution
rrectness of i
When doing any repair work, especially in the engine compart‐
l purpos
ment, pay attention to the following due to the cramped condi‐

tions:
nf
ercia
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
or
vated charcoal filter system, coolant and refrigerant, brake
m
m
atio
fluid and vacuum) and electrical wiring in their original po‐
om
n in
sitions.
or c
thi
te
sd
♦ Ensure that there is sufficient clearance to all moving or
iva
o
r
hot components.
rp
cu
o
m
f
en
ng
♦ Fuel and fuel lines in fuel system can become very hot
t.
yi Co
op
(danger of scalding)!
C py
ht. rig
rig ht
py by
♦ The fuel system is also under pressure! Before opening co Vo
by lksw
the system, place cloths around the connections. Then
cted agen
Prote AG.
carefully loosen connection to release the pressure!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!
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!
2. Safety instructions 3
Amarok 2011 ➤
2.2 Safety precautions when working on in‐

jection system
WARNING

tions:
sitions.
hot components.
♦ The engine must not be run when the fuel return line is
disconnected, this is because the coupling chamber will
be emptied due to the lack of the counterpressure.
Note
Diesel direct injection system control unit is equipped with an

event memory. Read event memory before and after making re‐
pairs or adjustments ⇒ Vehicle diagnostic tester.
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
rear seat and operated by a second person from this location.
♦ If test and measuring instruments are operated fromefront AG. pas‐
Volkswagen AG
senger seat and the vehicle is involved in an oaccident, ag n there does
lksw not
is a possibility that the person sitting in this
d byseat
V
may receive gu
ara
serious injuries when the airbag is triggered.
horis
e nte
e t or
au ac
To prevent injuries to persons and/orssdestruction of the injection
and glow plug system, the following must be noted:
ce
e
nl
pt
du
an
itte
♦ The ignition must be switched off before connecting or dis‐

y li
erm
ab
connecting preglow and injection system wiring as well as test

ility
ot p
equipment leads.
wit
, is n
h re
♦ Before disconnecting battery, obtain radio code for radios with

hole
anti-theft coding.
spec
es, in part or in w
♦ Disconnecting and connecting the battery must only be done

t to the co
with the ignition switched off, as otherwise the control unit for
diesel direction injection system could become damaged.
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 ➤

charge air system
WARNING

tions:
sitions.
hot components.

♦ Test equipment must always be secured on the rear seat and
operated by a 2nd person.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.

n AG. Volkswagen AG do
cooling system Volkswage es n
ot g
by ua
ed ran
oris tee
WARNING au
th or
ac
ss
ce
le
Steam may escape when expansion tank is opened. Wear eye

un
pt
an
d
protection and protective clothing to avoid eye injuries and

itte
y li
scalding. Cover cap with cloth and open carefully.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
tions:
rrectness of i
l purpos

nform
ercia
sitions.
m
♦ To avoid damage to lines, ensure sufficient clearance from

a
com
tio
all moving or hot components.

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
co lksw
by
cted agen
Prote AG.
2. Safety instructions 5
Amarok 2011 ➤ n AG. Volkswagen AG do
wage es n
4-cylinder diesel engine (2.0 l engine, common
yV
o rail) - Edition 04.2013
lks ot g
b ua
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Note
nform
ercia
♦ When the engine is warm, the cooling system is under pres‐

m
sure. If necessary, release pressure before beginning repair
a
com
tio
work.
n in
r
te o
thi
♦ Hoses are secured with spring-type clips. In case of repair,
s
iva
do
only use spring-type clips.
r
rp
cum
fo
en
g
♦ When installing or removing spring-type clips, we recommend

n
t.
yi Co
using spring-type clip pliers - VAS 6340- or Cop py
t. rig
gh ht
yri
♦ … hose clip pliers - VAS 6362- recommended. p by
co Vo
by lksw
cted agen
♦ When installing coolant hoses, route stress-free so that they Prote AG.
do not come into contact with other components (observe
markings on coolant connection and hose).
♦ Arrows on the coolant pipes and on the ends of the 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.
2.5 Safety precautions during road tests in

which testing and measuring equipment
is used
♦ Test and measuring instruments must always be secured to
the rear seat and operated by a second person from this lo‐
cation.
♦ Operating from the front passenger seat may result in an ac‐
cident caused by releasing the front passenger air bag which
can cause injuries to the person sitting there.

AG. Volkswagen AG d
agen oes
ksw not
by Vol
gu
ara
Amarok 2011 ➤
d
orise 4-cylinder diesel engine (2.0 nlteengine,
eo
common rail) - Edition 04.2013
th
au ra
ss c
ce
3 Repair instructions
le
un
pt
an
d
itte
y li
⇒ “3.1 General notes on the lubrication system”, page 7
erm
ab
ility
ot p
⇒ “3.2 General notes on fuel system”, page 7
wit
is n
h re
⇒ “3.3 Rules for cleanliness when working on fuel supply system/
ole,
spec
injection system”, page 8
t to the co
⇒ “3.4 Rules for cleanliness when working on charge air system”,
page 8
⇒ “3.5 Instructions for working on fuel system”, page 9
rrectne
⇒ “3.6 To avoid any risk of injuries to persons and/or the destruc‐
s
tion of the injection and glow plug system, the following must be
s o
noted”, page 10
cial p
f inform
⇒ “3.7 Instructions for hose connections with screw-type clips”,
mer
atio
page 11
om
n
c
i
3.1 General notes on the lubrication system
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
Note
t.
yi Co
Cop py
t. rig
The oil level must not be above the max. mark - danger of damage
gh ht
pyri by
to catalytic converter!
co Vo
by lksw
cted agen
Prote AG.
Caution
Finding metal shavings or a large quantity of small metal par‐

ticles during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To prevent this
from causing further damage, perform the following repairs:
♦ Thoroughly clean oil passages,
♦ Renew oil spray jets,
♦ Renew engine oil cooler,
♦ Renew oil filter element.
3.2 General notes on fuel system
Caution

tions:
sitions.
hot components.
3. Repair instructions 7
Amarok 2011 ➤ n AG. Volkswagen AG do
wage es n
4-cylinder diesel engine (2.0 l engine, common yrail)
Vo - Edition 04.2013
lk s ot g
b ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Note
nform
ercia
♦ When the engine is warm, the cooling system is under pres‐

m
sure. If necessary, release pressure before beginning repair
at
om
io
work.
n
c
in t
or
his
e
♦ Hoses are secured with spring-type clips. In case of repair,

at
do
riv
only use spring-type clips.

p
cum
for
en
g
♦ When installing or removing spring-type clips, we recommend

n
t.
yi Co
using spring-type clip pliers - VAS 6340- or Cop py
t. rig
gh ht
yri
♦ … hose clip pliers - VAS 6362- recommended. p by
co Vo
by lksw
cted agen
♦ When installing coolant hoses, route stress-free so that they Prote AG.
do not come into contact with other components (observe
markings on coolant connection and hose).
♦ Arrows on the coolant pipes and on the ends of the hoses must
be aligned.
3.3 Rules for cleanliness when working on

fuel supply system/injection system
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.
3.4 Rules for cleanliness when working on

charge air system
When working on the charge air system, pay careful attention to
the following rules for cleanliness:

Amarok 2011 ➤
♦ 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.
3.5 Instructions for working

lksw
on
agen
AG.fuel system
Volkswagen AG
does
n o ot g
yV ua
To prevent the high-pressure fuelris
ed pump from running while it is
b ran
tee
empty and to ensure that theuengine
tho starts quickly after parts have or
been renewed, it is important
ss
a to observe the following: ac
ce
e
nl
♦ If fuel system components between fuel tank and fuel high-
pt
du
an
pressure pump are removed or renewed, initial fuel filling must
itte
y li
be carried out.
erm
ab
ility
ot p
♦ If a fuel pump, fuel line (between fuel tank and fuel high-pres‐
wit
, is n
sure pump) or fuel filter is removed or renewed

h re
hole
spec
♦ Fuel system must be bled before starting engine for first time.
es, in part or in w
t to the co
♦ If the high-pressure fuel pump is removed or renewed, the fuel

system must be bled before engine is started for the first time.
rrectness of i
♦ Initial fuel filling procedure ⇒ page 316 .

l purpos
• Clean tools and workbench etc. before working on injection

system.
nf
ercia
• Thoroughly clean all unions and surrounding areas before dis‐

or
connecting.
m
m
atio
m
• When removing components, plug all open connections im‐

o
n in
or c
mediately with suitable clean sealing caps.

thi
te
sd
iva
• Do not remove sealing caps from components until immedi‐

o
r
rp
cu
ately prior to installation. Place removed components in new

o
m
f
en
ng
sealable plastic bags (if available, use original packaging of

t.
yi Co
op
new components). C py
ht. rig
rig ht
• If high-pressure lines are not renewed, they must be labelled
py by
co Vo
by lksw
on removal. High-pressure fuel lines must always be re-instal‐ Prote
cted AG.
agen
led in their original positions (i.e. on the same cylinder).
• Clean sealing surface of injector in cylinder head and injector
bore.
• Only cleaning set - VAS 6811- may be used for cleaning seal‐
ing surface of injector bore.
• For detailed information on how to use the cleaning set as well
as the order in which its components are applied, refer to the
⇒ operating manual provided with the cleaning set - VAS
6811- .
Amarok 2011 ➤
• The following components and seals/O-rings must always be

renewed when the injectors are removed and installed: “cop‐
per seal”, “O-ring for injector bore”, “O-ring for injector return
connection”, “injector return connection clip”
• The following components and seals/O-rings must always be
renewed when an injector is renewed: “copper seal”, “O-ring
for injector shaft” and “O-ring for injector return connection”
“injector return clip”
• Always fit new copper seals for the injectors. Check all new O-
rings for damage before installing. O-rings must be moist when
installed (assembly oil or clean engine oil). Use assembly tool
to install the “O-ring for injector return connection”.
. Volkswagen AG
a gen AG does
• Take care not to damage the injectors when removing the oldVol
ksw not
gu
copper seals. ed
by ara
nte
is
or eo
• Align high-pressure lines free from tension. First tighten
au
th all ra
unions hand-tight and then tighten to torque. ss c
ce
e
nl
pt
• Never attempt to reshape high-pressure fuel lines.
du
an
itte
y li
erm
• When working on any part of the high-pressure fuel system,
ab
ility
tools may only be used for loosening and tightening pipe un‐
ot p
wit
ions. All other components must always be removed and
, is n
h re
installed by hand without using tools or other equipment.
hole
spec
• Disassembling individual common rail components is not per‐
es, in part or in w
t to the co
mitted.
• The components should be replaced as complete units if faul‐
ty.
rrectness of i
• Never attempt to bleed the common rail system by loosening
l purpos
high-pressure components after starting the engine.

• Do not carry out any installation work on common rail system
nf
ercia
o
whilst engine is running.
rm
m
atio
m
• In particular, do not open or release high-pressure lines and

o
n in
c
electrical connectors.
or
thi
te
sd
a
• All cable ties which were opened or cut open during removal
iv
o
r
rp
cu
must be replaced with new ties in same position during instal‐
o
m
f
lation. en
ng
t.
yi Co
op py
• When the fuel system is open: do not work with compressed t. C rig
gh ht
air if this can be avoided. Do not move vehicle unless abso‐ yri
p by
o Vo
lutely necessary.
c by lksw
cted agen
Prote AG.
• 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.
3.6 To avoid any risk of injuries to persons

and/or the destruction of the injection
and glow plug system, the following
must be noted
♦ Persons wearing a pacemaker should not lean over the engine
compartment while the engine is running, as the injectors use
high voltage pulses.
♦ No fuel lines may be opened while the engine is running.
♦ Always switch off the ignition before connecting or discon‐
necting injection and glow plug system wiring or tester cables.
♦ Always switch off ignition before cleaning engine.
♦ The battery should only be disconnected and reconnected
with ignition switched off.

Amarok 2011 ➤
♦ Certain tests may lead to a fault being detected by the control

unit and stored. Therefore, after completing all checks and re‐
pairs, the fault memory must be read and if necessary cleared.
3.7 Instructions for hose connections with

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

“intake side”.
On the hose connections on the “delivery side”, there are screw-
type clips with “barbs” -arrows-.
Caution
AG. Volkswagen AG d
agen oes
lksw not
• Do not loosen d by Vthese screw-type clips and pull
o gback
ua over
the delivery rise hose. Risk of damage to the hose! ante
r
ho eo
ut ra
• If a sclip
s a has been removed, it must be renewed together c
with the hose.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
– Screw-type clips with “locking hooks” -arrows- may only be

h re
hole
loosened. Loosen bolt of screw-type clips sufficiently to re‐

spec
move hoses.
es, in part or in w
t to the co
Screw-type clips that are only loosened can be reused.

Hose and clip are supplied together as one part.
rrectness of i
– Do not use substances containing oil, silicone or grease when

l purpos
assembling. Only use clean water.

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 ➤
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 12
⇒ “1.2 Securing engine on engine and gearbox support VAS 6095
”, page 26
⇒ “1.3 Installing engine”, page 27
AG. Volkswagen AG d
1.1 Removing
Vol
kengine
swa
gen oes
not
by gu
ara
ed nte
oris eo
h
Special tools andut workshop ra
sa c
equipment required
s
ce
le
un
pt
♦ Lifting tackle - 3033-
an
d
itte
y li
erm
ab
♦ Support bracket - 10 - 222
ility
ot p
A-
wit
is n
h re
♦ Hook - 10 - 222 A /10-
ole,
spec
♦ Shackle - 10 - 222 A /12-
t to the co
♦ Adapter - 10 - 222 A /16-
♦ Adapter - 10 - 222 A /20-
qty. 2 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.
12 Rep. gr.10 - Removing and installing engine

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-
♦ Engine bung set - VAS
6122-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Removing and installing engine 13

Amarok 2011 ➤
♦ Drip tray for workshop hoist

- VAS 6208-
♦ Step - VAS 6292/4-
♦ Hose clip pliers - VAS
6340-
6362-
♦ Bracket - T10014-
♦ High-temperature grease -
G 052 133 A2-
♦ Cable ties
♦ Wooden block 10 x 30 x
10 cm
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
Procedure:
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Before carrying out further work, remove the battery. Check
whether a coded radio is fitted. Obtain anti-theft coding be‐
l purpos
forehand if necessary.
♦ The engine is removed upwards.
nform
ercia
♦ The gearbox remains installed.

m
at
om
io
♦ All cable ties that are opened or cut through when the engine
n
c
in t
or
is removed must be renewed/replaced in the same position

his
te
when the engine is installed.

a
do
priv
cum
or
♦ Seal open lines and unions with clean plugs from engine bung
f
en
ng
set - VAS 6122- .

t.
yi Co
Cop py
t. rig
♦ Collect drained coolant in a clean container for re-use or dis‐ gh ht
yri by
posal. cop Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
Caution

tions:
sitions.
♦ Cut through cable ties carefully and install new ones in the
same position.
– Remove bonnet ⇒ General body repairs, exterior; Rep. gr.

55 ; Bonnet .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing starter .
– Remove front left wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 50 ; Wheel housing liner .
– Remove underbody guard, if fitted ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody guard .
– Drain coolant ⇒ page 182 .
– Detach coolant hose -2- with both brackets -1-.
– Unscrew bolts -3-.
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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rm
ab
pe
ility
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– Release connector -2- on circulation pump - V55- -3- and pull wit
, is n
off. h re
hole
spec

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t to the co
rrectness of i
l purpos
nform
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tion in
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Prote AG.

Amarok 2011 ➤
– Detach circulation pump - V55- -2- from bracket with hoses

attached.
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– Pull latch -1- back. ir se
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– Press retaining lever -2- down and pull connector off.s au ac
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spec
es, in part or in w
t to the co
rrectness of i
– Open clip -1- and remove hose -2- from turbocharger.
l purpos
WARNING
nform
ercia
♦ The fuel and the fuel lines in the fuel system can become
m
a
very hot (danger of scalding)!
com
tion in
r
♦ The fuel system is also under pressure! Before opening

te o
thi
the system, place cloths around the connections. Then
s
iva
do
carefully loosen connection to release the pressure!
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♦ Wear eye and hand protection when performing any type

n
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op
of repair work on the fuel system! C py
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by
cted agen
Prote AG.

Amarok 2011 ➤
– Separate fuel lines -1-, -2- and -3-.

Vehicles with air conditioning system:
Note
To prevent damage to condenser or to refrigerant lines and ho‐

ses, ensure that lines and hoses are not stretched, kinked or bent.
To facilitate removing and 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
G. Volkswagen AG d
– Remove front exhaust pipe ⇒ page
lksw
age374
nA . oes
not
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– Remove cover from fuse isedbox above battery. ara
nte
or eo
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aut ra
– Unscrew nut -2- ofs battery positive cable -1-.
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rm
ab
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ility
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wit
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spec
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t to the co
rrectness of i
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– Unhook clips -1- and -3-.

nform
ercia
– Lay wiring harness -2- to one side.

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tion in
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te o
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Cop py
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Prote AG.
– Release and pull off connectors -2- and -3-.

– Remove shear bolts -1- and remove bow -4-.

Amarok 2011 ➤
– Unhook clips -2- and -3-.

– Release and pull off connector -1-.
– Open retainer -4- and detach wiring harness.
– Carefully cut through cable ties -arrows-.

– Lay wiring harness on engine and secure.
AG. Volkswagen AG d
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aut ra
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un
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ility
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wit
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h re
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spec
– Remove bolt -4-.
es, in part or in w
t to the co
Caution
rrectness of i
• Do not loosen screw-type clips and pull back over pres‐
l purpos
sure hose. Risk of damage to the delivery hose!

Removing screw-type clips ⇒ page 11 .
nform
mercia
a
com
t
– Remove hose/pipe -1- completely. To do this, loosen clips
ion in
-2- and -5- sufficiently to enable hose/pipe -1- to be pulled off.
r
te o
thi
s
iva
do
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– Open clip -2- and remove coolant hose -1-. Guide coolant hose
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downwards and allow coolant to drain.

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Cop py
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rig ht
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by lksw
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Prote AG.

Amarok 2011 ➤
– Pull line -2- out of brake servo.

– Open clip -1- and remove coolant hose -3-.
AG. Volkswagen AG d
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ris nte
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aut ra
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un
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wit
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spec
es, in part or in w
t to the co
rrectness of i
– Open clips -2- and -4- and remove coolant hoses -1- and -3-.
l purpos
– Remove vane pump with hoses connected, and secure it to

vehicle body ⇒ Running gear, axles, steering; Rep. gr. 48 ;
Hydraulic power steering .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
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t.
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Cop py
ht. rig
rig ht
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– Pull off hose -2- from turbocharger. by c lksw
cted agen
Prote AG.
– Pull hose -4- off union -5- and detach from clip -7-.
– Lay clip -1- aside with lines.
– Pull off hose -arrow- from turbocharger.

Amarok 2011 ➤
– Detach hoses from intake hose -3- bracket -arrow-.

– Remove pipe -5- from cylinder head cover.
– Release and pull off wiring harness connector -2-. Detach wir‐
ing harness -2- from intake hose retainer -3-.
– Open clips -1- and -4- and remove intake hose -3-.
AG. Volkswagen AG d
agen oes
olksw not
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aut ra
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ce
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– Detach vacuum hose -2- from toothed belt guard -1-.

un
pt
an
d
itte
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– Open clips -arrows- and remove toothed belt guard -1-.
erm
ab
ility
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spec
t to the co
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cial p
– Open bracket -1- and detach coolant hose -2-.

inform
mer
atio
om
n
c
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or
n thi
te
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o
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fo
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Release connector -arrow- and pull off from exhaust temper‐

ature sender 1 - G235- . Free wiring harness from fittings and
secure it to engine.

Amarok 2011 ➤
– Release connector -2-.

– Pull all clips -5- off radiator cowl.
AG. Volkswagen AG d
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– Remove bolts -1-. olksw
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nl
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ab
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– Release cowling -2- at left and right. To do this, press retaining
h re
hole
lever -1- forwards using a screwdriver, and raise radiator cowl
spec
-2- slightly.
es, in part or in w
t to the co
– Remove radiator cowl -2- with assistance of a 2nd mechanic.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Unscrew bolts -1- from left engine mounting -A-.
– Unscrew bolts -1- from right engine mounting -A-.

Amarok 2011 ➤
– Detach gearbox breather line -1- from clip -2- (on coolant hose
on rear right of engine).
– Unscrew bolt -1- for fuel lines -2- from bracket through wheel
housing.
– Install support bracket - 10 - 222 A- .
. Volkswagen AG
– Secure adapter - 10 - 222 A /16- and hook - 10 - 222ksA
wa/10-
gen Ato
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support bracket - 10 - 222 A- . by
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spec
t to the co
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cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
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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 ➤
– Engage hook - 10 - 222 A /10- in transport eye.
AG. Volkswagen AG d
agen oes
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– Engage hook - 10 - 222 A /2- in transport eye -arrow-.
ce
le
un
pt
an
– Engage shackle - 10 - 222 A /12- with hook - 10 - 222 A /2- on
d
itte
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adapter - 10 - 222 A /16- .
rm
ab
pe
ility
– Raise engine until left engine mounting is raised approx. 15
ot
wit
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mm and right engine mounting approx. 35 mm.
h re
hole
spec
es, in part or in w
Note
t to the co
Raise engine only sufficiently to allow a square timber to be in‐
rrectness of i
serted between chassis and gearbox.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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– Insert square timber -1-.
fo
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t.
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– Lower engine using support bracket - 10 - 222 A- until gearbox Cop py
t. rig
-2- rests completely on square timber -1- and support bracket yri
gh by
ht
- 10 - 222 A- is relieved.
op Vo
by c lksw
cted agen
Prote AG.
Caution
• Do not unscrew the two upper bolts -1-.

Amarok 2011 ➤
– Remove bolts -2- and -3-.

– Only unscrew bolt -1- beneath starter.
– Unscrew all connecting bolts for lower and centre engine/
gearbox. The two upper bolts initially remain screwed in.
– Remove support bracket - 10 - 222 A- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
– Install retainer - T10014- to front right of engine. s
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
rrectness of i
l purpos
– Engage lifting tackle - 3033- on workshop hoist - VAS 6100-

and attach to engine.
nform
ercia
– Engage adapter - 10 - 222 A /20- in lifting tackle - 3033- and

m
a
com
t
retainer - T10014- and secure with retaining clip.
ion in
r
te o
– Engage adapter - 10 - 222 A /20- in lifting tackle - 3033- and
thi
s
iva
transport eye -arrow- and secure with retaining clip.
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.

Amarok 2011 ➤
– Unscrew the two upper bolts -1-.

– If necessary, disconnect all connecting, coolant, vacuum and
intake hoses that have to be disconnected from Athe
G. Voengine
lkswageninAG
order to remove it. agen does
o lksw not
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– Carefully pull engine from gearboxris in longitudinal direction. Do
e nte
tho crankshaft whilst doing this.
not damage needle bearing inauthe eo
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un
pt
Caution
an
d
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ab
♦ Only a few millimetres of space are available between
ility
ot p
plenum chamber and radiator/lock carrier for removing
wit
is n
and installing the engine. The engine must therefore be
h re
ole,
guided carefully when raising and lowering.
spec
♦ Raise and lower the engine slowly with the assistance of
t to the co
a second mechanic.
♦ The workshop hoist - VAS 6100- must also be guided
rrectne
carefully when raising and lowering the engine.
ss o
cial p
f
– When raising and lowering engine, make sure that neither
inform
vacuum hose -1- nor union -2- on vacuum pump are damaged.
mer
atio
m
– Guide vacuum hose -1-, union -2- and vacuum pump past ple‐
o
n
c
num chamber when raising and lowering.
i
or
n thi
te
sd
a
– When raising and lowering engine, make sure that rollers of

iv
o
pr
c
belt drive and turbocharger do not damage radiator.
um
r
fo
en
ng
t.
– When raising and lowering engine, pay attention to lines and
yi Co
op py
hoses to prevent these from being damaged. t. C rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Check needle bearing -arrow- in crankshaft. If it is damaged

or has turned blue, it must be renewed ⇒ page 76 .
– If it is not damaged, lightly grease with high-temperature
grease - G 052 133 A2- .
– Slightly grease the journal (not the teeth) of the gears as well.

Amarok 2011 ➤
1.2 Securing engine on engine and gearbox support - VAS 6095-
Special tools and workshop

equipment required
♦ Lifting tackle - 3033-
♦ Adapter - 10 - 222 A /20-
♦ Engine and gearbox sup‐
port - VAS 6095-
♦ Workshop hoist - VAS
6100-
♦ Bracket - T10014-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
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hole
Procedure:
spec
es, in part or in w
Secure engine to engine and gearbox support - VAS 6095- to

t to the co
carry out repairs.

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Engage lifting tackle - 3033- with both adapters - 10 - 222 A /

20- -1- and retainer - T10014- -1- on engine.
Flywheel end: position 3. AG. Volkswagen AG d
agen oes
olksw not
Belt drive end: position 9 d by V gu
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
– Secure engine in engine and gearbox support - VAS 6095- .
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.
1.3 Installing engine

Special tools and workshop equipment required
♦ vehicle diagnostic tester
Installation is carried out in the reverse order; note the following:
Caution
♦ Only a few millimetres of space are available between

plenum chamber and radiator/lock carrier for removing
and installing the engine. The engine must therefore be
guided carefully when raising and lowering.
♦ Raise and lower the engine slowly with the assistance of
a second mechanic.
♦ The workshop hoist - VAS 6100- must also be guided
carefully when raising and lowering the engine.

Amarok 2011 ➤
. Volkswagen AG
does gen AG
– When raising and lowering engine, make
Vol
ksw sure that neither
a
not
vacuum hose -1- nor union -2- onevacuum
db
y pump are damaged. gu
ara
is nte
or
– Guide vacuum hose -1-, union
au -2- and vacuum pump past ple‐
th eo
ra
num chamber when raisings and lowering.
s c
ce
le
un
pt
– When raising and lowering engine, make sure that rollers of
an
d
itte
belt drive and turbocharger do not damage radiator.
y li
erm
ab
ility
– When raising and lowering engine, pay attention to lines and
ot p
wit
hoses to prevent these from being damaged.
is n
h re
ole,
– Check whether dowel sleeves for centering engine/gearbox
spec
are in cylinder block and install if necessary (gearbox re‐
t to the co
moved).
– Check clutch release bearing for wear and, if necessary, re‐
place (gearbox removed).
rrectne
Caution
ss o
cial p
f in
• Bring engine and gearbox together in longitudinal direc‐
form
mer
tion, not at an incline.
atio
m
• When bringing engine and gearbox together, make sure

o
n
c
i
or
n
that needle bearing -arrow- is not damaged.
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.
– First tighten the two upper bolts -1-.

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

Amarok 2011 ➤
– Tighten new bolts -1- for right engine mounting -A-.

– Install front exhaust pipe ⇒ page 374 .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 .
– Install vane pump ⇒ Running gear, axles, steering; Rep. gr.
48 ; Hydraulic power steering .
– Install underbody guard, if fitted previously ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody guard .
– Install front left wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 50 ; Wheel housing liner .
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Removing and
installing starter .
– Install bonnet ⇒ General body repairs, exterior; Rep. gr. 55 ;
Bonnet .
To prevent the high-pressure pump from running while it is empty
and to ensure that the engine starts quickly after parts have been
renewed, it is important to observe the following:
♦ If components of the fuel system between the fuel tank and
the high-pressure pump are removed or renewed, it is neces‐
sary for the fuel system to be bled. To do this, perform the
“Bleeding fuel system” function using the ⇒ Vehicle diagnostic
tester ⇒ page 316 .
♦ This process takes 130 seconds. Fuel pumps are actuated a
total of 3 times in the process. The process must not be ter‐
minated prematurely.
– Check oil level ⇒ page 147 .
Note
AG. Volkswagen AG d
agen oes
lksw not
Only reuse drained coolant if neither cylinder head nor cylinder
o
♦ d by
V gu
ara
block have been renewed. orise nte
eo
h
ut ra
♦ Soiled coolant must not be reused. ss a c ce
e
nl
pt
du
an
– Replenish coolant ⇒ page 182 .
itte
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erm
ab
– Carry out road test and read event memory ⇒ Vehicle diag‐
ility
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nostic tester.
wit
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Specified torques
hole
spec
♦ ⇒ “2.1 Removing and installing assembly mountings”,

es, in part or in w
t to the co
page 31
♦ ⇒ “2.2 Assembly overview - emission control (catalytic con‐
verter)”, page 379
rrectness of i
♦ ⇒ “2.1 Assembly overview - emission control (diesel particu‐

l purpos
late filter)”, page 377

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

Amarok 2011 ➤
AG. Volks4-cylinder
wagen AG diesel engine (2.0 l engine, common rail) - Edition 04.2013
agen does
olksw not
byV gu
ara
d
2 Assembly mountings
ise nte
or eo
h
aut ra
s c
⇒ “2.1
s Removing and installing assembly mountings”, page 31
ce
e
nl
pt
du
2.1 Removing and installing assembly
an
itte
y li
erm
mountings
ab
ility
ot p
wit
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Left and right engine support to crankcase
h re
hole
spec
es, in part or in w
Caution
t to the co
• Nut -2- must not be loosened.
rrectness of i
• If nut -2- is loosened, engine mounting must subsequently
be renewed.
l purpos
♦ Engine mounting connection to engine support may only

be loosened if engine mounting is to be renewed.
nform
mercia
at
om
io
– Secure engine support -1- to crankcase with bolts -3-.
n
c
in t
or
his
e
– Bolts -3- must always be renewed.

at
do
priv
c
Specified torque
um
for
en
ng
t.
yi
Component Specified torque
Co
Cop py
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Bolts -3- 50 Nm +180°
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Left engine mounting to frame
– Secure engine mounting -A- to frame with bolts -1-.
Specified torque
Bolts -1- 50 Nm + 90°
Right engine mounting to frame

– Secure engine mounting -A- to frame with bolts -1-.
Specified torque
Bolts -1- 50 Nm + 90°
2. Assembly mountings 31
Amarok 2011 ➤
Left engine mounting to engine support

– Bolt new engine mounting -3- to engine support -1- with nut
-2-.
– Nut -2- must always be renewed.
Specified torque
Nut -2- 90 Nm + 90°
Right engine mounting to engine support

– Bolt new engine mounting -3- to engine support -2- with nut
-1-.
– Nut -1- must always be renewed.
Specified torque
Nut -1- 90 Nm + 90°
lkswage es n
o ot g
yV
Gearbox mounting to gearbox
ir se
d b ua
ran
o tee
h
– Secure gearboxs aumounting -A- to gearbox with bolts -1-.
t or
ac
s
ce
le
un
pt
an
d
itte
Specified torque
y li
rm
ab
pe
ility

ot
wit
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Bolts -1- 50 Nm + 90°

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Gearbox mounting to gearbox cross member

l purpos
– Secure gearbox mounting -A- to gearbox cross member with

bolts -1-.
nform
ercia

m
Specified torque
com
tion in
r
te o

thi
s
iva
do
Bolts -1- 30 Nm + 90°

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

lkswage es n
o ot g
byV ua Amarok 2011 ➤
d ran
ir se
tho 4-cylinder diesel enginete(2.0
eo l engine, common rail) - Edition 04.2013
au ra
c
ss
ce
le
13 – Crankshaft group
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
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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
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1. Cylinder block (pulley end) 33

Amarok 2011 ➤
1 Cylinder block (pulley end)

⇒ “1.1 Assembly overview - cylinder block”, page 34
⇒ “1.2 Assembly overview - sealing flange, belt pulley end”, page
36
⇒ “1.3 Assembly overview - poly V-belt drive”, page 37
⇒ “1.4 Assembly overview - poly V-belt drive, vehicles without A/
C system”, page 39
⇒ “1.5 Removing and installing gpoly
en AGV-belt”,
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⇒ “1.6 Removing and installing
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page 42 or
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⇒ “1.7 Removing
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⇒ “1.8 Removing and installing vibration damper”, page 44

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⇒ “1.9 Renewing crankshaft oil seal - belt pulley end”,
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page 48
hole
spec
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1.1 Assembly overview - cylinder block
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1 - Cylinder block
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❑ Removing and installing
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sealing flange on belt

pulley end ⇒ page 48 .
nform
ercia

dual-mass flywheel
m
⇒ page 55 .
com
tion in

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sealing flange on fly‐

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wheel end ⇒ page 57 .

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crankshaft
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⇒ page 73 .
t. C rig
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❑ Dismantling and assem‐
op Vo
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cted agen
Prote AG.
rods ⇒ page 66
2 - Guide tube
❑ Renew O-ring.
3 - Spreader clip
4 - Gaskets
❑ Renew after removing
5 - Oil filter bracket
❑ Oil filter bracket and en‐
gine oil cooler
⇒ page 151 .
6 - Bolt
❑ First fit upper left and
lower right bolts and
then tighten all four bolts
diagonally.
❑ 14 Nm +180°
34 Rep. gr.13 - Crankshaft group

Amarok 2011 ➤
7 - Bolt
❑ 13 Nm
8 - Thermostat (4/2-way valve)
❑ Thermostat is firmly installed in valve.
❑ Can only be renewed complete.
❑ Removing and installing ⇒ page 187
9 - O-ring
10 - Lifting eye
11 - Bracket for ancillaries
❑ Observe tightening sequence ⇒ page 43 . n AG. Volkswagen AG do
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s a tightening sequence ⇒ page 43 . ac
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13 - Bolt
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❑ 25 Nm
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14 - Oil sump
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❑ Clean sealing surface before fitting.
h re
hole
❑ Install with silicone sealant ⇒ Electronic Parts Catalogue (ETKA) .
spec
es, in part or in w
❑ Removing and installing ⇒ page 140 .
t to the co
15 - Bolt
❑ 15 Nm
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Amarok 2011 ➤
1.2 Assembly overview - sealing flange, belt pulley end
1 - Bolt
❑ Loosen and tighten with
counterhold - 3415-
❑ Do not additionally oil
the thread and shoulder.
❑ 120 Nm + 90°
2 - Crankshaft toothed belt pul‐
ley AG. Volkswagen AG d
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3 - Crankshaft oil seal for belt
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❑ Do not additionally oil or
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grease the oil seal seal‐
spec
ing lip.
es, in part or in w
t to the co
❑ Before installing, re‐
move oil residue from
crankshaft journal using
rrectness of i
a clean cloth.
❑ Renewing ⇒ page 46 .
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4 - Sealing flange at belt pulley

end nform
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❑ Insert with silicone seal‐

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ant ⇒ Electronic Parts

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❑ Must seat on dowel

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pins.
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⇒ page 48 . t. Cop py
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6 - Dowel pin
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7 - Bolt
❑ Specified torque and tightening sequence ⇒ page 36 .
Sealing flange at belt pulley end - Prescribed torque and tighten‐

ing sequence
– Tighten bolts for sealing flange at belt pulley end in the se‐
quence -1 … 10- in 3 stages as follows:
1. Screw bolts -1 ... 10- in as far as stop by hand.
2. Tighten bolts -1 … 6- in diagonal sequence to 15 Nm.
3. Tighten bolts -7 … 10- to 15 Nm.

Amarok 2011 ➤
1.3 Assembly overview - poly V-belt drive
1 - Poly V-belt
❑ Mark direction of rota‐
tion before removing.
❑ Check for wear.
❑ Do not kink.
⇒ page 40
2 - Bolt
❑ 10 Nm + 90°
3 - Belt pulley and vibration
damper
❑ Installation position:
hole in vibration damper
must align over protru‐
sion on crankshaft
toothed belt pulley.
❑ Can only be installed in
one position. Holes are
offset.
4 - Bolt
❑ 20 Nm
5 - Idler roller
❑ For toothed belt
6 - Dowel sleeve olks
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❑ Check for correct seat‐ sed b ua
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ing in ancillary bracket.
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❑ Inserted in hole forss the
left-hand (direction of
ce
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un
pt
travel) bolt -11- on the

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rear side of the bracket.

rm
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❑ Observe prescribed torque and tightening sequence during installation ⇒ page 38

h re
hole
spec
8 - High-pressure pump
es, in part or in w
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9 - Alternator
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❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 .

l purpos
10 - Bolt
❑ When reusing bolt, tighten to 20 Nm plus 90° further.
nform
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❑ New bolt: 20 Nm + 180°

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11 - Centre hex stud

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❑ Observe tightening sequence ⇒ page 38 .

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❑ 40 Nm + 90°
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12 - Bolt
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13 - Bolt
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❑ 25 Nm

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14 - Sleeve ss
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❑ Before installing, push vane pump back slightly.
un
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15 - Bracket
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ility
16 - Nut
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❑ For bracket of Hall sender - G40- .
h re
ole,
❑ 25 Nm
spec
17 - Bolt
t to the co
❑ 40 Nm +180°
rrectne
18 - Vane pump
s
❑ Removing and installing ⇒ Running gear, axles and steering; Rep. gr. 48 .
s o
cial p
f in
19 - Bolt
form
mer
❑ 25 Nm
atio
om
n
20 - Belt pulley
c
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21 - Bolt
sd
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❑ 25 Nm
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22 - Bolt
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23 - Bolt
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❑ 20 Nm + 90°
24 - Idler roller
❑ For poly V-belt.
25 - Air conditioner compressor
❑ Removing and installing ⇒ Heating, air conditioning system; Rep. gr. 87 .
26 - Bolt
❑ Prescribed torque ⇒ Electrical system; Rep. gr. 27 .
27 - Poly V-belt tensioning element
❑ Swing with ring spanner to slacken ribbed belt ⇒ page 40
Ancillary bracket - specified torques and tightening sequence

– Insert securing bolts for ancillary bracket as follows:
♦ Bolts -1- and -2-
– Tighten securing bolts for ancillary bracket in sequence
-1 … 6- in 2 stages as follows:
1. Screw all bolts in to stop by hand.
2. Tighten all bolts to 40 Nm.
3. Turn bolts -1, 2, 5 and 6- 90° further.
4. Turn bolts -3- and -4- 180° further.

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1.4 Assembly overview - poly V-belt drive, vehicles without A/C system ss
ce
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nl
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1 - Poly V-belt
ab
ility
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❑ Check for wear.
spec
es, in part or in w
❑ Do not kink.
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⇒ page 40
rrectness of i
2 - Bolt
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❑ 10 Nm + 90°
nform
ercia
3 - Belt pulley and vibration

m
damper
at
om
ion
❑ Installation position:
c
in t
or
hole in vibration damper
his
ate
must align over protru‐
do
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sion on crankshaft
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toothed belt pulley.
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4 - Bolt
❑ 20 Nm
5 - Idler roller
❑ For toothed belt
6 - Dowel sleeve
❑ Check for correct seat‐
ing in ancillary bracket.
❑ Inserted in hole for the
left-hand (direction of
travel) bolt -11- on the
rear side of the bracket.
❑ Observe prescribed torque and tightening sequence during installation ⇒ page 40
9 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 .
10 - Bolt
❑ 20 Nm +180°
11 - Centre hex stud
❑ 40 Nm + 90°
12 - Bolt
❑ 40 Nm + 90°
13 - Bolt
❑ 25 Nm

Amarok 2011 ➤
14 - Sleeve
❑ Push back slightly before installing vane pump.
15 - Bracket
16 - Nut
❑ For bracket of Hall sender - G40- .
❑ 25 Nm
17 - Bolt
❑ 40 Nm +180°
18 - Vane pump
❑ Removing and installing ⇒ Running gear, axles and steering; Rep. gr. 48 .
AG. Volkswagen AG d
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❑ 25 Nm ed by gu
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20 - Belt pulleyauth eo
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21 - Bolt
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❑ 25 Nm
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22 - Bolt
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❑ Prescribed torque ⇒ Electrical system; Rep. gr. 27 .

wit
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23 - Poly V-belt tensioning element
hole
spec
❑ Swing with ring spanner to slacken ribbed belt ⇒ page 40
es, in part or in w
t to the co
Ancillary bracket - specified torques and tightening sequence

rrectness of i
– Insert securing bolts for ancillary bracket as follows:

l purpos

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ercia

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tion in
r
– Tighten securing bolts for ancillary bracket in sequence

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-1 … 6- in 2 stages as follows:
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1. Screw all bolts in to stop by hand.

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3. Turn bolts -1, 2, 5 and 6- 90° further.
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4. Turn bolts -3- and -4- 180° further.
Prote AG.
1.5 Removing and installing poly V-belt


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olksw notAmarok 2011 ➤
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4-cylinder dieselrisengine
ed b
(2.0 l engine, common rail) - Edition
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♦ Locking pin - T10060 A- ss c
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nform
ercia

m
at
om
ion
– Mark direction of rotation of poly V-belt.
c
in t
or
his
te
– Turn the tensioning element -1- in -direction of arrow- with ring

a
do
riv
spanner SW 16 -2- to slacken the poly-V belt.

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cum
for
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t.
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Cop py
t. rig
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pyri by
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Prote AG.
– Lock tensioning element using locking pin - T10060 A- .

– Remove poly V-belt.
Installing
Note
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor, power steering vane pump)
are secured tightly.
♦ When installing poly V-belt, check direction of belt rotation and
proper seating of belt in pulleys.
♦ Place the poly-V belt last on the tensioning element.
– Remove locking pin - T10060 A- .

After completing repair, always:
– Start engine and check belt running.

Amarok 2011 ➤
Belt drive without air conditioner compressor

1- Tensioning roller
2- Alternator pulley
3- Vane pump
4- Poly V-belt
5- Crankshaft pulley
Belt drive with air conditioner compressor

1- Crankshaft pulley
2- Tensioning roller
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3- Alternator pulley yV
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4- Vane pump ir se tee
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5- Air conditioner compressor pulley ss
ce
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un
pt
6- Poly V-belt
an
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itte
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7- Idler roller
erm
ab
ility
ot p
wit
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ole,
spec
t to the co
rrectne
1.6 Removing and installing tensioner for
poly V-belt ss o
cial p
f inform
mer
Removing
atio
om
– Remove poly V-belt

n
c
i
or
⇒ “1.5 Removing and installing poly V-belt”, page 40 .

thi
te
sd
iva
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .

pr
cum
r
fo
en
ng
– Remove alternator ⇒ Electrical system; Rep. gr. 27 .

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

Amarok 2011 ➤
– Remove bolt -arrow- for tensioning element -1- and remove

tensioning element in -direction of arrow-.
Installing
– Install alternator ⇒ Electrical system; Rep. gr. 27 .
– Install poly V-belt
⇒ “1.5 Removing and installing poly V-belt”, page 40 .
– Connect battery ⇒ Electrical system; Rep. gr. 27 .
– Re-learn window lifter, enter radio code, set clock and, if nec‐
essary recode control units which have fault entries.
Specified torques
♦ ⇒ “1.3 Assembly overview - poly V-belt drive”, page 37
♦ ⇒ “1.4 Assembly overview - poly V-belt drive, vehicles without
A/C system”, page 39
1.7 Removing and installing ancillary brack‐

et
♦ Torque wrench - V.A.G 1331-
lkswage es n
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Removing
spec
es, in part or in w
– Remove high-pressure pump ⇒ page 347 .

t to the co
– Remove the generator ⇒ Electrical system; Rep. gr. 27 .

rrectness of i
WARNING
l purpos
The air conditioner refrigerant circuit must not be opened.

nform
mercia
at
om
– Remove air conditioner compressor ⇒ Heating, air condition‐

ion
c
ing; Rep. gr. 87

in t
or
his
ate
– Secure air conditioner compressor to body so that the refrig‐

do
riv
erant lines and hoses are not under tension.

p
cum
for
en
ng
t.
– Screw off vane pump for power assisted steering together with
yi Co
op
connected lines and fasten to body ⇒ Running gear, axles,
C py
t. rig
gh
steering; Rep. gr. 48
ht
pyri by
Vo
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cted agen
Prote AG.

Amarok 2011 ➤
– Unscrew deflection rolls -1- and -2- and screw out bolt of
toothed belt guard -arrow-.
– Pull connector -1- out of bracket -2-.

lkswage es n
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Nut -3- cannot be seenau or felt. A small hand-held mirror is required
t or
ac
ss
to unscrew and insert nut -3-.
ce
le
un
pt
an
d
itte
– Remove nut -3- and bracket -2-.
y li
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pe
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
– Unscrew bolts -1….6- and remove ancillary bracket.

m
Installing
a
com
tion in

r
te o
thi
s
iva
– Make sure that the dowel sleeve ⇒ Item 6 (page 37) on the
do
r
rp
rear of the bracket is in the hole for the bolt. If the dowel sleeve
um
fo
is missing, it must be replaced.

en
ng
t.
yi Co
op py
– Installing the generator ⇒ Electrical system; Rep. gr. 27 . t. C rig
gh ht
pyri by
– Installing high-pressure pump ⇒ page 347 .
co Vo
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cted agen
Prote AG.
Specified torques
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 105
1.8 Removing and installing vibration damp‐

er

Amarok 2011 ➤
Removing
– Remove poly V-belt ⇒ page 40 .
– Loosen bolts -arrows- for vibration damper, counterholding on
crankshaft toothed belt pulley bolt with a ring spanner.
– Unscrew bolts and remove vibration damper.
Installing
lkswage es n
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Assembly of the vibration damper is only possible in one position:
ss
ce
e
The vibration damper hole must be positioned over the projection

nl
pt
du
on the toothed belt pulley -arrow-.

an
itte
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erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Install vibration damper with new bolts -arrows-.

nf
ercia
– Tighten bolts -arrows- for vibration damper, counterhold on

or
crankshaft toothed belt pulley bolt with a ring spanner.

m
m
atio
om
Specified torques
n in
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e

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Cop py
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co lksw
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Prote AG.

Amarok 2011 ➤
1.9 Renewing crankshaft oil seal - belt pulley end

equipment required
♦ Oil seal extractor - 3203-
♦ Counterhold tool - 3415-
♦ Assembly tool - T10053-
♦ Torque wrench (5…50 Nm)
- V.A.G 1331-
♦ Torque wrench (40…200olkswage es n
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Nm) - V.A.G 1332- d by V ua
ran
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ris tee
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ss
ce
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un
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an
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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
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fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Removing
Prote AG.
– Remove toothed belt ⇒ page 107 .

– Remove crankshaft toothed belt pulley. To do this, lock tooth‐
ed belt pulley using counterhold - 3415- .
– To guide seal extractor - 3203- , screw centre bolt into crank‐
shaft as far as stop by hand.
– Unscrew inner part of oil seal extractor 2 turns (approx. 3 mm)
from the outer part and lock in position with the knurled screw.
– Oil threaded head of oil seal extractor.

Amarok 2011 ➤
AG. V4-cylinder
olkswagen AGdiesel engine (2.0 l engine, common rail) - Edition 04.2013
agen does
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– Screw oil seal ed b extractor forcibly as far as possible
y arainto oil seal.
nte
ris
o eo
– Loosen aut knurled screw and turn inner part against crankshaft
h
ra
untils the oil seal is pulled out.
s c
ce
le
un
pt
Installing
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
Note
ole,
spec
The oil seal sealing lip must not be additionally oiled or greased.
t to the co
– Remove oil residues from crankshaft journal with a clean cloth.
rrectne
– Fit guide sleeve - T10053/1- onto crankshaft journal.
ss
– Slide seal over guide sleeve - T10053/1- onto crankshaft jour‐
o
cial p
f i
nal.
nform
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
t. rig
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pyri by
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by c lksw
cted agen
Prote
– Press oil seal in as far as stop with press sleeve - T10053- and
AG.
central bolt.
– Install crankshaft toothed belt pulley.
– Install toothed belt ⇒ page 107 .
Specified torques

Amarok 2011 ➤
1.10 Removing and installing sealing flange on pulley end

equipment required
- V.A.G 1331-
♦ Torque wrench (40…200
Nm) - V.A.G 1332-
♦ Hand drill with plastic brush
♦ Flat scraper
♦ Silicone sealant ⇒ Elec‐
tronic Parts Catalogue (ET‐
KA)
lkswage es n
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ss
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e
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itte
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ility
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hole
spec
es, in part or in w
Removing
t to the co

– Remove crankshaft toothed belt pulley. To do this, lock tooth‐
rrectness of i
ed belt pulley using counterhold - 3415- .

l purpos
– Drain off engine oil.

– Remove sump ⇒ page 140 .
nf
ercia
orm
m
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om
n in
or c
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Prote AG.

Amarok 2011 ➤
– Unscrew bolts -1 … 10- and carefully remove sealing flange

from the glued joint.
– Remove sealing flange. If necessary, loosen sealing flange
using light blows with a rubber headed hammer.
– Remove sealant residues from cylinder block with a flat scra‐
per.
– Remove residual sealant on sealing flange using a rotating

plastic brush (wear protective goggles).
– Clean sealing surfaces. They must be free of oil and grease.
Installing
Note
♦ Observe expiry date of sealing compound.

♦ The sealing flange must be installed within 5 minutes
AGof
. Voap‐
lkswagen A
plying the silicone sealant. olks
wage
n G do
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V
by ua
♦ Sealant bead must be no thicker thanris2…3
ed mm. Excess seal‐ ran
tee
ant can find its way into the sump and
uth block the strainer in the
o
or
suction line and drip on the sealing
ss surface of the crankshaft
a ac
seal.
ce
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nl
pt
du
an
♦ Before applying sealant bead, cover sealing surface of oil seal
itte
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erm
with a clean cloth.

ab
ility
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wit
, is n
– Cut off nozzle on tube at front marking (∅ of nozzle approx. h re

hole
3 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
e
– Apply a thin bead of sealant at the edge of the joint between

at
do
riv
the cylinder block and the sump -arrows-.

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for
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t.
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Cop py
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pyri by
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by
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Prote AG.

Amarok 2011 ➤
– Apply silicone sealant bead as shown in the illustration to clean

sealing surface of sealing flange.
AG. Volkswagen AG d
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– Thinly coat lowerthosealing
ris surface -shaded area- on sealing ntee
flange with sealant.
au
or
ac
ss
ce
– Fit sealing flange immediately and lightly tighten all bolts.
le
un
pt
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d
itte
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ab
Note
pe
ility
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wit
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h re
♦ When fitting sealing flange with oil seal installed use the guide
hole
sleeve - T10053/1- .
spec
es, in part or in w
t to the co
♦ Sealing compound must dry for approx. 30 minutes after in‐
stallation. Only then fill with engine oil.
rrectness of i
– Tighten sealing flange securing bolts diagonally and alternate‐
ly.
l purpos
– Install crankshaft toothed belt pulley.

nform
ercia
– Install sump ⇒ page 140 .

m
– Install toothed belt and adjust the valve timing ⇒ page 107 .
com
tion in
r
Specified torques
te o
thi
s
iva
do

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cum
fo
en

ng
t.
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op py
♦ ⇒ “1.4 Assembly overview - poly V-belt drive, vehicles without t. C rig
gh ht
A/C system”, page 39 pyri by
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♦ ⇒ “1.1 Assembly overview - sump, oil pump”, page 137 Prote AG.

Amarok 2011 ➤
2 Ancillary drive
⇒ “2.1 Assembly overview - ancillary drive”, page 51
⇒ “2.2 Retrofitting preparation for ancillary drive”, page 51
2.1 Assembly overview - ancillary drive
1 - Hub
❑ Note marking when in‐
stalling
2 - Bolt
❑ 20 Nm +180°
3 - Belt pulley
4 - Bolt
❑ 20 Nm + 90°
5 - Plug
AG. Volkswagen AG d
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pt
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
2.2 Retrofitting preparation for ancillary

at
do
riv
drive
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for
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pyri by
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Prote AG.
2. Ancillary drive 51
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
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aut ra
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pt
du
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Procedure
itte
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ility
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WARNING
hole
spec
es, in part or in w
Always use the original TDC mark for all adjustments to the
t to the co
engine.
rrectness of i
l purpos
Note
nform
ercia
♦ Contact surfaces must be free of oil, wax and grease. To clean

them, remove vibration damper.
m
at
om
io
♦ Set engine to TDC.
n
c
in t
or
his
ate
do
riv
– Remove vibration damper ⇒ page 44 .

p
cum
for
– Clean contact surfaces thoroughly.

en
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by
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Prote AG.
The hub fits in only one position. If incorrectly positioned, the bolt
holes will be offset.
– Set mark on hub -arrow- to “12 o'clock” during assembly be‐

cause holes in damper and hub align in this position.

Amarok 2011 ➤
– Then secure vibration damper -2- to hub -1- using new bolts.
– Set ancillary drive belt pulley -1- on hub using new bolts and
tighten.
– Clip plug -arrow- into place.
– Install poly V-belt ⇒ page 40 .
Specified torque
♦ ⇒ “2.1 Assembly overview - ancillary drive”, page 51
After completing repair, always:
– Start engine and check that belt runs properly.
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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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
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Ancillary drive 53
Amarok 2011 ➤
3 Cylinder block (gearbox end)

⇒ “3.1 Assembly overview - cylinder block, gearbox end”,
page 54
⇒ “3.2 Removing and installing dual-mass flywheel”, page 55
⇒ “3.3 Removing and installing sealing flange on gearbox side”,
page 57
3.1 Assembly overview - cylinder block, gearbox end
1 - Seal
❑ Do not apply additional
oil or grease the sealing
lip of the oil seal.
a clean cloth.
❑ Renew crankshaft oil
seal (belt pulley end)
⇒ page 46 .
2 - Sealing flange
❑ Must sit on dowel
sleeves.
AG. Volkswagen AG d
❑ Insert with silicone seal‐ ksw
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not
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ant ⇒ Electronic Parts byV
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Catalogue (ETKA) . rised
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❑ Removing and installing s aut ra
c
⇒ page 48 . s
ce
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nl
pt
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3 - Cylinder block
an
itte
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erm
ab
ility
crankshaft
ot p
wit
⇒ page 73 .
, is n
❑ Dismantling and assem‐ h re

hole
spec
bling pistons and con‐
es, in part or in w
rods ⇒ page 66 .
t to the co
4 - Bolt
rrectness of i
❑ 60 Nm + 90°
l purpos
5 - Dual-mass flywheel
❑ To loosen securing
nform
ercia
bolts, lock using 3067.

m
at
om
6 - Intermediate plate
on
c
in t
or
❑ Must sit on dowel sleeves.

his
ate
do
riv
❑ Do not damage or bend when assembling.

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7 - Bolt
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❑ 15 Nm C py
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8 - Sealing flange with oil seal
py by
co Vo
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❑ With sender wheel for engine speed.
agen
Prote AG.
❑ Renew complete unit only.

❑ Do not apply additional oil or grease the sealing lip of the oil seal.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Use support sleeve supplied when installing.

Amarok 2011 ➤
9 - Engine speed sender - G28-
❑ 5 Nm
3.2 Removing and installing dual-mass fly‐

wheel
Removing
wage es n
– Remove gearbox ⇒ Power transmission; yRep.
Vol gr. 34 ; Re‐
ks ot g
moving and installing gearbox . ise
d b ua
ran
r tee
ho
aut or
ac
Caution ss
ce
le
un
pt
an
d
To prevent damage to the dual-mass flywheel when removing,

itte
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erm
the bolts -B- must not be removed with an impact wrench or

ab
ility
similar. The bolts may only be removed by hand.
ot p
wit
is n
h re
ole,
spec
– Mark position of dual-mass flywheel in relation to engine.
t to the co
– Rotate dual-mass flywheel -A- so that bolts -B- align centrally

with the holes -arrows-.
rrectne
– When unscrewing bolts -B-, ensure that bolt heads do not

come into contact with the dual-mass flywheel -arrows-. The
flywheel will otherwise be damaged when turning further.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Cylinder block (gearbox end) 55

Amarok 2011 ➤
– Insert counterhold - 3067- in hole on cylinder block -B-.

– Unbolt dual-mass flywheel.
Installing
– Insert counterhold - 3067- in hole on cylinder block -A-.

Specified torques
♦ ⇒ “3.1 Assembly overview - cylinder block, gearbox end”, page
54 agen
AG. Volkswagen AG d
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ed ran
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au ac
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du
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itte
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ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
3.3 Removing and installing sealing flange on gearbox side

equipment required
♦ Torque wrench -
V.A.G 1331-
♦ Tool insert 24 mm - V.A.G
1332/11-
AG. Volkswagen AG d
agen oes
olksw not
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nl
pt
du
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itte
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ab
ility
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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
atio
om
n in
or c
♦ Depth gauge - VAS 6082-

thi
te
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rig ht
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by lksw
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Prote AG.
♦ 3 hexagon bolts M6 x 35 mm
♦ 2 hexagon bolts M7 x 35 mm

Amarok 2011 ➤
Removing
Note
♦ For the sake of clarity, the work is performed with the engine
removed.
♦ The procedure is identical whether the engine is installed or
removed.
– Removing gearbox ⇒ Rep. gr. 34 ; Removing and installing

gearbox .
Pressing out sealing flange with sender wheel
– Remove flywheel.
– Remove intermediate plate.
– Turn crankshaft to the TDC for cylinder 1 as shown.
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
– Remove engine speed sender - G28- -arrow-
an
itte
y li
erm
ab
– Unscrew bolts of sealing flange.
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
Sealing flange and sender wheel are pressed off the crankshaft t to the co
together using 3 M6 x 35 mm bolts. 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 ➤
– Screw in 3 M6 x 35 mm bolts into threaded holes of sealing

flange -arrows-.
– Screw bolts (max. 180° per bolt) into sealing flange alternately
in order to press it and the sender wheel of crankshaft togeth‐
er.
Pressing in sealing flange with sender wheel
Note
♦ Sealing flange with PTFE seal is equipped with a sealing lip

support ring. This support serves as an assembly sleeve. It
must not be removed before installation.
♦ Sealing flange and sender wheel must not be separated or
turned after removal from packaging.
♦ The sender wheel is held in its installation position on the as‐
sembly device - T10134- by a locating pin.
olkswagen AG
en AG. V
♦ The sealing flange and sealoare
lksw one unit. They can only
ag does
nbe
o
renewed together with ethe
d b sender wheel.
yV t gu
ara
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♦ The assembly device ut - T10134- is held in its position relative
ho eo
ra
to the crankshafts by a guide pin inserted into a hole in the
s a c
crankshaft.
ce
le
un
pt
an
d
itte
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rm
ab
Assembly tool - T10134-
pe
ility
ot
wit
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A - Clamping surface
h re
hole
B - Hexagon nut
spec
es, in part or in w
C - Assembly housing t to the co

D - Locating pin
rrectness of i
E - Hexagon socket head bolt

l purpos
F - Guide pin for diesel engines (black knob)

G - Guide pin for petrol engines (red knob)
nform
ercia
A - Fit seal with sender wheel on assembly tool - T10134-

m
a
com
tion in
– Screw on nut -B- until just before it touches the clamping sur‐
r
te o
thi
face -A- of the threaded spindle.

s
iva
do
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fo
en
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

Amarok 2011 ➤ . Volkswagen AG
gen AG does
swa
4-cylinder diesel engine (2.0 l engine, common rail)Vo-lkEdition 04.2013 not
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db ran
rise tee
– Clamp assembly device - T10134- in a vice on clamping
tho sur‐ or
face -A- of threaded spindle. s au ac
s
ce
e
nl
– Press assembly housing -C- downwards until it lies on nut
pt
du
an
-B- -arrow-.
itte
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erm
ab
– Screw nut onto threaded spindle until inner part of assembly
ility
ot p
device and assembly housing are at same height.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove safety clip -arrow- of the new sealing flange.
l purpos
nf
ercia
Note
orm
m
atio
m
The sender wheel must not be taken out of the sealing flange or
o
n in
c
twisted.
or
thi
te
sd
iva
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m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
– Place sealing flange with front side facing down on a clean
level surface.
– Push sealing lip support ring -A- downwards in direction of ar‐

row until it lies on flat surface.

Amarok 2011 ➤
– Upper edge of sender wheel and front edge of sealing flange

must align -arrows-.
– Place sealing flange with front side facing downwards onto

assembly tool - T10134- so that locating pin -B- can be inser‐
ted in sender wheel hole -A-.
Note
Ensure sealing flange lies flat on assembly tool.
– Push sealing flange and support ring for sealing lip -B- against
surface of assembly tool - T10134- whilst tightening the 3
knurled screws -A- so that locating pin cannot slide out of
sender wheel hole.
Note
AG. Volkswagen AG d
agen oes
lksw n
When installing dsealing
by
Vo flange, ensure that senderotwheel
gu
ara remains
fixed in assemblyrise device. nte
ho eo
aut ra
s c
B - Fit assembly
s tool - T10134- with sealing flange on crankshaft
ce
le
flange
un
pt
an
d
itte
y li
• Crankshaft flange must be free of oil and grease.

erm
ab
ility
ot p
• Engine is positioned at TDC of cylinder 1

wit
is n
h re
ole,
– Screw nut -B- on until it reaches end of threaded spindle.

spec
– Press threaded spindle of assembly tool - T10134- in direction

t to the co
of arrow, until hexagon nut -B- lies against assembly housing

-A-.
rrectne
– Align flat side of assembly housing to crankcase's sealing sur‐

face on the oil sump side.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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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 ➤
– Secure assembly tool - T10134- to crankshaft flange with hex‐

agon socket head bolts -A-.
Note
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
prox. 5 full turns).
– To guide sealing flange into cylinder block, screw in 2 M7 ×

35 mm bolts -A-.
C - Bolting assembly tool - T10134- onto crankshaft flange
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
– Push assembly housing -C-orby is hand in direction of arrow until
ed
nte
sealing lip support ring -B-aut touches crankshaft flange -A-.
h eo
ra
ss c
– Push guide pin for diesel engines (black knob) -D- into hole in
ce
e
nl
pt
crankshaft. This ensures that the sender wheel reaches its fi‐
du
an
itte
nal installation position.

y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
The guide pin for petrol engines (red knob) -F- must not be inser‐
es, in part or in w
ted in threaded hole of crankshaft.

t to the co
– Tighten the two hexagon socket head bolts of the assembly

rrectness of i
tool hand-tight.
l purpos
– Screw nut -E- onto threaded spindle by hand until it lies against
assembly housing -C-.
nf
ercia
D - Pressing sender wheel onto crankshaft flange using assembly

orm
tool - T10134-
m
atio
om
n in
or c
thi
te
sd
iva
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cu
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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.

Amarok 2011 ➤
– Tighten nut of assembly tool - T10134- using torque wrench -

V.A.G 1331- and flared ring spanner tool insert AF A24 - V.A.G
G. Volkswagen AG d
1332/11- . lksw
agen oes
n o ot g
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Specified torque ir se
db ran
tee
ho
ut or
Component ss
a Specified torque ac
ce
le
Tighten nut of assembly tool - 35 Nm
un
pt
an
d
T10134-
itte
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rm
ab
pe
ility
ot
wit
Note
, is n
h re
hole
spec
After hexagon nut is tightened to 35 Nm, a small air gap must still
es, in part or in w
be present between cylinder block and sealing flange.
t to the co
E - Checking sender wheel installation position on crankshaft
rrectness of i
– Screw nut -E- on until it reaches end of threaded spindle.
l purpos
– Unscrew 2 bolts -A- from cylinder block.
nform
ercia
– Unscrew the three knurled screws -B- out of sealing flange.

m
a
com
– Remove assembly tool - T10134- .
tion in
r
te o
– Remove sealing lip support ring.
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.
– The sender wheel is in the correct installation position on the
crankshaft if a gap -a- = 0.5 mm exists between crankshaft
flange -A- and sender wheel -B-.
– Place caliper gauge on crankshaft flange.

– Measured distance -a- between crankshaft flange and sender
wheel.
If dimension -a- is too small:
– Re-press sender wheel ⇒ page 64 .
If dimension -a- is achieved:
– Tighten new sealing flange securing bolts diagonally and al‐
ternately.

Amarok 2011 ➤
– Install engine speed sender - G28- -arrow- and tighten secur‐

ing bolt.
– Install intermediate plate.
– Install flywheel with new bolts.
F - Re-pressing sender wheel
– Secure assembly tool - T10134- to crankshaft flange with hex‐

agon socket head bolts -A-.
– Tighten the two hexagon socket head bolts hand-tight.
– Push the assembly tool - T10134- against the sealing flange
by hand.
– Screw nut -E- onto threaded spindle by hand until it lies against
assembly housing -C-.
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 ➤
– Tighten nut of assembly tool - T10134- using torque wrench -

V.A.G 1331- and flared ring spanner tool insert AF 24 - V.A.G
1332/11- .
Specified torque
Tighten nut of assembly tool - 40 Nm
T10134-
– Check the sender wheel installation position on crankshaft
again ⇒ page 63
If dimension -a- is too small again:
– Tighten nut of assembly tool - T10134- as follows:
AG. Volkswagen AG d
agen oes
Specified torque Volksw not
gu
d by ara
ise nte
Component Specified
hor torque eo
aut ra
Tighten nut of assembly tool - s 45 Nm
s c
ce
e
T10134-
nl
pt
du
an
itte
y li
– Check the sender wheel installation position on crankshaft
erm
ab
again ⇒ page 63
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
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cu
o
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f
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
cted agen
Prote AG.

Amarok 2011 ➤
4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 66
⇒ “4.2 Checking piston and cylinder bore”, page 68
⇒ “4.3 Piston and cylinder dimensions”, page 69
⇒ “4.4 Measuring piston projection at TDC”, page 70
⇒ “4.5 Checking radial clearance of conrods”, page 71
⇒ “4.6 Bearing shells - installation position”, page 71
⇒ “4.7 Separating new conrod”, page 72
4.1 Assembly overview - pistons and conrods
1 - Piston rings
❑ Offset gaps by 120°.
❑ Use piston ring pliers to
remove and install.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
⇒ page 67 .
Volkswagen AG
❑ Checking ring-to-groove swagen AG. does
clearance ⇒ page 68 b.y Volk not
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2 - Piston ho
ri tee
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ac
❑ With combustion ss cham‐
ber.
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❑ Mark installation posi‐

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❑ Installation position and

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allocation of piston to
hole
spec
cylinder ⇒ page 68 .
es, in part or in w
t to the co
❑ Arrow on piston crown

points to belt pulley end.
❑ Checking ⇒ page 68 .
rrectness of i
❑ Install using piston ring

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clamp.
❑ If piston skirt is cracked,
renew piston.
nf
ercia
or
❑ Checking piston projec‐

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atio
tion at TDC
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⇒ page 70 .
or c
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3 - Piston pin
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❑ If difficult to remove,
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heat piston to 60 °C. yi

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❑ Remove and install us‐
C py
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ing drift - VW 222- .
ht
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4 - Circlip
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Prote AG.
5 - Conrod
❑ Mark cylinder allocation -A- with coloured pen.
❑ Installation position: Marking -B- faces towards pulley end.
❑ With industrially cracked conrod cap.
❑ Measuring radial clearance ⇒ page 71

Amarok 2011 ➤
6 - Bearing shell
❑ Note installation position ⇒ page 71 .
❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi‐
cation: Black line on bearing surface in area of joint.
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
❑ Check for secure seating.
❑ Axial clearance, wear limit: 0.37 mm
❑ Check radial clearance with Plastigage; wear limit: 0.08 mm.
❑ Do not rotate crankshaft when checking radial clearance.
7 - Cylinder block
❑ Checking cylinder bores ⇒ page 69 .
❑ Piston and cylinder dimensions ⇒ page 69 .
8 - Conrod bearing cap
❑ Note installation position.
9 - Oil spray jet
❑ For piston cooling.
10 - Bolt
❑ Insert without sealant.
❑ 25 Nm n AG. Volkswagen AG do
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❑ Renew afterthremoving
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❑ Oil threads
ss and contact surface.
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❑ Use old bolt for measuring radial clearance.

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❑ 30 Nm + 90°
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Checking piston ring gap

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spec
t to the co
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♦ Feeler gauges
um
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fo
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t.
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– Push piston ring at right angle from above down into lower
Co
op py
cylinder bore to approx. 15 mm from bottom end of cylinder.
t. C rig
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Piston ring New Wear limit
by lksw
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dimensions in mm
AG.
1st compression ring 0.20 … 0.40 1.0

2nd compression ring 0.20 … 0.40 1.0
Oil scraper ring 0.25 … 0.50 1.0
4. Pistons and conrods 67

Amarok 2011 ➤
Checking ring-to-groove clearance

♦ Feeler gauges
– Clean annular groove before check.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.06 … 0.09 0.25 AG. Volkswagen AG d
agen oes
2nd compression ring 0.05 … 0.08 0.25 Volksw not
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Oil scraper ring 0.03 … 0.06 0.15
orised
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Installation position and allocation of piston to cylinder
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Arrow on piston crown -arrows- points in direction of cylinder 1.
pt
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spec
t to the co
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4.2 Checking piston and cylinder bore
s o
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f inform
Checking piston
mer
atio
– Using a micrometer (75 … 100 mm), measure approx. 15 mm

om
from the lower edge, perpendicular to the piston pin axis.

c
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• Maximum deviation from nominal dimension: 0.04 mm

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Nominal dimension ⇒ page 69

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gh
Note
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pyri by
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Piston must be renewed if piston shaft reveals cracking.
AG.

Amarok 2011 ➤
Checking cylinder bores

♦ Internal dial test indicator 50…100 mm
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-. Difference between actual
and nominal diameter max. 0.10 mm.
Note n AG. Volkswagen AG do

lkswage es n
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Cylinder bores must not be measured
ir se
d when the cylinder block is
b ua
ran
secured to engine and gearboxthsupport - VAS 6095- , as meas‐
o tee
or
urements may be incorrect. ss au ac
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4.3 Piston and cylinder dimensions

an
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Piston Ø Cylinder bore Ø

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Basic di‐ mm 80.96 81.01

h re
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mension
spec
t to the co
rrectness o
cial p
f inform
mer
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Cop py
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by
cted agen
Prote AG.

Amarok 2011 ➤
4.4 Measuring piston projection at TDC

equipment required
♦ Measuring bridge -
VW 382/7- from measuring
tool - VW 382-
♦ Measuring plate -
VW 385/17- from measur‐
ing tool - VW 385-
♦ Dial gauge - VAS 6079-
AG. Volkswagen AG d
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Test procedure h re
hole
spec
♦ The piston projection in the genuine part must be measured
es, in part or in w
on all pistons when installing new pistons or a short engine.

t to the co
♦ If you have measured the piston projection and it is not same

for all pistons, use the highest value to determine the correct
rrectness of i
gasket size.
l purpos
♦ Depending on piston projection, fit the appropriate cylinder

head gasket according to following table.
nform
ercia
♦ Turn crankshaft clockwise to measure.

m
at
– Secure dial gauge - VAS 6079- with measuring bridge -

om
ion
VW 382/7- and measuring plate -VW 385/17- to cylinder block

c
in t
or
as shown in the illustration.

his
ate
do
priv
cum
for
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Prote AG.

Amarok 2011 ➤
olkswagen AG
en AG. V
– Measure the projection
ksw
ag of each piston at
doethe
s notwo points marked
Vol
with -arrows-
ed b (at the rear side and front side of
y t gu
athe
ran piston seen
in theholongitudinal
ris direction of the engine). tee
t or
au a
– Install
ss the appropriate cylinder head gasket depending
c upon
piston projection, according to following table:
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pt
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Piston projection Identification
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ab
Holes/notches
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0.91 mm … 1.00 mm 1
, is n
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1.01 mm … 1.10 mm 2
hole
spec
es, in part or in w
1.11 mm … 1.20 mm 3
t to the co
rrectness of i
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mercia
at
om
4.5 Checking radial clearance of conrods
ion
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in t
or
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ate
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priv
♦ Plastigage
um
for
en
ng
t.
Procedure
yi Co
Cop py
t. rig
– Remove conrod bearing cap. Clean bearing cap and bearing
gh ht
pyri by
journal.
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by c lksw
cted agen
Prote AG.
– Place a Plastigage corresponding to the width of the bearing
on the journal or into the bearing shells.
– Fit conrod bearing cap and tighten to 30 Nm without turning
further angle and without rotating crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
Radial clearance:
• Wear limit: 0.08 mm
– Renew conrod bolts.
4.6 Bearing shells - installation position

Bearing shell -1- with oil hole -arrow- for conrod.
Bearing shell -2- without oil hole for conrod bearing cap.
– Position bearing shells in centre of conrod and conrod bearing
cap when fitting.
Dimension -a- must be identical on both sides.

Amarok 2011 ➤
4.7 Separating new conrod

Procedure:
On new conrods it is possible that the breaking point is not fully
separated. Proceed as follows if the conrod bearing cap cannot
be removed by hand:
– Mark allocation of conrod to cylinder.
– Lightly clamp the conrod in a vice using aluminum vice clamps,
as shown in the illustration.
Note
♦ Only clamp the conrod lightly in order to avoid damaging it.

♦ Conrod is clamped below the dashed line.
– Unscrew bolts -arrows- around 5 turns.
AG. Volkswagen AG d
– Using a plastic hammer, carefully knock against conrod bear‐ agen oes
olksw not
ing cap in -direction of arrow- until it is loose. d by V gu
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ility
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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ate
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priv
cum
for
en
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Cop py
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pyri by
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co lksw
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cted agen
Prote AG.

Amarok 2011 ➤
5 Crankshaft
⇒ “5.1 Assembly overview - crankshaft”, page 73
⇒ “5.2 Crankshaft dimensions”, page 74
⇒ “5.3 Measuring axial clearance of crankshaft”, page 74
⇒ “5.4 Measuring radial clearance of crankshaft”, page 75
⇒ “5.5 Renewing needle bearing in crankshaft”, page 76
5.1 Assembly overview - crankshaft
1 - Bearing shells 1, 2, 4 and 5

❑ For bearing cap without lkswage es n
Vo ot g
oil groove. d by ua
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ir se tee
❑ For cylinder block with utho
or
oil groove. ss
a ac
ce
le
❑ Do not interchange
un
pt
used bearing shells
an
d
itte
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(mark).
rm
ab
pe
ility
2 - Bolt
ot
wit
, is n
h re
hole
spec
❑ To measure radial clear‐
es, in part or in w
ance, tighten to 65 Nm
t to the co
but not further.
❑ 65 Nm + 90°
rrectness of i
3 - Bearing cap
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❑ Bearing cap 1: belt pul‐

ley end.
❑ Bearing cap 3 with re‐
nform
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cesses for thrust wash‐

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a
ers.
com
tion in
❑ Bearing shell retaining
r
te o
thi
lugs in cylinder block

s
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and bearing caps must

r
rp
align.
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t.
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4 - Thrust washer
Co
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t. rig
❑ For bearing cap 3.
gh ht
pyri by
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❑ Note fixing arrange‐
c by lksw
cted agen
ment.
Prote AG.
5 - Bearing shell 3
❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove.
❑ Do not interchange used bearing shells (mark).
6 - Needle bearing
7 - Crankshaft
❑ With toothed belt pulley for oil pump drive. Toothed belt pulley is not available as separate part.
❑ Axial clearance new: 0.07…0.17 mm; wear limit: 0.37 mm
❑ Measure radial clearance with Plastigage , new: 0.03…0.08 mm; wear limit: 0.17 mm
❑ Do not rotate crankshaft when checking radial clearance.
❑ Crankshaft dimensions ⇒ page 74 .
5. Crankshaft 73
Amarok 2011 ➤
8 - Thrust washer
❑ For cylinder block, bearing 3
5.2 Crankshaft dimensions

(Dimensions in mm)
Main Conrod
journal ∅ journal ∅
Basic dimension 54.00 -0.022 50.90 -0.022
-0.042 -0.042
5.3 Measuring axial clearance of crankshaft

♦ Universal dial gauge bracket - VW 387-
AG. Volkswagen AG d
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olksw not
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♦ Dial gauge - VAS 6079- horise nte
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ab
pe
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
Procedure
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– Fit dial gauge - VAS 6079- with universal dial gauge holder -
VW 387- to cylinder block as shown in the illustration and set
nform
ercia
against crank web.

m
a
com
– Press crankshaft against dial gauge by hand.

ion in
r
te o
– Set dial gauge to “0”.

thi
s
iva
do
– Push crankshaft away from dial gauge and read off measured
r
rp
cum
fo
value.
en
ng
t.
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op
Axial clearance: C py
t. rig
gh ht
yri by
• New: 0.07…0.17 mm op Vo
by c lksw
cted agen
Prote
AG.

Amarok 2011 ➤
5.4 Measuring radial clearance of crank‐

shaft
♦ Plastigage
Procedure:
Note
♦ Mark used bearings for re-installation but not on bearing sur‐

face.
♦ If bearing shells have worn down to nickel layer, they must be
renewed.
– Remove bearing cap and clean crankshaft journal.

– Place a Plastigage corresponding to the width of the bearing
on the journal or into the bearing shells.
• The Plastigage must lie in the middle of the bearing shell.
– Fit bearing cap and tighten. Do not rotate crankshaft.
Specified torque AG. Volkswagen AG d
agen oes
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Component Specified
rised torque ara
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Bearing cap aut 30 Nm ra
ss c
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– Remove bearing cap again.

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ab
ility
ot p
Radial clearance:
wit
is n
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• New: 0.03 … 0.08 mm
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
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pr
cum
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fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
5. Crankshaft 75
Amarok 2011 ➤
5.5 Renewing needle bearing in crankshaft

equipment required
♦ Internal puller - Kukko 21/2-
and internal puller - Kukko AG. Volkswagen AG d
22/1- agen oes
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♦ Centring mandrel - 3176- rised
nte
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♦ Drift - VW 207 C- ss a ra
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pe
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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com
tion in
r
te o
thi
s
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rp
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en
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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.
Removing
• Gearbox is separated from engine.
– 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.

Amarok 2011 ➤
– 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.
Installation depth dimension -a- = 1.5 to 1.8 mm.
AG. Volkswagen AG d
agen oes
olksw not
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ed
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ab
pe
ility
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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com
tion in
r
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thi
s
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t.
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Cop py
ht. rig
rig ht
py by
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by lksw
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Prote AG.
5. Crankshaft 77
Amarok 2011 ➤
15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 78
⇒ “1.2 Assembly overview - cylinder head cover”, page 81
⇒ “1.3 Removing and installing cylinder head”, page 85
⇒ “1.4 Removing and installing cylinder head cover”, page 93
⇒ “1.5 Removing and installing injector seals”, page 99
AG. Volkswagen AG d
agen
⇒ “1.6 Removing and installing vacuum pump”, page 102 Volksw
oes
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⇒ “1.7 Checking compression”, page 103 orise nte
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1.1 Assembly overview - cylinder head s a c
s
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le
un
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erm
Note
ab
ility
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♦ The plastic packing pieces for protecting the open valves must
h re
not be removed until immediately before fitting cylinder head.
ole,
spec
♦ If the cylinder head is replaced, all the coolant in the system
t to the co
must also be renewed.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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Cop py
t. rig
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78 Rep. gr.15 - Cylinder head, valve gear

Amarok 2011 ➤
1 - Cylinder head
❑ After renewing, renew
entire coolant.
❑ Check for distortion
⇒ page 80 .
⇒ page 85 .
2 - Washer
3 - Cylinder head bolt
❑ Before installing, place
washers in cylinder
head
⇒ Item 2 (page 79) .
❑ Observe sequence
when loosening and
tightening ⇒ page 80 .
4 - Oil pressure switch - F1-
❑ Identification: green wage
es n
olks ot g
❑ 0.5 bar d by V ua
ran
ir se
❑ If sealthis leaking, nip
o tee
or
open
ss
au
and renew. ac
ce
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nl
pt
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an

itte
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⇒ page 154 .
erm
ab
ility
ot p
❑ 22 Nm
wit
, is n
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5 - Centre hex stud

hole
spec
❑ 25 Nm
es, in part or in w
t to the co
6 - Lifting eye
7 - Glow plug
rrectness of i
❑ 18 Nm
l purpos
8 - Gasket
nf
ercia
9 - Vacuum pump
rm
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atio
om
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c
DANGER!
or
thi
te
sd
a
The vacuum pump may,

iv
o
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rp
cu
under no circumstances,
o
m
f
be dismantled as the
en
ng
t.
yi
vacuum part could other‐
Co
Cop py
wise malfunction. This
t. rig
gh ht
yri
would result in the failure
p by
co Vo
lksw
of the brake servo.
by
cted agen
Prote AG.

10 - Bolt
❑ 10 Nm
11 - Clip
12 - Coolant temperature sender - G62-
13 - Seal
1. Cylinder head 79
Amarok 2011 ➤
14 - Bolt
❑ 10 Nm
15 - Coolant hose connection
16 - Gasket
17 - Bolt
❑ 25 Nm
18 - Lifting eye
19 - Cylinder head gasket
❑ Note marking ⇒ page 81 .
20 - Hall sender - G40-
❑ For camshaft position.
21 - Bolt AG. Volkswagen AG d
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❑ 10 Nm ed byV gu
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Observe tightening sequence of cylinder head bolts.
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nl
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erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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Checking cylinder head for distortion
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.

♦ Straightedge 500 mm - VAS 6075-
♦ Feeler gauge -1-
Max. permissible distortion: 0.1 mm.

Amarok 2011 ➤
Note
Reworking diesel cylinder heads is not permissible.
Cylinder head gasket identification

♦ Part No. = arrow 1
♦ Holes = arrow 2
♦ Production control code = arrow 3 (can be disregarded)
Note
♦ Different thicknesses of cylinder head gasket are fitted de‐

pending on the piston projection. When renewing gasket,
install new gasket with same identification.
♦ Piston projection in genuine part must be determined when
installing new pistons or a short engine ⇒ page 70 .
1.2 Assembly overview - cylinder head cover
1 - High-pressure accumulator
(fuel rail)
❑ Do not attempt to re‐
shape high-pressure
lines.
AG. Volkswagen AG d
❑ Observe rules for clean‐ agen oes
olksw not
liness ⇒ page 7 . d byV gu
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❑ Removing and installing hor eo
ut
high-pressure lines ss a ra
c
⇒ page 338 .
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an
2 - Bolt
d
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ab
❑ 22 Nm
ility
ot p
3 - Fuel return line

wit
is n
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❑ Cannot be renewed
ole,
spec
separately
t to the co
❑ To fuel tank.
❑ The fuel return line must
not be kinked, damaged
rrectne
or blocked.
❑ The fuel return lines
s
must not be dismantled.

s o
cial p
❑ Removing ⇒ page 83
inform
mer
❑ Checking catches
atio
⇒ page 83 .
om
n
c
❑ Fitting ⇒ page 83
or
n thi
te
sd
❑ Lock ⇒ page 84
iva
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pr
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fo
4 - Injector
en
ng
t.
yi
❑ If the injectors are to be
Co
Cop py
re-installed, they must ht. rig
rig ht
always be re-fitted on py by
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the same cylinder. Prote
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agen
❑ Before re-using “high-

pressure line”, perform
1. Cylinder head 81
Amarok 2011 ➤
visual check of taper

seals for damage, e.g. transverse scores or corrosion. Always renew pipe if damaged.
5 - O-ring
6 - Bolt
❑ 8 Nm +180°
7 - O-ring
8 - Seal
AG. Volkswagen AG d
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9 - Clamping plate orise nte
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10 - Cap ss a c
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11 - Gasket
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12 - Cylinder head cover
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13 - Bolt
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❑ Renew seal if damaged
❑ Tightening sequence ⇒ page 84 .
t to the co
❑ 10 Nm
14 - Gasket
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❑ Renew if damaged or leaking.
ss
15 - Vacuum hose
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16 - Pipe assembly
form
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❑ For crankcase ventilation. atio

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❑ Press release buttons to remove.

c
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17 - O-ring
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18 - Grommet
Co
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19 - Sealing bush for high-pressure accumulator (fuel rail) rig ht
py by
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20 - Injector seal
❑ Renew if damaged or leaking ⇒ page 99 .
21 - Bracket
22 - Bolt
❑ 10 Nm

Amarok 2011 ➤
Disconnecting fuel return lines

– With engine switched off, carefully pull return line connections
off at piezo injectors. To do this, press the two clips downwards
-arrow A- and, at the same time, pull the release bolt upwards
-arrow B-.
AG. Volkswagen AG d
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Check catches uthor eo
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Caution
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• Carefully pull fuel return lines upwards when disconnect‐
ab
pe
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ing as the 4 catches -arrow- can fracture.
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• After disconnecting, check the 4 catches -arrow- to see
h re
hole
whether they are fractured or have broken off.
spec
es, in part or in w
• Always replace damaged fuel return lines.
t to the co
• A damaged fuel return line that becomes loose when en‐
gine is running causes damage to piezo injector. The
rrectness of i
piezo injector must then be replaced.
l purpos
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Fit fuel return line

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– Apply a thin coating of diesel fuel to the new O-rings on the

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return-line connections.
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– Connect fuel return line and press the two clips downwards as
t. rig
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far as they will go -arrows-.
p by
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Prote AG.
1. Cylinder head 83
Amarok 2011 ➤
Lock fuel return line

– After fuel return line has been pushed on completely, press
the locking bolt downwards -arrow-.
Tightening sequence for cylinder head cover

– Hand-tighten cylinder head cover in the sequence -1 … 6-.
– Tighten bolts in the sequence -1 … 6-.
AG. Volkswagen AG d
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Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.

Amarok 2011 ➤
1.3 Removing and installing cylinder head

equipment required
♦ Guide pins - 3070-
♦ Diesel injection pump lock‐
ing pin - 3359-
♦ Crankshaft stop - T10050-
♦ Counterhold tool - T10051-
♦ Puller - T10052-
♦ Bit XZN 10 - T10385-
AG. Volkswagen AG d
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1. Cylinder head 85
Amarok 2011 ➤

1331-
1332-
♦ Socket set 1/4", 22-piece -
VAS 5528-
6122-
♦ Drip tray for workshop hoist AG. Volkswagen AG d
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Cop py
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♦ Hose clip pliers - VAS 6362-
cop Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
Note
♦ Before carrying out further work, disconnect battery earth

strap. Check whether a coded radio is fitted. Obtain anti-theft
coding first if necessary.
♦ All cable ties which are opened or cut through when cylinder
head is removed must be fastened in the same position when
cylinder head is installed.
♦ All connectors which are separated during disassembly must
be reconnected in the original position when installing.
♦ Seal open lines and unions with clean plugs from engine bung
set - VAS 6122- .
♦ Collect drained coolant in a clean container for re-use or dis‐
posal.
AG. Volkswagen AG d
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Caution ise d b ara
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When doing anyssrepair
a
work, especially in the engine compart‐ c
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pt
tions:
du
an
itte
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ab
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sitions.
hole
spec
es, in part or in w
t to the co
rrectness of i
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Note
Glow plugs -arrows- project out of cylinder head. After removal,

nf
ercia
the cylinder head must not be placed on the glow plugs. If nec‐
orm
essary, remove glow plugs ⇒ page 405 .

m
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or c
Removing
thi
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– Disconnect battery earth strap with ignition switched off ⇒ C py
t. rig
Electrical system; Rep. gr. 27 ; Disconnecting and reconnect‐
gh ht
yri by
ing battery . cop Vo
by lksw
cted agen
Prote AG.
– Remove camshaft pulley from hub.
– Remove camshaft hub. To do this, pull camshaft hub off using
puller - T10052- .
1. Cylinder head 87
Amarok 2011 ➤
– Counterhold hub with counter-hold tool - T10051- and release

hub bolt -1-.
– Unscrew hub bolt approx. 2 turns.
– Position puller - T10052- and align with hub holes.

– Tighten bolts -1-.
– Apply tension to hub by evenly tightening puller -2- until hub
separates from taper of camshaft. Hold puller with 30 mm
spanner whilst doing this. agen
AG. Volkswagen AG d
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– Remove hub from taper of camshaft. d by ara
rise nte
tho eo
au ra
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nl
pt
du
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itte
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erm
ab
ility
ot p
– Unscrew bolt -arrow- from toothed belt guard.
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
– Screw off Hall sender - G40- -arrow-.
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 ➤

– Remove pipe -5- from cylinder head cover.
wage
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Vol t gu
– Release and pull off wiring harness d bconnector -2-. Detach wir‐
y ara
ing harness -2- from intake hose riseretainer -3-. nte
ho t eo
au ra
– Open clips -1- and -4- andssremove intake hose -3-. c
ce
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nl
pt
– Remove air filter with attachments ⇒ page 370 .
du
an
itte
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– Remove particulate filter ⇒ page 381 .
erm
ab
ility
ot p
– Remove turbocharger ⇒ page 267 .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Unclip connector -2- on oil pressure switch - F1- .

m
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ion
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or
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ate
do
priv
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for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Disconnect connector -2- at coolant temperature sender -

G62- -1-.
Note
Components for coolant temperature sender - G62- are difficult

to see. A small hand-held mirror is required to unscrew and insert
coolant temperature sender - G62- .
– Loosen clamp for coolant hose -1- and pull off coolant hose
-1-.
– Loosen clamp for coolant pipe -4- and pull coolant pipe -4- out
at union -2-.
– Remove cylinder head cover ⇒ page 93 .
– Remove intake manifold ⇒ page 354 .
– Remove/pull off all necessary coolant hoses, vacuum lines
and plug-in electrical connectors.
1. Cylinder head 89
Amarok 2011 ➤
– Comply with specified sequence when undoing cylinder head

bolts.
Note
♦ A second mechanic is required to remove and install the cyl‐

inder head.
♦ Before removing cylinder head, remove toothed belt tensioner
from stud. Make sure that toothed belt tensioner does not fall
to the floor.
♦ Check that all necessary hoses and lines have been discon‐
nected.
♦ Do not place cylinder head onto dowel sleeves -A- when re‐
moving and installing.
AG. Volkswagen AG d
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– First raise cylinder head on gearbox side Voand
lksw pull slightly to not
gu
left. Whilst doing this, remove toothed
se
dbelt
by tensioner from stud. ara
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– When lifting cylinder head out, aguide
ut
h
electrical lines and cool‐ ra
ant hoses past transport eyelet.
ss c
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un
pt
an
d
itte
Caution
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erm
ab
ility
ot p
Risk of damage to glow plug pins -arrow- when cylinder head

wit
is n
is being lowered.
h re
ole,
spec
♦ Do not lay removed cylinder head with installed glow plugs

down on sealing surface, as glow pins -arrow- project past

t to the co
sealing surface.
rrectness o
cial p
f inform
mer
atio
om
n
c
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sd
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pr
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
Caution
AG. Volkswagen AG d
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Avoid damage to sealing surfaces:
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♦ When using abrasive utho paper do not use a grade less than eo
ra
100. ss a c
ce
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♦ Carefully remove any sealant residue from the cylinder
un
pt
an
d
head and cylinder block. Ensure that no long scores or

itte
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scratches are made on the surfaces.
erm
ab
ility
ot p
♦ Carefully remove remains of emery and abrasives.
wit
is n
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spec
Installing
t to the co
rrectne
Caution
s
Avoid damage to cylinder block.
s o
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f in
♦ No oil or coolant may be contained in hole pockets for cyl‐
form
mer
inder head bolts in cylinder block.
atio
m
Danger of cylinder head gasket leaks.

o
n
c
i
or
n thi
e
♦ Do not remove new cylinder head gasket from packaging

t
sd
va
until it is ready to be fitted.

i
o
pr
cum
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fo
♦ Handle the cylinder head gasket very carefully to prevent en

ng
t.
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damage to the silicone coating or the indented area of the t. Cop py
gasket.
rig
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pyri by
Vo
co
Avoid damage to open valves.
by lksw
cted agen
Prote AG.
♦ When installing an exchange cylinder head, the plastic
protectors fitted to protect the open valves should not be
removed until the cylinder head is ready to be fitted.
Avoid damage to valves and piston crowns after working on
valve gear.
♦ Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.
1. Cylinder head 91
AG. Volkswagen AG d
agen oes
olksw not
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Amarok 2011 ➤ thor eo
u ra
4-cylinder diesel
ss a engine (2.0 l engine, common rail) - Edition 04.2013
c
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e
nl
pt
du
an
itte
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Note erm
ab
ility
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wit
♦ Proceed with extreme caution. The assistance of a second
, is n
h re
mechanic is vital.
hole
spec
♦ Always renew cylinder head bolts.
es, in part or in w
t to the co
♦ Renew seals, gaskets, self-locking nuts, bolts tightened
through an additional specified angle and securing clamps.
rrectness of i
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
l purpos
♦ If an exchange cylinder head is installed, contact surfaces be‐

tween roller rocker fingers and running surface of cam must
nform
ercia
be oiled.
m
at
om
i
♦ Hose unions and air intake pipes/hoses must be free of oil and
on
c
grease when installing.
in t
or
his
ate
♦ When cylinder head or cylinder head gasket is renewed, the
do
priv
c
entire coolant ⇒ page 182 and the engine oil must be
um
for
en
changed.
ng
t.
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Cop py
t. rig
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– To centre, screw guide pins -3070/9- into outer threaded holes cop Vo
by lksw
on intake side.
cted agen
Prote AG.
• Cylinder head gasket installation position: marking “top” or

part number towards cylinder head
– Position cylinder head gasket.
– Thread cylinder head into toothed belt guard and position belt
tensioner onto stud. When doing this, cylinder head must not
scrape over dowel sleeves -A-.
– Fit cylinder head.
– Insert 8 cylinder head bolts and screw in to stop by hand.
– Unscrew guide pins -3070/9- through bolt holes in cylinder
head and screw remaining cylinder head bolts in to stop by
hand.

agen
AG. Volkswagen AG d
oes Amarok 2011 ➤
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4-cylinder
by Vol
diesel engine (2.0 l engine,
gu
ara
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Cylinder head bolt tho sequence
tightening
eo
s au ra
c
s
– Tighten cylinder head in 4 stages in sequence shown as fol‐
ce
le
un
pt
lows:
an
d
itte
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erm
1- Tighten initially with torque wrench:
ab
ility
ot p
Stage I = 35 Nm
wit
is n
h re
ole,
Stage II = 60 Nm
spec
2- Turn further with rigid spanner:
t to the co
Stage III = 1/4 turn (90°)
rrectne
Stage IV = 1/4 turn (90°)
ss
– Secure bolt -arrow- of toothed belt guard.
o
cial p
f in
– Install hub and camshaft pulley.
form
mer
atio
om
n
c
i
– Installing turbocharger ⇒ page 267 .
or
n thi
te
sd
va
– Install particulate filter ⇒ page 381 .

i
o
pr
cum
r
fo
– Install cylinder head cover ⇒ page 93 .
en
ng
t.
yi Co
op
– Install intake manifold ⇒ page 354 .
C py
t. rig
gh ht
yri by
– Reconnect battery earth strap with ignition switched off ⇒
cop Vo
by lksw
cted
Electrical system; Rep. gr. 27 ; Disconnecting and reconnect‐
agen
Prote AG.
ing battery .
total of 3 times in this case. The process must not be termi‐
nated prematurely.
– Carry out road test and read all event memories.
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 78
♦ ⇒ “1.2 Assembly overview - cylinder head cover”, page 81
1.4 Removing and installing cylinder head

cover
1. Cylinder head 93
Amarok 2011 ➤
♦ Socket - T40055-
AG. Volkswagen AG d
agen oes
olksw not
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pt
du
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ab
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es, in part or in w
Removing t to the co
Observe safety precautions ⇒ page 3 .
rrectness of i
Observe rules for cleanliness ⇒ page 7 .

l purpos
– Unclip crankcase breather -1- from cylinder head cover -2-.

– Remove coolant hose -3- from exhaust gas recirculation cool‐
nf
ercia
er connection -4-.
orm
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om
n in
or c
thi
te
sd
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Pull connector -2- off fuel pressure sender - G247- -1-.

Amarok 2011 ➤
– Unscrew bolts -2- for fuel line -1-.
– Remove vacuum hose -2- from toothed belt guard -1-.

– Pull vacuum hose -arrow- off from cylinder head cover.

AG. Volkswagen AG d
agen oes
olksw not
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t to the co
Caution
rrectness of i

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nform
ercia

m
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com

ion in
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te o

thi
s
iva
gine is running causes damage to piezo injector. The

do
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rp

um
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Cylinder head 95
Amarok 2011 ➤

-arrow B-.
– Pull all fuel return lines -1- off piezo injectors. lkswage es n
o ot g
byV ua
d
– Release connectors -2- and pull them off piezo injectors.
o
ir se
ran
tee
th or
au ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew union nuts -1- from piezo injectors.
rrectness of i
– Ensure cleanliness. No dirt must be allowed to get into the
l purpos
disconnected fuel return lines or the open connections on the

piezo injectors.
nf
ercia
– Unscrew bolts -2- from high-pressure accumulator (fuel rail).
orm
m
– Pull cable guide -3- from high-pressure accumulator (fuel rail). atio
om
n in
or c
thi
te
sd
iva
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rp
cu
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f
en
ng
t.
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Cop py
t. rig
gh
– Unclip connector -2- and pull off from fuel pressure regulating
ht
pyri by
Vo
o
valve - N276- -1-.
c by lksw
cted agen
Prote AG.
– Pull fuel hose -3- from high-pressure accumulator (fuel ail)
-4-.

Amarok 2011 ➤
– Remove high-pressure accumulator (fuel rail) -1-. Guide high-

pressure accumulator (fuel rail) past fuel return line and fuel
lines.
– Ensure cleanliness. No dirt may get into the injector holes on
the cylinder head cover.
– Remove injectors ⇒ page 327 .
– Unscrew cylinder head cover bolts in the sequence -6 … 1-

and remove cylinder head cover.
Installing
AG. Volkswagen AG d
agen oes
olksw not
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un
pt
– Hand-tighten cylinder head cover in the sequence -1 … 6-.
an
d
itte
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erm
– Tighten bolts in the sequence -1 … 6-.
ab
ility
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is n
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t to the co
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form
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or
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 97
Amarok 2011 ➤

– First, fit top part of toothed belt guard to middle -1- of toothed
belt guard from the rear.
– Then, fit toothed belt guard to middle -2- and -3- of toothed belt
guard at the top.
sary for the fuel system to be bled. To do this, perform the Volkswa
“Bleeding fuel system” function using the ⇒ Vehiclesdiagnostic
agen
AG. gen AG
does
k w
tester ⇒ page 316 . by Vol not
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♦ This process takes 130 seconds. Fuel pumps ho are actuated a tee
ut or
total of 3 times in the process. The process
ss a must not be ter‐ ac
ce
e
nl
pt
du
an
Specified torques
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ab

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hole
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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n in
or c
thi
te
sd
iva
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rp
cu
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
1.5 Removing and installing injector seals

equipment required
♦ Lambda probe open ring
spanner set - 3337-
♦ Tool set - T10055-
♦ Assembly tool - T10208/2-
1331-
♦ Tool set - T10133-
♦ Oil seal extractor - T 40195-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
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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
♦ Injector remover - T40402-

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
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f
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ng
t.
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Removing t. Cop py
rig
gh ht
Observe safety precautions ⇒ page 4 . pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 99
Amarok 2011 ➤

Caution

gine is running causes damage to piezo injectors. The
AG. Volkswagen AG d
agen oes
olksw not
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b ara
– With engine switched
rise
d off, carefully pull return line connections
nte
off at piezoutinjectors. To do this, press the two clips downwards
ho eo
ra
-arrow A- ss a
and, at the same time, pull the release bolt upwards c
-arrow B-.
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– Remove only piezo injectors of which injector seal is to be re‐

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– Remove noise insulation at injectors.

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Caution
es, in part or in w
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You must therefore proceed very carefully in order to avoid

unnecessary assembly work or further damage.
rrectness of i
Ensure cleanliness. No dirt may get into the injector holes on

l purpos
First remove leaked oil or fuel with workshop equipment.

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Amarok 2011 ➤
– Position puller - T10055- with puller - T10402- -1- and -2- as

shown and pull piezo injectors out upwards by tapping with
head of sliding hammer.
– Screw oil seal extractor - T40195- forcibly as far as possible
into seal by hand.
Pull injector seal out upwards by tapping using oil seal extractor
- T40195- , adapter - T101333/2- and slide hammer - T10133/3- .
– After removal, check whether the spring washer is still on the
old seal.
If not, check that spring washer does not remain in injector shaft.
Installing
Caution
You must therefore proceed very carefully in order to avoid

unnecessary assembly work or further damage.
Remember that the cylinder head cover is made of plastic.
A plastic cylinder head cover is damaged easily during repairs.
Check cylinder head cover for damage.
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– Initially position new injector seal by hand. olksw
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– Then carefully push new injector seal in to stoprisedusing assem‐ ara
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– Apply a thin coating of diesel fuel to the new O-rings on the s
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1. Cylinder head 101

Amarok 2011 ➤

1.6 Removing and installing vacuum pump

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DANGER!
om
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or
The vacuum pump may, under no circumstances, be disman‐

his
ate
do
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tled as the vacuum part could otherwise malfunction. This

p
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would result in the failure of the brake servo.

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Amarok 2011 ➤
Removing
– Place cloths under vacuum pump -1-.
– Pull vacuum line -2- off vacuum pump -1-.
– Unscrew bolts -arrows- for vacuum pump -1-.
– Remove vacuum pump -1- from cylinder head.
Installing
Note
♦ Ensure that vacuum pump coupling seats properly in cam‐

shaft.
♦ The vacuum pump has been correctly seated in camshaft if it
is lying completely against the cylinder head.
♦ The seal must be renewed.
– Install vacuum pump -1- and tighten securing bolts -arrows-.

– Connect brake servo vacuum line -1- to vacuum pump.
Specified torques
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1.7 Checking compression

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♦ Jointed spanner - 3220-

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1. Cylinder head 103

Amarok 2011 ➤
♦ Compression tester - V.A.G 1763- with adapter - V.A.G

1763/8-
♦ Torque wrench (5…50 Nm) - V.A.G 1331-

Test prerequisite
• Engine oil temperature min. 30 °C.
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Test procedure Volksw
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Procedure: orise nte
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– Pull connectors soff
s a the injectors. c
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– Remove glow plug from relevant cylinder using U/J extension

un
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an
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and 10 mm socket - 3220- ⇒ page 405 .

itte
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– Screw in adapter - V.A.G 1763/8- in place of the glow plugs. ab

ility
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– Check compression using compression tester - V.A.G 1763- . h re

ole,
Using compression tester ⇒ operating instructions . spec

– Start engine until tester shows no further pressure increase.

t to the co
Compression pressures:
New: 25…31 bar
rrectne
Wear limit: 19 bar

ss
Maximum permissible difference between all cylinders: 5 bar

o
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– Install glow plugs with U/J extension and 10 mm socket - 3220-

mer
⇒ page 405 .
atio
om
– Read engine control unit event memory ⇒ Vehicle diagnostic

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Amarok 2011 ➤
2 Toothed belt drive

⇒ “2.1 Assembly overview - toothed belt drive”, page 105
⇒ “2.2 Removing and installing toothed belt”, page 107
2.1 Assembly overview - toothed belt drive
1 - Toothed belt
❑ Check for wear.
❑ Do not kink.
⇒ page 107 .
2 - Bolt
❑ Use counterhold tool -
3415- to loosen and
tighten.
❑ Do not additionally oil or agen
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3 - Crankshaft toothed belt pul‐
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4 - Nut
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❑ 20 Nm
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5 - Idler roller
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6 - Nut
❑ 20 Nm +45°
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7 - Tensioning roller
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8 - Bolt
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❑ 20 Nm +45°
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9 - Camshaft pulley
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10 - Bolt
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11 - Bolt
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❑ To remove, use puller - T10052- .

13 - Rear toothed belt guard
14 - Bolt
❑ 20 Nm
15 - Bolt
2. Toothed belt drive 105

Amarok 2011 ➤
❑ 10 Nm agen
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17 - Bolt aut
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❑ 50 Nm + 90°
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18 - Idler roller
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19 - Hub
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❑ Use counterhold tool - T10051- to loosen and tighten.
hole
spec
❑ To remove, use puller - T40064- . es, in part or in w
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20 - Nut
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❑ 95 Nm
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21 - Toothed belt pulley on high-pressure pump

22 - Bolt
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m
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❑ 23 Nm
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23 - Coolant pump
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26 - Toothed belt guard lower part Prote AG.
27 - Bolt
❑ 10 Nm
28 - Bolt
❑ 10 Nm + 90°
29 - Belt pulley and vibration damper
❑ Assembly through offset holes only possible in one position

Amarok 2011 ➤
2.2 Removing and installing toothed belt

equipment required
♦ Locking pin - 3359-
♦ Crankshaft stop - T10050-
♦ Special wrench, long reach
- T10264-
♦ Locking tool - T10265-
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Amarok 2011 ➤
Removing
Note
Whenever adjustment work is done on toothed belts, it must be

performed only when the engine is cold, as the indicator position
on the tensioning element varies depending on the engine tem‐
perature.
AG. Volkswagen AG d
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– Remove underbody guard, if fitted ⇒ GeneralVbodyolks repairs,
w not
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exterior; Rep. gr. 66 ; Underbody guard .sed by ara
nte
ri
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– Remove poly V-belt ⇒ page 40 . aut ra
c
ss
– Detach vacuum hose -2- from upper toothed belt guard -1-.
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– Unscrew bolt -3- for bracket -1-.

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Amarok 2011 ➤
– Unscrew bolts -arrows-. Counterhold

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– Relax poly V-belt tensioning
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– Remove lower toothed belt guard. To do this, unscrew bolts
-arrows-.
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atio
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– Turn engine to TDC and lock crankshaft toothed belt pulley in

position with crankshaft stop - T10050- . To do this, push the
crankshaft stop into the teeth of the toothed belt pulley from
the latter's face side. The toothed segment of the camshaft
must be at the »12 o'clock position«.
Note
The markings on the crankshaft toothed belt pulley -2- and the
crankshaft stop - T10050- -1- must align. At the same time, the
pin of the crankshaft stop - T10050- must engage in the drilling in
the sealing flange.
The arrow on the camshaft pulley must be at almost »12 o'clock«.

– Mark direction of rotation of toothed belt.

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4-cylinder diesel engine (2.0 l engine,
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– Lock the camshaft hub with - 3359- . To do this, locking
ss
au
pin ra
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insert locking pin through outer free elongated hole into hole
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in cylinder head.
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– Loosen bolts -arrows- approx. 90°.
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es, in part or in w
t to the co
rrectness of i
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– Loosen bolts -2- approx. 90° for high-pressure pump toothed

belt pulley using bit XZN 10 - T10385- .
nform
mercia
a
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tion in
r
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– Loosen belt tensioner securing nut -1-.

– Turn eccentric of tensioning roller anti-clockwise -arrow- using
socket - T10264- , until the tensioning roller can be locked with
locking tool - T10265- .

Amarok 2011 ➤
– Now turn tensioning roller eccentric clockwise -arrow- onto

stop and tighten securing nut -1- hand-tight.
– First remove toothed belt from camshaft pulley and then from
the other pulleys.
Installing
Prerequisites
• Ignition switched off.
• Engine must be cold.
• Tensioning roller must be locked with locking tool - T10265-
and secured at right stop.
• Crankshaft locked in position with crankshaft stop - T10050- .
Note
♦ Whenever adjustment work is done on toothed belts, it must

be performed only when the engine is cold, as the indicator
position on the tensioning element varies depending on the
engine temperature.
♦ Renew securing bolts for camshaft pulley and high-pressure
pump pulley.
♦ If necessary, turn camshaft hub until it can be secured in po‐
sition with counter-hold tool - T10172- and adapters -
T10172/4- . To do this, hand-tighten at least one securing bolt
-1-.
– Lock the camshaft hub with locking pin - 3359- . To do this,

in cylinder head.
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– Loosen the hand-tightened bolts again. Volkswa not
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Prote AG.
2. Toothed belt drive
Amarok 2011 ➤
– Turn hub of high-pressure pump at bolt heads with screwdriver

until it can be secured in position with diesel injection pump
locking pin - 3359- .
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– Lock high-pressure pump hub with diesel injection pump lock‐
ing pin - 3359- . To do this, push locking pin into adjustment
rrectness of i
hole outside toothed belt pulley.
l purpos
– Turn camshaft pulley and toothed belt pulley of high-pressure

pump in their elongated holes clockwise to stop.
nform
ercia
– Fit toothed belt to crankshaft toothed belt pulley, tensioning

m
roller, camshaft pulley, toothed belt pulley of coolant pump and
at
om
io
toothed belt pulley of high-pressure pump.
n
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– Finally, place toothed belt onto idler roller.
ate
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– Undo the fastening nuts of the tensioning roller and pull out
um
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Ensure that belt tensioner seats correctly in rear toothed belt

guard -arrow-.
– Carefully turn belt tensioner eccentric clockwise using angle

driver - T10264- until indicator -2- is slightly above middle of
gap in base plate. The base plate corrects itself when preten‐
sion is applied.
Ensure that securing nut -1- does not turn as well.
– Hold tensioning roller in this position and tighten securing nut
of tensioning roller.

Amarok 2011 ➤
– Fit counterhold - T10172- as shown. Press counter-hold tool -

T10172- in direction of arrow and keep camshaft pulley in
pretensioning position.
– In this position, tighten securing bolts -1- of camshaft pulley
and those of toothed belt pulley for high-pressure pump.
– Remove diesel injection pump locking pin - 3359- and crank‐
shaft stop - T10050- .
– Turn crankshaft at least two full rotations in engine direction of
rotation and set to slightly before TDC No. 1 cylinder.
– Place crankshaft stop - T10050- on the crankshaft toothed belt
pulley again.
– Now turn crankshaft in engine direction of rotation until crank‐

shaft stop pin -arrow- engages in sealing flange whilst turning.
AG. Volkswagen AG d
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Note
h re
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spec
During the following checking procedure, only the camshaft and

t to the co
crankshaft must be secured in position. It is very difficult to find

the securing position of the high-pressure pump hub again. How‐
ever, a slight deviation -arrow- does not influence the engine
rrectne
operation.
s
– Check whether:
s o
cial p
f i
♦ Camshaft hub can be locked with locking pin - 3359- .

nform
mer
♦ Tensioning roller indicator is centred or maximum 5 mm to

atio
m
right of base plate notch.

o
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or
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If camshaft hub cannot be locked:

te
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r
– Pull crankshaft stop - T10050- back until pin uncovers hole.

p
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– Twist crankshaft out at little above TDC by turning it in the

t.
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opposite direction of engine rotation.
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– Now turn crankshaft slowly in direction of engine rotation until
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camshaft hub can be secured in position.
cted agen
Prote AG.
– After locking, loosen securing nuts of crankshaft toothed belt

pulley.
If pin of crankshaft stop - T10050- is standing on left next to hole:

Amarok 2011 ➤
– Turn crankshaft in engine direction of rotation until crankshaft

stop pin engages in sealing flange whilst turning.
– Tighten securing bolts of camshaft toothed belt pulley.
If pin of crankshaft stop - T10050- is standing on right next to hole:
– Turn crankshaft a little in direction opposite to engine direction
of rotation.
– Turn crankshaft in engine direction of rotation until crankshaft
stop pin arrow engages in sealing flange whilst turning.
– Tighten securing bolts of camshaft toothed belt pulley.
Continuation
– Remove locking pin - 3359- and crankshaft stop - T10050- .
– Turn crankshaft at least 2 rotations in engine direction of ro‐ n AG. Volkswagen AG do
tation and set again to TDC no. 1 cylinder. lkswage es n
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– Repeat measurement. o
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– If camshaft hub can be secured in position, tighten securing
ss
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bolts as follows:
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♦ Camshaft pulley: tighten bolts. Counterhold with counterhold
erm
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- T10172- and adapters - T10172/4- .
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♦ High-pressure pump pulley: tighten bolts. Counterhold with
h re
counterhold - T10172- and adapters - T10172/8- .
hole
spec
es, in part or in w
– Install toothed belt guard - lower part.
t to the co
– Install vibration damper/belt pulley.
rrectness of i
l purpos
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ercia
– First, fit top part of toothed belt guard to middle -1- of toothed
m
at
om
i
belt guard from the rear.
on
c
in t
or
– Then, fit toothed belt guard to middle -2- and -3- of toothed belt
his
ate
guard at the top.
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Prote AG.

Amarok 2011 ➤
– Secure toothed belt guard -3- with clips -arrows-.

– Clip vacuum hose -2- into upper toothed belt guard -1-.
– Tighten bolt -3- for bracket -1-.

Specified torques
lkswage es n
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Amarok 2011 ➤
3 Fresh air supply system, belt drive

⇒ “3.1 Assembly overview - fresh air supply system”, page 116
⇒ “3.2 Removing and installing blower for fresh air supply sys‐
tem”, page 117
⇒ “3.3 Removing and installing air filter housing for fresh air sup‐
ply system”, page 117
⇒ “3.4 Removing and installing bracket for fresh air supply sys‐
tem”, page 118
3.1 Assembly overview - fresh air supply system
1 - Heat shield
❑ For air filter housing.
2 - Bolt
❑ 6 Nm
3 - Air filter bracket
⇒ page 118 . n AG. Volkswagen AG do
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4 - Bolt byV
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5 - Hose ss
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6 - Spring-type clip
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7 - Hose clip
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8 - Blower
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⇒ page 117 .
es, in part or in w
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9 - Bracket
10 - Bolt
rrectness of i
❑ 6 Nm
l purpos
11 - Rubber sleeve
❑ Qty. 2.
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❑ To air filter
orm
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❑ To toothed belt guard atio

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12 - Nut
or
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13 - Bracket
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14 - Air filter housing

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❑ Removing and installing Cop py
⇒ page 117 .
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❑ ⇒ ETKA (Electronic
co Vo
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cted
Parts Catalogue)
agen
Prote AG.
15 - Bolt
❑ 6 Nm

Amarok 2011 ➤
3.2 Removing and installing blower for fresh

air supply system
Removing
– Disconnect electrical connector -2-. Release clip -1- and de‐
tach hose.
AG. Volkswagen AG d
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pe
ility
– Loosen screw-type clip -1- and then remove bolts -arrows-
ot
wit
, is n
from bracket.
h re
hole
– Remove blower for fresh air supply system
spec
es, in part or in w
t to the co
Installing
rrectness of i
♦ ⇒ “3.1 Assembly overview - fresh air supply system”,
page 116
l purpos
nform
mercia
a
com
tion in
3.3 Removing and installing air filter hous‐

r
te o
thi
ing for fresh air supply system

s
iva
do
r
rp
cum
fo
Removing
en
ng
t.
yi Co
op
– Unscrew bolts -arrows- and remove heat shield -1-. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Fresh air supply system, belt drive 117

Amarok 2011 ➤
– Loosen screw-type clip -arrow-, and remove air filter housing.

Installing
page 116
3.4 Removing and installing bracket for

fresh air supply system
Removing
– Remove air filter housing ⇒ page 117 .
– Detach blower for fresh air supply system ⇒ page 117 .
– Release wiring harness.
– Remove bolts -arrows- and remove bracket.
Installing
Install in reverse order. In the process, note the following:
page 116
AG. Volkswagen AG d
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un
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rm
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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
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cum
fo
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
cted agen
Prote AG.

Amarok 2011 ➤
4-cylinder diesel engine (2.0
en AG . Vol lengine,
kswagen common
AG rail) - Edition 04.2013
ag does
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ed
4 Valve gear thoris nte
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⇒ “4.1 Assembly overview - valve gear”,
s
page 119
ce
e
nl
pt
du
⇒ “4.2 Measuring axial clearance of camshaft”, page 121
an
itte
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ab
⇒ “4.3 Measuring radial clearance of camshafts”, page 122
ility
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wit
⇒ “4.4 Removing and installing camshafts”, page 123
, is n
h re
⇒ “4.5 Removing and installing camshaft oil seal”, page 129 hole
spec
es, in part or in w
⇒ “4.6 Checking hydraulic compensation element”, page 131
t to the co
⇒ “4.7 Renewing valve stem seals”, page 132
rrectness of i
4.1 Assembly overview - valve gear
l purpos
Note
nform
ercia
♦ Cylinder heads with cracks between the valve seats may be

m
at
om
i
used without reducing engine life, provided the cracks are
on
c
in t
small and not more than 0.5 mm wide.
or
his
ate
♦ The plastic packing pieces for protecting the open valves must
do
priv
c
not be removed until immediately before fitting cylinder head.
um
for
en
ng
t.
yi
♦ When cylinder head is renewed, the coolant must be com‐
Co
op py
pletely renewed as well.
t. C rig
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by c lksw
cted agen
Prote AG.
4. Valve gear 119

Amarok 2011 ➤
1 - Seal
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip.
move residual oil from Volkswagen AG
camshaft journal usingswaagen AG. does
clean cloth. y Volk not
gu
edb ara
❑ To install, mask
horis off nte
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groove onaucamshaft
t tap‐ ra
c
er (e.g. using
ss
Sellotape)
ce
le
un
pt
an
d
itte
⇒ page 129 .
y li
erm
ab
2 - Bolt
ility
ot p
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is n
❑ Observe sequence
h re
when loosening and
ole,
spec
tightening ⇒ page 121 .
t to the co
❑ 10 Nm
3 - Retaining frame
rrectne
❑ Seal with silicone seal‐
Catalogue (ETKA) .
ss o
cial p
4 - Exhaust camshaft
f inform
mer
⇒ page 123 .
atio
om
n
c
5 - Inlet camshaft
i
or
n thi
te

sd
iva
o
r
⇒ page 123 .
p
cum
r
fo
en
ng
6 - Roller rocker finger

t.
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❑ Mark installation posi‐
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❑ Do not interchange.
cted agen
Prote AG.
❑ Check roller bearing for
ease of movement.
❑ Oil contact surface.
7 - Hydraulic compensation element
❑ Mark installation position.
❑ Lubricate contact surfaces before installing.
8 - Valve
❑ Do not rework. Only lapping in is permitted.
❑ Mark installation position for re-installation.
❑ Valve dimensions ⇒ page 136
❑ Checking valve guides ⇒ page 135 .
9 - Cylinder head
10 - Valve stem seal
11 - Valve spring
12 - Valve spring plate
13 - Valve cotter
14 - Cap

Amarok 2011 ➤
Retaining frame - tightening sequence

Undoing the frame
– Unscrew bolts of support frame in sequence -24…1-.
Tightening
– First, tighten bolts of support frame hand-tight in sequence
-1….24-.
– Tighten retaining frame bolts in sequence -1…24-.
4.2 Measuring axial clearance of camshaft
Vol
ksw
age es n
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by ua
ed ran
Special tools and workshop equipment required oris tee
th or
au
♦ Universal dial gauge bracket - VW 387- ss
ac
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.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Procedure
– Remove retaining frame ⇒ page 121 .
4. Valve gear 121

Amarok 2011 ➤
– Fasten dial gauge - VAS 6079- to cylinder head with universal

dial gauge bracket - VW 387- as shown in the illustration.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
Axial clearance of inlet and outlet camshafts:
• Specification: 0.048…0.118 mm.
• Wear limit: 0.17 mm.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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4.3 Measuring radial clearance of cam‐ horise nte
eo
ut
shafts a ra
ss c
ce
e
nl
pt
du
an
itte
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♦ Plastigage
erm
ab
ility
ot p
Procedure
wit
, is n
h re
– Remove roller rocker finger.
hole
spec
es, in part or in w
– Remove bearing cap and clean crankshaft journal.
t to the co
– Place a length of Plastigage corresponding to the width of the
bearing on the journal to be measured or into the bearings.
rrectness of i
• Plastigage must lie in the middle of the bearing.
l purpos
– Fit retaining frame and tighten without rotating camshafts

⇒ page 121 .
nform
ercia
– Remove retainer frame.

m
at
om
ion
c
in t
or
Radial clearance: 0.035 … 0.085 mm. his

ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
4.4 Removing and installing camshafts

equipment required
♦ Diesel injection pump lock‐
ing pin - 3359-
♦ Puller - T10052-
♦ Camshaft fitting tool -
T40094-
♦ Camshaft clamping tool -
T40095-
♦ Camshaft fitting tool -
T40096-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
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nl
pt
du
an
itte
♦ Torque wrench - V.A.G 1331/-

y li
erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
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t.
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123
op Vo
by c lksw
Prote
cted AG.
agen 4. Valve gear
Amarok 2011 ➤
♦ Torque wrench - V.A.G 1332/-
olksw
♦ Silicone adhesive sealant ⇒ Electronic PartswagCatalogue
en AG. V (ET‐
agen AG
does
KA) Volks not
gu
by ara
ed nte
Removing ris
tho e or
au ac
– Remove fuel filter ⇒ page 239
ss .
ce
le
un
pt
– Removed toothed belt from camshaft and high-pressure pump
an
d
itte
y li
⇒ page 107 .
rm
ab
pe
ility
– Remove cylinder head cover ⇒ page 93 .
ot
wit
, is n
h re
– Unscrew and remove bolts -arrows- for toothed belt and cam‐
hole
shaft.
spec
es, in part or in w
– Remove camshaft pulley from hub.
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
– Counterhold hub with counter-hold tool - T10051- and release

s
iva
do
hub securing bolt -1-.

r
rp
cum
fo
en
g
– Unscrew hub securing bolt approx. 2 turns.

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

Amarok 2011 ➤
– Position puller - T10052- and align with hub holes.

– Tighten securing bolts -1-.
– Apply tension to hub by evenly tightening puller -2- until hub
separates from taper of camshaft.
Note
Hold puller with a spanner 30 mm whilst doing this.
– Remove hub from taper of camshaft.

– Remove vacuum pump ⇒ page 102 .
– Unscrew retaining frame securing bolts in sequence -24…1-.

– Remove retaining frame.
– Carefully remove camshafts.
Installing
Note
wage
Seal contact surface between retaining frame and cylinder yV
o head
lks es n
ot g
using silicone adhesive sealant ⇒ Electronic Parts Catalogue
ir se
d b ua
ran
(ETKA) . tho tee
or
au ac
ss
ce
le
un
pt
Caution
an
d
itte
y li
erm
ab
Camshafts may only be installed with camshaft fitting tool -
ility
ot p
T40094- as described below. Otherwise the axial bearings in
wit
is n
the retaining frame will be destroyed and the cylinder head
h re
ole,
must be replaced.
spec
Make sure that no sealant residues get into the cylinder head
t to the co
or the bearings.
rrectne
– Remove remaining sealant and from cylinder block and re‐
taining frame using, for example, a rotating plastic brush. ss o

cial p
f inform
– Oil running surfaces of both camshafts.

mer
atio
m
Set up camshaft fitting tool - T40094- for camshafts as follows:

o
n
c
i
or
n thi
te
sd
a
– Remove supports -T40094/3-, -T40094/4- and -T40094/5-

iv
o
pr
from base plate (bolted from underneath).

cum
r
fo
en
ng
t.
yi Co
Cop py
Note
t. rig
gh ht
pyri by
Vo
co lksw
by
If the supports of the camshaft fitting tool - T40094- are not yet
cted agen
Prote AG.
marked, mark the removed supports, e.g. with number stamps,
so they can be fitted in the original positions later.
4. Valve gear 125

Amarok 2011 ➤
– Install supports -T40094/9- and -T40094/10- instead at vacant

outer positions.
– Place support -T40094/2- at position “A” and support
-T40094/1- at position “F”.
– First insert inlet camshaft as shown. Ensure that indentation
-arrow- for cylinder head bolt faces »outwards«.
– Position 0.50 mm feeler gauge and push support -T40094/8-

into inlet camshaft groove.
– Insert exhaust camshaft and lock via groove -arrow- with

-cover T40094/11-.
– Position clamping tool - T40096/1- on exhaust camshaft pul‐
leys.
Caution
The exhaust camshaft tensioning roller has been discontinued n AG. Volkswagen AG do
⇒ Electronic Parts Catalogue (ETKA) . olks
wage es n
o V t gu
by
In the case of exhaust camshafts with tensioning roller,risensure
ed
ara
nte
that the clamping jaw marked with an arrow is seated tho on the eo
au ra
wider gear. ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
– Tension camshaft fitting tool - T40096/1- with knurled wheel

ility
ot p
until teeth flanks align. If necessary, use a 13 mm open-ended

wit
is n
spanner to assist.
h re
ole,
– Slide exhaust camshaft towards inlet camshaft until teeth en‐

spec
gage.
t to the co
– Place retaining frame on camshafts.

• All camshaft bearings must be seated on the camshafts.
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
126
by lksw
cted agen
Rep. gr.15 - Cylinder head, valve gear Prote AG.
Amarok 2011 ➤
– Position camshaft fitting tool - T40095- as shown, thereby fix‐

ing camshafts in position in retaining frame.
– Remove cover - T40094/11- .
– Pull support - T40094/8- out of inlet camshaft groove.
– Cut off nozzle on tube at front marking (∅ of nozzle approx.

2 mm).
– Apply beads of sealant (approx. 2…3 mm wide) -arrows- onto
clean sealing surfaces of cylinder head as illustrated.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
Sealant beads must not be thicker than specified, otherwise ex‐
hole
spec
cess sealant could enter the camshaft bearings.
es, in part or in w
t to the co
– Install new cap ⇒ Item 14 (page 120) flush on cylinder head.
– Remove camshafts from camshaft fitting tool - T40095- to‐
rrectness of i
gether with retaining frame and camshaft fitting tool - T40094- .
l purpos
– Carefully insert camshafts and retaining frame into cylinder

head.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Valve gear 127

Amarok 2011 ➤
– First tighten securing bolts of retaining frame hand-tight in se‐

quence -1….24-.
• The retaining frame should make contact with the cylinder
head over the complete surface.
– Tighten retaining frame bolts to final torque in the sequence
-1…24-.
– Remove camshaft fitting tool - T40095- and clamping tool -
T40096/1- .
– Renew camshaft seal ⇒ page 129 .
Note
♦ After installing camshafts wait for approx. 30 minutes before

starting engine. The hydraulic compensation elements must
settle (otherwise valves will strike pistons).
♦ After working on valve gear, carefully crank engine at least 2
revolutions by hand to ensure that no valves make contact on
starting.
– Fit hub on camshaft.
– Tighten securing bolt -1- of hub. Use counter-hold tool -

T10051- to do this.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
– Push camshaft pulley onto hub.

h re
ole,
spec
t to the co
Note
The toothed segment -arrow- of the camshaft belt pulley must be

rrectne
on top.
ss
– Insert securing bolts -1- by hand without play to camshaft pul‐

o
cial p
ley.
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 ➤
– Lock hub with diesel injection pump locking pin - 3359- .

– Install toothed belt and adjust valve timing ⇒ page 107 .
– Install vacuum pump ⇒ page 102 .
– Install cylinder head cover ⇒ page 93 .
– Install fuel filter.
Specified torques
♦ ⇒ “4.1 Assembly overview - valve gear”, page 119
4.5 Removing and installing camshaft oil seal

equipment required
♦ Fitting tool - 10 - 203-
♦ Oil seal extractor - 3240-
1331-
1332-
♦ Bolt M12 x 1.5 x 65
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
Removing
at
om
ion
c
in t
– Removed toothed belt from camshaft and high-pressure pump

or
his
e
⇒ page 107 .
at
do
priv
– Remove camshaft pulley and hub ⇒ page 123 .

um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
129
by lksw
cted agen
Prote 4. Valve gear
AG.
Amarok 2011 ➤
– Insert thrust piece - 3240/1- into camshaft.
– Unscrew inner part of oil seal extractor - 3240- 2 turns (approx.

3 mm) from the outer part and lock in position with the knurled
screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against camshaft
until oil seal is pulled out.
Installing
Note
The oil seal sealing lip must not be additionally oiled or greased.
– Remove oil residues from crankshaft journal with a clean cloth.

olkswagen AG
en AG. V
– Fit guide sleeve - 3240- onto camshaft as shown in illustration. olkswag does
not
V gu
by ara
– Carefully slide oil seal -1- over guide sleeve onto camshaft.
ris
ed nte
tho eo
– Carefully place seal onto camshaft. s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Press in oil seal with press piece of fitting tool - 10 - 203- and
rrectness of i
bolt M12 × 1.5 x 65 as far as stop.

l purpos
– Install camshaft pulley and hub ⇒ page 107 .

– Install toothed belt and adjust the valve timing ⇒ page 107 .
nf
ercia
Specified torques
rm
m
atio
m

o
n in
or c
thi

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

Amarok 2011 ➤
4.6 Checking hydraulic compensation ele‐

ment
♦ Feeler gauges
Note
♦ The hydraulic compensation elements cannot be repaired.

♦ Irregular valve noise during starting is normal.
Procedure:
– Start engine and run until the radiator fan has switched on
once.
– Increase engine speed to about 2500 rpm for 2 minutes (per‐
form road test if necessary).
– If the hydraulic compensation elements are still noisy, find out
which is the defective compensation element as follows:
AG. Volkswagen AG d
agen
– Remove cylinder head cover ⇒ page 93 . olksw
oes
not
byV gu
ara
d
– Turn crankshaft by the bolt for the toothed belt wheel until
oris cam
e nte
eo
of supporting element to be tested is facing upwards. aut
h
ra
ss c
– Press roller rocker finger downwards -arrow- to check clear‐
ce
le
un
pt
ance between cam and roller rocker finger.
an
d
itte
y li
rm
– If a 0.20 mm feeler gauge can be inserted between cam and
ab
pe
ility
roller rocker finger, replace hydraulic compensation element.
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.
4. Valve gear 131

Amarok 2011 ➤
4.7 Renewing valve stem seals

lkswage es n
o ot g
Special tools and workshop byV ua
d ran
equipment required ir se tee
tho
u or
a ac
♦ 10 mm jointed spanner - ss
ce
le
3220-
un
pt
an
d
itte
♦ Valve stem seal puller -
y li
rm
ab
3364-
pe
ility
ot
wit
♦ Valve stem seal fitting tool -
, is n
h re
3365-
hole
spec
♦ Removal and installation
es, in part or in w
t to the co
device for valve cotters -
VAS 5161 A- with guide
plate - VAS 5161/23- and
rrectness of i
spacer ring - VAS
5161/23-1-
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.
Procedure
– Remove all glow plugs using jointed spanner - 3220- .
⇒ page 405
– Remove camshafts ⇒ page 123 .
– Place guide plate - VAS 5161/23- onto cylinder head.
– Secure guide plate on intake manifold side with knurled screw
- VAS 5161/12- and tighten it hand-tight to studs using M6
collarless nuts -1-.
– Screw sealing bolts - VAS 5161/10- into the guide plate.

Amarok 2011 ➤
– Screw adapter - VAS 5161/11- hand-tight into the relevant

glow plug thread.
– Insert punch - VAS 5161/3- in the guide plate and use a plastic
hammer to knock loose the firmly seated valve cotters.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
– Screw attachment fork - VAS 5161/5- with ratchet piece -

erm
ab
VAS 5161/6- into guide plate .

ility
ot p
wit
, is n
– Push spacer ring - VAS 5161/23-1- onto the assembly car‐

h re
tridge - VAS 5161/8- .

hole
spec
es, in part or in w
– Connect adapter - VAS 5161/11- to compressed air supply,

t to the co
using a standard commercially available union and apply pres‐

sure continuously.
rrectness of i
• Minimum pressure: 6 bar

l purpos
– Attach pressure fork - VAS 5161/2- to ratchet piece and press

assembly cartridge downwards.
nf
ercia
– At the same time, turn knurled screw of assembly cartridge

or
clockwise until tips engage in valve cotters.

m
m
atio
m
– Move knurled screw backwards and forwards slightly. This

o
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or c
causes the valve cotters to be pressed apart and taken into

thi
e
the assembly cartridge.

t
sd
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– Release pressure fork.

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– Remove assembly cartridge with spacer ring, valve plate and Cop py
valve spring.
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– Pull off valve stem seals using valve stem seal puller - 3364- . Prote AG.
4. Valve gear 133

Amarok 2011 ➤
Note
A plastic sleeve -A- is included with the new valve stem oil seals.
– Fit plastic sleeve -A- onto valve stem to prevent damage to

new valve stem oil seal -B-.
– Lightly oil sealing lip of valve stem seal.
– Push valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– If necessary, use a plastic head hammer to tap lightly on fitting
tool until valve stem oil seal is fitted to stop.
– Remove plastic sleeve.
– Insert valve spring and valve plate into cylinder head.
– If valve cotters have been removed from assembly cartridge ,

they need to be put into insertion device - VAS 5161/18- first.
Note
Larger diameter of valve cotters face upwards.

AG. Volkswagen AG d
agen oes
– Press assembly cartridge onto insertion device from above Vol
ksw not
gu
and pick up valve cotters. se
d by ara
nte
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nl
pt
du
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– Insert assembly cartridge - VAS 5161/8- into guide plate again.
itte
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– Press pressure fork downwards and pull knurled screw up‐
ility
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wards, turning it clockwise and anticlockwise. This action will
wit
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install the valve cotters.
h re
hole
spec
– Reduce pressure on pressure fork whilst pulling on knurled
es, in part or in w
screw.
t to the co
Installation is carried out in the reverse order; note the following: rrectness of i
– Install glow plugs ⇒ page 405 .

l purpos
– Install camshafts ⇒ page 123 .

nform
ercia
Note
m
at
om
io
♦ Engine is not to be rotated for approx. 30 minutes after instal‐

n
c
in t
r
ling camshafts. The hydraulic compensation elements must

o
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settle (otherwise valves will strike pistons).

at
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priv
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♦ After working on the valve gear, turn the engine carefully at

for
en
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least 2 rotations to ensure that none of the valves make con‐

n
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tact when the starter is operated. C py
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Prote AG.

Amarok 2011 ➤
5 Inlet and exhaust valves

⇒ “5.1 Reworking valve seats”,
agen
AG. Vopage
lkswag135
en AG
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olks ot g
⇒ “5.2 Checking
ed
by valve guides”, page 135
V ua
ran
ris tee
⇒ “5.3 Valve
au
tho dimensions”, page 136 or
ac
ss
5.1 Reworking valve seats
ce
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un
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Note
ility
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Valve seats must not be reworked due to the very small toleran‐
hole
spec
ces.
es, in part or in w
t to the co
5.2 Checking valve guides
rrectness of i
♦ Universal dial gauge bracket - VW 387-
l purpos
nform
mercia
a
com
tion in
r
te o
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t.
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Cop py
ht. rig
rig ht
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Prote AG.
Test procedure
– Insert new valve in guide. The end of the valve stem must be
flush with the guide. On account of differing stem diameters,
only use inlet valve in inlet guide and exhaust valve in exhaust
guide.
– Determine rock. Wear limit: max. 1.3 mm
– Cylinder head must be renewed if rock exceeds wear limit.
5. Inlet and exhaust valves 135

Amarok 2011 ➤
5.3 Valve dimensions
Note
Valves must not be reworked. Only lapping-in is permitted.
Dimension Inlet valve Exhaust valve

∅a mm 26.60 26.00
∅b mm 5.940 5.940
c mm 99.30 99.10
α ∠° 45 45
AG. Volkswagen AG d
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Prote AG.

Amarok 2011 ➤
17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump, oil pump”, page 137
Volkswa gen AG AG.
agen
does
⇒ “1.2 Removing and installing oil sump”,
Vol
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horisoil pump”, page 146 nte
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shaft module”, page 146
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⇒ “1.5 Checking engine oil level”, page 147
y li
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⇒ “1.6 Removing and installing oil level and oil temperature send‐
ility
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er G266 ”, page 147
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⇒ “1.7 Removing and installing dipstick tube”, page 148
spec
es, in part or in w
1.1 Assembly overview - sump, oil pump
t to the co
rrectness of i
Note
l purpos
Renew cover in sump every time it is removed ⇒ ETKA (electronic

parts catalogue)
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Prote AG.
1. Sump, oil pump 137

Amarok 2011 ➤
1 - Bolt
❑ 15 Nm
2 - Sealing flange
❑ With seal.
❑ Must seat on dowel
sleeves.
❑ Insert with silicone seal‐
Catalogue (ETKA) . AG. Volkswagen AG d
agen
❑ Do not apply additional Volksw
oes
not
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oil or grease the sealing d by ara
lip of the oil seal. rise nte
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❑ Before installing, re‐ ss a c
ce
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un
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an
d
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a clean cloth.
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ility
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⇒ page 48 .
wit
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3 - Toothed belt for oil pump
hole
spec
❑ Check for damage.
es, in part or in w
t to the co
❑ Replace if necessary.
Note
rrectness of i
l purpos
♦ Belts which have been in use

longer can sag.
nform
ercia
♦ This is not a fault and does not

necessarily mean belt needs re‐
m
a
placing.
com
tion in
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te o
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4 - Bolt
s
iva
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❑ 10 Nm
rp
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5 - Oil dipstick
t.
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Cop py
❑ The oil level must not be above the max. mark!
t. rig
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❑ Markings ⇒ page 147 . cop Vo
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Prote AG.
6 - Guide tube
7 - Clip
8 - Dowel sleeves
9 - O-ring
10 - Bolt
❑ 15 Nm
11 - Oil pump with pressed-on toothed belt pulley
❑ With 12 bar pressure relief valve
❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
If toothed belt or oil pump have to be removed:
♦ Check oil pump for free movement
♦ It must be possible to turn toothed belt pulley easily
♦ Replace if tight/binding.
12 - Bolt
❑ 15 Nm
138 Rep. gr.17 - Lubrication

Amarok 2011 ➤
13 - Suction line
❑ Clean strainer if soiled.
14 - Baffle plate
15 - Bolt
❑ 15 Nm
16 - Bolt
❑ 15 Nm
17 - Oil sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant ⇒ Electronic Parts Catalogue (ETKA) .
Note
Renew cover in sump every time it

is removed ⇒ ETKA (electronic
parts catalogue)
18 - Bolt
❑ 15 Nm AG. Volkswagen AG d
agen oes
ksw
19 - Seal by
Vol not
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❑ Renew after removing horise nte
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20 - Oil drain plug ss c
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❑ 30 Nm
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21 - Bolt
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❑ Only for vehicles compliant with emission standard EU 5.
h re
ole,
❑ 10 Nm
spec
22 - Oil level and oil temperature sender - G266-
t to the co
❑ Black 3-pin connector
rrectne
s
23 - Seal
s o
cial p
f
inform
mer

atio
m
24 - Oil level and oil temperature sender - G266- wiring harness

o
n
c
i
or

thi
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sd
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25 - Bolt
p
cum
r
fo
en
ng
❑ Insert without sealant. yi

t.
Co
op
❑ 27 Nm
C py
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26 - Oil spray jet
op Vo
by c lksw
cted agen
❑ For piston cooling. Prote AG.

Amarok 2011 ➤
1.2 Removing and installing oil sump

equipment required
♦ 10 mm jointed spanner -
VAS 3185-
♦ Special wrench, long reach
- T10058-
- V.A.G 1331-
♦ Used oil collection and ex‐
traction unit - V.A.G 1782-
AG. Volkswagen AG d
agen oes
olksw not
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♦ Support bracket - 10 - 222 A-

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
te
Silicone sealant ⇒ Electronic Parts Catalogue (ETKA)

a
do
priv
cum
or
Hand drill with plastic brush

f
en
ng
t.
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Eye protection Cop py
t. rig
gh ht
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Flat scraper p by
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by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
Removing
– Place used oil collection and extraction unit - V.A.G 1782- un‐
der engine and drain engine oil.
Note
♦ Observe environmental regulations for disposal.

♦ The following procedures are for the left side of the vehicle.
This procedure also applies for the right side of the vehicle.
– Remove bolt -1- and pull it out from anti-roll bar -3-.
– Remove bolts -2-.
– Remove anti-roll bar -3- to side.
Vehicles with four-wheel drive:
Note
When removing sump on a vehicle with four-wheel drive, bracket

for final drive must be removed to allow drive shaft to be pulled
downwards slightly. This is necessary to allow the sump to be
taken out later over the shaft.
– Unscrew bolt -arrow- from bracket -1-.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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pt
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itte
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ility
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wit
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spec
es, in part or in w
– Unscrew bolts -arrows- and remove bracket -1- for final drive.
t to the co
– Pull final drive downwards slightly.

rrectness of i
Continuation for all vehicles:

l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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o
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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.

Amarok 2011 ➤
– Position engine with support bracket - 10 - 222 A- as shown

and take up weight of engine in installation position.
Note
The securing bolts for the assembly

. Volksmountings
wagen AG may only be re‐
gen AG with support
moved if the engine isolksupported bracket
do - 10-222
swa es n
ot g
A- ! db
y V ua
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ris tee
utho or
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ss
ce
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nl
pt
du
an
itte
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– Unscrew bolts -3- for coolant pipe -2- at left assembly mount‐
ility
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ing and remove coolant pipe -2- from coolant hose -1-.
wit
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
– Unscrew bolts -3- for engine support -1- on left and right -1-.
om
ion
c
in t
or
his
e
Caution
at
do
priv
cum
for

en
ng
t.
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op
C py
t. rig
gh
be renewed.
ht
pyri by
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by
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Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
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ise nte
thor eo Amarok 2011 ➤
u ra
ss a 4-cylinder diesel engine (2.0 l engine,
c common rail) - Edition 04.2013
ce
le
un
pt
– Unscrew bolts -1- from right engine mounting -A-.
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
hole
Before lifting engine on vehicles with an air conditioner, pull elec‐
spec
trical connection off air condition compressor otherwise it may be
es, in part or in w
t to the co
damaged.
– Pull electrical connections off air conditioner compressor.
rrectness of i
l purpos
nform
ercia
– Raise engine by 90 - 100 mm with support bracket - 10 - 222

A- and spindle - 10 - 222 A/10- -a-.
m
a
com
tio
– Remove front anti-roll bar with coupling rods ⇒ Rep. gr. 40
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
co lksw
by
cted agen
Prote AG.
– Unclip coolant hose -1- from brackets -arrows- on bottom of

radiator and tie coolant hose -1- up slightly.
For vehicles compliant with emission standard EU 5.
– Pull electrical connector -arrow- off oil level and oil tempera‐
ture sender - G266- .
– Turn crankshaft until recesses in dual-mass flywheel are visi‐
ble for unscrewing sump bolts.
Note
In vehicles without recesses in dual-mass flywheel, dual-mass

flywheel must be removed ⇒ page 54 .

Amarok 2011 ➤
– Remove connecting bolts for sump and gearbox.

– Diagonally unscrew bolts of oil sump.
– Loosen sump with light blows of a rubber headed hammer if
necessary.
– Remove sump.
– Remove sealant remaining on crankcase with flat scraper.
WARNING
Wear eye protection.
– Remove sealant residues on oil sump using a rotating brush,

e.g. with a hand drill with a plastic brush attachment.
Installing
Note
♦ Observe expiry date of sealing compound.

♦ Sump must be installed within 5 minutes of applying silicone
sealing compound.
– Cut off nozzle on tube at front marking (∅ of nozzle approx.

3 mm).
– Apply silicone sealant to clean sealing surface of sump as
shown. Sealant bead must be: AG. Volkswagen A
agen G do
es n
ksw
♦ 2…3 mm thick. y Vol ot g
ua
db ran
ise
♦ Run bead along inner side thof
or bolt holes -arrows-. tee
or
au ac
ss
ce
e
Caution
nl
pt
du
an
itte
y li
Danger of blocking lubrication system with excess sealant.

erm
ab
ility
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♦ Do not apply sealant bead thicker than specified.

wit
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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
144
AG.
Rep. gr.17 - Lubrication
AG. Volkswagen AG d
agen oes
Volksw Amarok
not
gu
2011 ➤
y
rised b
(2.0 l engine, common rail) - Edition ara04.2013
nte
utho eo
ra
a
– Apply bead of sealant onto clean sealing surface
ss of sump as c
illustrated.
ce
e
nl
pt
du
an
itte
• Thickness of sealant bead: 2…3 mm.
y li
erm
ab
ility
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wit
, is n
Note
h re
hole
spec
♦ Take particular care when applying sealant bead at front and
es, in part or in w
rear of sealing flange -arrows-.
t to the co
♦ Oil sump must be installed within 5 minutes after applying
sealant.
rrectness of i
♦ When installing sump with engine removed, ensure that sump l purpos
is flush with crankcase at flywheel end.
nf
ercia
– Place oil sump in position and slightly tighten the sump--to-
or
gearbox connecting bolts and all the oil sump bolts. Ensure
m
m
atio
m
that sump is flush against intermediate plate and gearbox

o
n in
c
flange.
or
thi
te
sd
– Tighten sump bolts.
iva
o
r
rp
cu
– Tighten bolts between sump and gearbox.
o
m
f
en
ng
t.
yi Co
– Secure anti-roll bar to subframe. Use new bolts. Tighten bolts Cop py
t. rig
when vehicle is standing on its wheels in an unloaded condi‐ yri
gh by
ht
tion or when vehicle is raised and wheels are also in the empty cop Vo
by lksw
weight position ⇒ front suspension; Rep. gr. 40 .
cted agen
Prote AG.
Note
♦ Renew cover in sump every time it is removed ⇒ ETKA (elec‐

tronic parts catalogue)
♦ Let sealing compound dry for approx. 30 minutes after instal‐
ling oil sump. Only then fill with engine oil.
– Install bracket on vehicles with four-wheel drive

– Carefully guide engine into engine mounting with support
bracket - 10 - 222 A- and secure engine to engine mounting
⇒ page 31 .
Specified torques
♦ ⇒ “1.1 Assembly overview - sump, oil pump”, page 137
Anti-roll bar to coupling rod 110 Nm
Bolts between sump and gear‐ 40 Nm
box.

Amarok 2011 ➤
1.3 Removing and installing oil pump

Removing
– Unscrew bolts -arrows- for oil pump -1- and baffle plate -2-.
– Remove baffle plate.
wage es n
– Detach oil pump -1- from toothed belt. yV
olks ot g
ua
d b ran
Installing ir se tee
tho
u or
a ac
Installation is carried out in the reverse order; note the
ss following:
ce
e
nl
pt
du
an
itte
y li
Note erm
ab
ility
ot p
Renew O-ring.
wit
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h re
hole
spec
es, in part or in w
– Insert new dowel sleeves when oil pump has no dowel sleeves
t to the co
-arrows- for centring oil pump.
– Check oil pump for ease of movement, turn toothed belt pulley
rrectness of i
with one finger for this.
l purpos
Note
nf
ercia
o
♦ Renew sluggish oil pump.
rm
m
atio
m
♦ Renew damaged toothed belt.

o
n in
or c
thi
♦ The toothed belt can sag after long use, this is not a fault.
te
sd
iva
o
r
rp
cu
o
m
– Check toothed belt for oil pump.
f
en
ng
t.
yi Co
op
– Fit oil pump with toothed belt pulley into toothed belt and tight‐ C py
t. rig
en along with baffle.
gh ht
pyri by
Vo
co lksw
by
– Install sump ⇒ page 140 . cted agen
Prote AG.
– Replenish engine oil and check oil level ⇒ page 147 .

Specified torques
1.4 Removing and installing oil pump, vehi‐

cles with balancer shaft module
Removing
Caution
Bolt on intermediate gear wheel must not be loosened.

Amarok 2011 ➤
– Remove circlip -1- with circlip pliers.

– Use a commercially available magnet to pull drive shaft -2- out
of oil pump -arrow-.
– Unscrew bolt -4- and detach suction line from oil pump.
– Remove bolts -3- and -5- and remove oil pump.
Installing
Note
♦ Renew O-ring.
♦ Renew damaged or over-tensioned circlip.
♦ Circlip must lie in base of groove.
– Ensure both dowel sleeves are in place before installing oil

pump.
AG. Volkswagen AG d
agen oes
Specified torques olksw not
y V gu
d b ara
♦ ⇒ “1.1 Assembly overview rise - sump, oil pump”, page 137 nte
tho eo
au ra
ss c
1.5 Checking engine oil level
ce
e
nl
pt
du
an
itte
y li
Oil capacities:
erm
ab
ility
ot p
With oil filter change: 7.0 l wit

, is n
h re
Without oil filter change: 6.7 l
hole
spec
Engine oil specifications:

es, in part or in w
t to the co
⇒ Maintenance ; Booklet 11
Markings on oil dipstick
rrectness of i
l purpos
Note
nform
ercia
The oil level may be in area -d- due to the infiltration of fuel in the
engine oil as a result of unfavourable driving conditions after fill‐
m
at
ing. This is a perfectly normal and self-regulating characteristic.

om
ion
It is not necessary to adjust the engine oil level.

c
in t
or
his
ate
do
riv
1 - Min. mark
p
cum
for
en
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2 - Max. mark
n
t.
yi Co
Cop py
a - Oil level in min. mark area: replenish engine oil!
t. rig
gh ht
pyri by
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b - Oil level in middle range: can be topped-up with engine oil.
c by lksw
cted agen
Prote AG.
c - Oil level in max. mark area: Do not replenish engine oil!
d - The oil level may be in this area as a result of particular driving
conditions.
1.6 Removing and installing oil level and oil

temperature sender - G266-
Removing
– Drain off engine oil.

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
– Disconnect connector
Vol-3-.
ksw not
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y
db ara
– ise and remove
Unscrew boltshor-1- oil level and oil temperature nte
eo
sender - G266-
au
t -item 4-. ra
c
ss
Installing
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
– Renew self-locking bolts -1- and seal -2-.
ility
ot
wit
, is n
– Replenish engine oil and check oil level ⇒ page 147 .
h re
hole
spec
Specified torques
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
ti
1.7 Removing and installing dipstick tube
on in
r
te o
thi
Removing
s
iva
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rp
cum
Observe general notes on the lubrication system ⇒ page 7
fo
en
ng
t.
yi Co
Observe rules for cleanliness when working on charge air system Cop py
⇒ page 8 ht. rig
rig ht
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co Vo
– Release and pull off connector -1- for intake air temperature
by lksw
cted agen
Prote
sender - G42- together with charge air pressure sender - G31-
AG.
-1-.
– Remove charge air pipe. Loosen clip -arrow- and pull hose
connection with charge air pipe -1- off throttle valve module -
J338- -2-.

Amarok 2011 ➤
– Loosen clip -1- and pull charge air hose off charge air pipe.
Then remove bolt -2- and remove pipe -arrow-.
– Loosen lower attachment -arrow- for dipstick tube. Unclip wir‐

ing harness retainer from engine speed sender - G28- on tube
-1-.
– Remove nut -2-. Move wiring harness retainer aside. Then re‐
move bolt -1- and remove dipstick tube -arrow- .upwards.
Volkswag AG en AG
agen does
Installing yV
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db ara
Installation is carried out in rise
the hreverse order; note the following: nte
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Always renew O-ring on dipstick tube every time tube is removed.

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Amarok 2011 ➤
2 Oil filter, oil pressure switch

⇒ “2.1 Assembly overview - oil filter housing with engine oil cool‐
er”, page 150
⇒ “2.2 Removing and installing oil filter housing with engine oil
cooler”, page 151
⇒ “2.3 Removing and installing oil pressure switch F1 ”,
page 154
⇒ “2.4 Checking oil pressure switch F1 ”, page 156
⇒ “2.5 Checking oil pressure”, page 157
⇒ “2.6 Measure oil consumption”, page 157
2.1 Assembly overview - oil filter n Ahousing

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1 - O-ring
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2 - Cap
❑ 25 Nm
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3 - O-ring
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4 - O-ring
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5 - Oil filter element

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at
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on the lubrication sys‐

p
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7 - Bolt
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❑ 10 Nm
8 - Spreader clip
9 - Engine oil cooler
❑ Observe general notes
on the lubrication sys‐
tem ⇒ page 7
❑ Ensure clearance to ad‐
jacent components.
❑ Coolant hose schematic
diagram ⇒ page 175 .
❑ Checking engine oil
cooler for leaks
⇒ page 159
engine oil cooler

Amarok 2011 ➤
⇒ page 151 .
10 - Bolt
❑ 11 Nm
11 - Rubber seals
❑ May not be lubricated with oil
❑ Fit into lugs on engine oil cooler.
12 - Bolt
❑ Specified torques and installation sequence ⇒ page 151 .
13 - Oil filter bracket
❑ Ensure clearance to adjacent components.
❑ Removing and installing oil filter bracket ⇒ page 151 .
14 - Rubber seals
❑ May not be lubricated with oil
❑ Fit into lugs on oil filter bracket.
Oil filter bracket - specified torques and installation sequence
Note
Renew bolts for oil filter bracket. AG. Volkswagen AG d

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– First tighten upper left andholower right bolts.
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Stage Bolts Specified torque/turning further angle

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1. -arrows- in diagonal sequence, 14 Nm

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hole
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2.2 Removing and installing oil filter housing

with engine oil cooler
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WARNING
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Do not lubricate rubber seals (8 and 11) with oil. Oil would
rm
make the coolant seals swell up.

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2. Oil filter, oil pressure switch 151

Amarok 2011 ➤

equipment required
♦ Used oil collection and ex‐
traction unit - V.A.G 1782-
- VAS 6208-
6362-
♦ Removal lever - 80 - 200-
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Removing
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Prote AG.

Amarok 2011 ➤
– Remove oil filter element.

Observe instructions for hose connections with screw-type clips
⇒ page 11 .
AG. Volkswagen AG d
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– Loosen screw-type clip -2- and pull charge air pipe -1- off from
ot
wit
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throttle valve module - J338- with throttle valve potentiometer
h re
- G69- and intake manifold flap motor - V157- .
hole
spec
es, in part or in w
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tion in
– Unscrew securing bolt -1- for charge air pipe.

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Prote AG.
– Unscrew securing bolt from charge air pipe bracket -2- on

coolant pipe -1-.

Amarok 2011 ➤
– Pull oil dipstick out of guide tube -1- a little and undo bolt -2-.
– Press off expanding clip -3- using removal lever - 80 - 200- .
– Pull oil dipstick guide tube off cylinder block upwards and push
to side.
– Place drip tray for workshop crane - VAS 6208- under point of
separation.
– Remove coolant hose, loosen hose clip -1- for this.
– Place used oil collection and extraction unit - V.A.G 1782- un‐
der engine.
– Unscrew bolts -arrows- and remove oil filter bracket with en‐
gine oil cooler.
Installing
Note agen
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♦ Renew gaskets, seals and O-rings. orise
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Hose unions and air intake pipes/hoses mustssbe
a free of oil and
u
♦ ra
c
grease when installing.
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– Filling with coolant ⇒ page 182

erm
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Specified torques
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♦ ⇒ “2.1 Assembly overview - oil filter housing with engine oil

ole,
cooler”, page 150

spec
t to the co
2.3 Removing and installing oil pressure

switch - F1-
rrectne

ss o
cial p
f inform
mer
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Cop py
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Prote AG.

Amarok 2011 ➤
♦ Jointed wrench 24 mm - T40175-

AG. Volkswagen AG d
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Removing
– Unscrew securing bolt -1- from right engine mounting -A- and
remove engine mounting.
rrectness of i

l purpos
– Unscrew oil pressure switch - F1- -B- from cylinder head using
nform
articulated wrench, 24 mm - T40175- .

mercia
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Note
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Collect escaping engine oil with cloths.

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Installing
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– Tighten oil pressure switch - F1- . cted agen
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Specified torques

Amarok 2011 ➤
2.4 Checking oil pressure switch - F1-

equipment required
♦ Oil pressure tester - V.A.G
1342-
♦ Voltage tester - V.A.G
1527/B-
♦ Auxiliary measuring set -
V.A.G 1594/C-
♦ Current flow diagram
⇒ Current flow diagrams,
Electrical fault finding and
Fitting locations
AG. Volkswagen AG d
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Test prerequisites tion in

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• Oil level OK, checking ⇒ page 147

iva
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• Engine oil temperature at least 80 °C (radiator fan must have

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Test procedure opyri
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Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
– Pull connector off oil pressure switch - F1- .

Amarok 2011 ➤
AG. Vo(2.0
lksw l engine,
agen common rail) - Edition 04.2013
n AG do
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– Remove oil pressure switch - F1- -2- ed
byand screw into oil pres‐
V ua
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sure tester - V.A.G 1342- . horis tee
ut or
a ac
– Screw tester into oil filter bracket
ss in place of oil pressure
switch .
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– Connect brown wire -1- of tester to earth (-).
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– Connect voltage tester - V.A.G 1527 B- to battery positive (+)
ility
and oil pressure switch using cables from auxiliary test set - ot p
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V.A.G 1594 C- .
hole
spec
• LED must not light up.
es, in part or in w
t to the co
If the LED lights up:
– Replace oil pressure switch - F1-
rrectness of i
If LED does not light up:
l purpos
– Start engine and increase revolutions slowly.

• From 0.30…0.60 bar the LED must light up, otherwise renew
nf
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oil pressure switch - F1- .
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2.5 Checking oil pressure

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Prerequisite
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• Oil pressure tester - V.A.G 1342- is connected ⇒ page 156 . yi

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– Increase engine speed further.
co lksw
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• Oil pressure at idling speed: at least 0.6 bar (vehicles compli‐
ant with EU 4 standard: 1.2 - 2.1 bar).
• Oil pressure at 2,000 rpm: at least 1.0 bar (vehicles compliant
with EU 4 standard: 1.6 - 2.1 bar).
• Oil pressure at 3,700 rpm in the case of vehicles compliant
with EU 4 standard: 3.0 - 4.0 bar.
• At higher engine speeds, the oil pressure must not exceed 5.0
bar.
Note
In the case of vehicles compliant with the EU 4 standard, the oil

pressure at 2,000 rpm can be between 3.0 and 4.0 bar during the
first 1000 km.
If specification is not attained:

– Renew oil pump if necessary ⇒ page 146 .
Note
Mechanical damage, e.g. to bearings, could also be the cause for

oil pressure being too low.
2.6 Measure oil consumption

♦ Vehicle diagnostic tester
Procedure
– Pull handbrake on.

Amarok 2011 ➤
– Manual gearbox: gear stick in neutral.

– Automatic gearbox: move selector lever to position “N”.
– Connect ⇒ Vehicle diagnostic tester.
– Switch ignition on.
olkswagen AG
en AG. V
– Carry out program oOil ag does
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V l
⇒ Vehicle diagnostic
ed by tester and follow instructions. gu
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AG. Volkswagen AG d
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thor Amarok e o2011 ➤
u ra
4-cylinder diesel
ss a engine (2.0 l engine, common rail) - Edition 04.2013
c
ce
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nl
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3 Engine oil cooler
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⇒ “3.1 Checking engine oil cooler for leaks”, page 159
wit
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3.1 Checking engine oil cooler for leaks
hole
spec
es, in part or in w
t to the co
equipment required
rrectness of i
♦ Refractometer - T10007 A-
♦ Hose clamps up to 25 mm - l purpos
3094-
nf
ercia
♦ Cooling system tester -
orm
V.A.G 1274-
m
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♦ Adapter for cooling system
or c
thi
tester - V.A.G 1274/8-
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♦ Spring-type clip pliers -

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VAS 5024 A-
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♦ Drip tray - V.A.G 1306- or
C py
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drip tray - VAS 6208-
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3. Engine oil cooler 159

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ara
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Prerequisites:
pt
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• Engine cold
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Test procedure ot p
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spec
es, in part or in w
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– Loosen hose clip on engine oil cooler with spring-type clip pli‐
ers - VAS 5024- .
rrectness of i
– Remove engine oil cooler with housing ⇒ page 151 .
l purpos
nform
ercia
Note
m
at
om
i
♦ Collect escaping coolant with drip tray - VAS 6208- .
on
c
in t
or
♦ Collect leaking engine oil with an absorbent cleaning cloth, if
his
ate
necessary.
do
priv
cum
or
♦ Do not damage engine oil cooler housing when securing with

f
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screw clamp.
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Checking when removed Prote
cted AG.
agen
– Secure housing with the old gasket on a suitable, flat, clean

surface using a suitable screw clamp -4-.
– Fit plug -2- to venting connection of expansion tank -1-.
– Fit coolant hose -3- to engine oil cooler -5- and to expansion
tank -1-.
– Fill expansion tank up to “max.” mark.
– Fit cooling system tester - V.A.G 1274- with adapter for cooling
system tester - V.A.G 1274/8- on coolant expansion tank-1-.
– Using hand pump on tester, build up a pressure of approx. 1.6
bar.
– Observe pressure drop on pressure gauge. A pressure drop
within 10 minutes is not permitted.
If pressure drops:
– Renew engine oil cooler ⇒ page 151 .
– Renew seal for housing.
– Check coolant level and, if necessary, replenish
⇒ page 182 .
– Check engine oil level and, if necessary, replenish
⇒ page 147 .

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
lksw not
4 Balancer shaft module Vo gu
d by ara
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⇒ “4.1 Assembly overview - balancer shaft module”,
aut page 161 ra
c
ss
⇒ “4.2 Removing balancer shaft module”, page 163
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⇒ “4.3 Installing a new balancer shaft module”, page 165
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⇒ “4.4 Installing a previously used balancer shaft module again”,
ility
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page 168
wit
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4.1 Assembly overview - balancer shaft module
spec
t to the co
1 - Oil sump
❑ Tightening sequence
rrectne
⇒ page 163 .
ss
⇒ page 140 .
o
cial p
f in
2 - Bolt
form
mer
❑ 10 Nm
atio
om
n
c
3 - Suction hose
i
or
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❑ Clean strainer if soiled.
sd
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4 - Bolt
fo
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t.
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❑ 10 Nm
Co
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5 - O-ring
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❑ Renew after removing Prote
cted AG.
agen
6 - Oil pump
❑ Before installing, check
that both dowel sleeves
for centring oil pump on
balancer shaft module
are fitted.
7 - Drive shaft for oil pump
8 - Circlip
❑ Must lie in base of
groove.
❑ Renew damaged or
over-tensioned circlip.
9 - Spur gear for balancer shaft
10 - Bolt
❑ 20 Nm + 90°
11 - Hub
❑ For intermediate gear wheel.
12 - Bolt
❑ 90 Nm + 90°
13 - Thrust washer
4. Balancer shaft module 161

Amarok 2011 ➤
14 - Intermediate gear wheel

❑ The new intermediate gear wheel has coating which wears down until the correct tooth backlash is at‐
tained.
Caution
When installing the inter‐
mediate gear wheel, en‐
sure that the thrust
washer is seated cor‐
rectly ⇒ page 163 .
❑ Installation position: Part number must be visible.

❑ Installing ⇒ page 165 .
15 - Thrust washer
❑ If necessary, attach to housing with grease when installing intermediate gear wheel.
16 - Spur gear for crankshaft
17 - Balancer shaft module
❑ Removing ⇒ page 163 agen
AG. Volkswagen AG d
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❑ Installing new balancer shaft module by V ⇒ page 165 .
o gu
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❑ Reinstalling previously run balancer
horis shaft module ⇒ page 168 . nte
eo
ut ra
❑ Before installing, check that
ss a the two dowel sleeves for centring balancer shaft c module on cylinder block
are fitted.
ce
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nl
pt
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18 - Bolt
itte
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ility
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❑ Note tightening sequence: installing new balancer shaft module ⇒ page 165 , reinstalling previously run
wit
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balancer shaft module ⇒ page 168 .

h re
hole
spec
❑ M7 = 13 Nm + 90°
es, in part or in w
❑ M8 = 20 Nm + 90°
t to the co
19 - Oil extraction pipe

rrectness of i
20 - Bolt
❑ 10 Nm
l purpos
21 - Bolt
nf
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❑ 40 Nm
orm
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atio
22 - Bolt
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❑ 45 Nm
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23 - Bolt
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❑ Tighten in stages and in diagonal sequence.

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❑ Initial tightening torque: 5 Nm
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❑ 15 Nm opy
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24 - Seal
by
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Prote AG.
❑ Permanently attached to drain plug.
25 - Oil drain plug
❑ With seal.
❑ 30 Nm

Amarok 2011 ➤
Oil spray jet and pressure relief valve

1- Bolt with pressure relief valve, 27 Nm
2- Oil spray jet (for cooling of pistons)
Thrust washer installation position
Caution
When installing intermediate gear wheel, make sure that thrust

washer -A- does not slip out of balancer shaft module inden‐
tations -arrows- and subsequently become jammed. If neces‐
sary, fix in place with grease on balancer shaft module.
Sump - tightening sequence n AG. Volkswagen AG do

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– Renew bolts for oil sump. d byV ua
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– Tighten bolts in diagonal sequence
utho
in 3 stages as follows: or
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ss
1. Initially tighten bolts -1 … 20- diagonally.
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2. Tighten bolts -arrows- securing sump to gearbox.

itte
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3. Tighten bolts -1 … 20- diagonally in stages.

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es, in part or in w
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4.2 Removing balancer shaft module

rrectness of i

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nform
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om
ion
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ate
do
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en
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co lksw
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cted agen
Prote AG.

Amarok 2011 ➤
♦ Crankshaft stop - T10050- for engines with round crankshaft

toothed belt pulley
Removing
– Pull oil dipstick out.
– Remove sump ⇒ page 140 . AG. Volkswagen AG d
agen oes
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– Remove vibration damper ⇒ page d by 44 .
V gu
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– Rotate crankshaft to TDCutand lock in position with crankshaft
ho eo
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stop - T10050- . ss a c
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The markings on the crankshaft toothed belt pulley -2- and the
wit
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crankshaft stop - T10050- -1- must align. At the same time, the
h re
hole
pin of the crankshaft stop - T10050- must engage in the drilling in
spec
the sealing flange.
es, in part or in w
t to the co
rrectness of i
– Unscrew bolts in sequence -6 … 1- and remove balancer shaft

l purpos
module together with oil pump.

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Cop py
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
4.3 Installing a new balancer shaft module

equipment required
♦ Bits - T10099-
♦ Locking device - T10255-
♦ 14 mm tool insert - T10393-
AG. Volkswagen AG d
agen oes
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d by ara
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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
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pr
cum
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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.

Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - EditionA04.2013
G. Volkswagen n AG do
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au ac
ss
♦ The spur gear drive of the balancer shaft module must be in‐
ce
e
nl
pt
du
stalled with correct tooth backlash.
an
itte
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erm
♦ A coating is applied to the new intermediate gear wheel to set
ab
ility
the correct tooth backlash.
ot p
wit
, is n
♦ Intermediate gear wheels that have a white point are partly
h re
hole
coated around the circumference. Intermediate gear wheels
spec
without a white spot are fully coated around the circumference
es, in part or in w
t to the co
♦ The coating is quickly worn away, as a result of which the tooth
backlash is set.
rrectness of i
♦ For this reason a new balancer shaft module must always be
installed with a new intermediate gear wheel with special coat‐
l purpos
ing.
♦ A white spot is positioned only on partly coated intermediate
nf
ercia
o
gear wheel to ensure correct installation position.
rm
m
atio
m
♦ For intermediate gear wheels with coating around the com‐

o
n in
c
plete circumference the installation position is not relevant.

or
thi
te
sd
a
♦ Bolts that are firmly tightened at a specified angle must be

iv
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renewed.
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ng
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op
• Crankshaft locked in position with crankshaft stop - T10050- .
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pyri by
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by
Caution cted agen
Prote AG.
The threaded connection of the intermediate gear wheel must

be loosened to position the balancer shaft module. When doing
this, do not loosen the bolt fully to prevent that the thrust wash‐
er does not slip behind the intermediate gear wheel. Thrust
washer installation position ⇒ page 163
Note
For illustration purposes the following procedure is described with

sealing flange removed.
– Before positioning balancer shaft module on cylinder block,

loosen bolt -1- for intermediate gear wheel approx. 45°.
– Check to see whether both dowel sleeves are in place to cor‐
rectly position balancer shaft module on cylinder block.
– Place balancer shaft module on cylinder block.
Note
Take care not to damage coating on intermediate gear wheel.

Amarok 2011 ➤
– Fit bolts in sequence -1 … 6- and hand-tighten at first.

– Tighten bolts of balancer shaft module as follows:
1. Initially tighten bolts in the sequence
olks
w-1
age… 6- to 6 Nm. es n
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by ara
2. Tighten bolts -3- and -5- tori13
se Nm.
d
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tho eo
3. Turn bolts -3- and -5- s90°
s a further with rigid spanner.
u ra
c
ce
e
4. Tighten bolts -1 … 2-, -4- and -6- to 20 Nm.
nl
pt
du
an
itte
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5. Turn bolts -1 … 2-, -4- and -6- 90° further with rigid spanner.
erm
ab
ility
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wit
, is n
h re
hole
spec
– Lock balancer shaft with locking device - T10255- . To do this,
es, in part or in w
turn balancer shaft if necessary.
t to the co
• Locking tool pin must engage in groove in balancer shaft when
doing this.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
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sd
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t.
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Cop py
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pyri by
Vo
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by
cted agen
Prote AG.
– Carefully fit gear wheel of balancer shaft onto balancer shaft.

While doing this, press intermediate wheel to one side slightly.
Note
♦ Ensure threaded holes in balancer shaft are central within

elongated holes of balancer shaft gear wheel.
♦ If elongated holes in balancer shaft gear wheel cannot be
aligned with the threaded holes, the balancer shaft gear wheel
must be turned further by a corresponding number of teeth and
must be mounted again.
– Securely tighten balancer shaft gear wheel -arrows-.

– Remove locking tool - T10255- .

Amarok 2011 ➤
The following 3 procedures must be performed simultaneously

(2nd mechanic required):
– Press intermediate gear wheel -3- forcefully (with assistance
of a wooden rod if necessary) in -direction of arrow- into teeth
of drive gear wheel -2- and balancer shaft gear wheel -1-
(meshing together).
– When doing so, turn the balancer shaft gear wheel -1- slightly
in an anticlockwise direction.
– Firmly tighten bolt for intermediate gear wheel using bit -
T10099- and 14 mm tool insert - T10393-
⇒ Item 13 (page 161) .
– Remove crankshaft stop - T10050- .
Note
No backlash may be perceptible after installing intermediate gear agen AG. Volkswagen AG do
wheel. This can be checked by hand using light force. yV
olks
w es n
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b ua
ed ran
oris tee
Further installation is carried out in the reverse order.au
t In the proc‐
h or
ac
ess, note the following: ss
ce
le
un
pt
an
d
itte
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– Install belt pulley/vibration damper (replace securing bolts)
rm
ab
pe
ility
⇒ page 44
ot
wit
, is n
h re
hole
spec
Specified torques
es, in part or in w
t to the co
rrectness of i
4.4 Installing a previously used balancer
l purpos
shaft module again
nform
ercia
Caution
m
a
com
tion in
r
If the bolt for the intermediate wheel has been removed, a new
te o
thi
intermediate wheel with coating must be installed and the hub

s
iva
do
r
⇒ Item 11 (page 161) including bolt ⇒ Item 12 (page 161) and

rp
cum
fo
thrust washer must be renewed. This also applies to replace‐

en
ng
t.
yi
ment of the drive gear wheel on the crankshaft and to removal
Co
op py
of the crankshaft. Otherwise, the tooth backlash will be incor‐ t. C rig
gh ht
rect. Procedure when installing ⇒ page 165 . pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ If the previously used balancer shaft module is to be reinstalled

and neither has the drive gear wheel on crankshaft been re‐
newed nor has the crankshaft been removed, proceed as
follows. The intermediate gear wheel must also not have been
loosened.
♦ Renew bolts tightened through an additional specified angle.

Amarok 2011 ➤
– Lock balancer shaft with locking device - T10255- . To do this,

turn balancer shaft if necessary.
• Locking tool pin must engage in groove in balancer shaft when
doing this.
– Check to see whether both dowel sleeves are in place to cor‐
rectly position balancer shaft module on cylinder block.
– Place balancer shaft module on cylinder block.
• The intermediate gear wheel must mesh in the crankshaft
drive gear wheel when the balancer shaft is locked.
• The intermediate gear wheel must have a slight tooth back‐
lash.
– Fit bolts in sequence -1 … 6- and hand-tighten at first.

AG. Volkswagen AG d
– Tighten bolts of balancer shaft module as follows: agen oes
olksw not
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by ara
1. Initially tighten bolts in the sequence -1 … 6- to ris 6 Nm.
ed
nte
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ut
2. Tighten bolts -3- and -5- to 13 Nm. ss a ra
c
ce
le
3. Turn bolts -3- and -5- 90° further with rigid spanner.
un
pt
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d
itte
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4. Tighten bolts -1 … 2-, -4- and -6- to 20 Nm.
erm
ab
ility
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5. Turn bolts -1 … 2-, -4- and -8- 90° further with rigid spanner.
wit
is n
h re
– Remove crankshaft stop - T10050- .
ole,
spec
Further installation is carried out in the reverse order. In the proc‐
t to the co
ess, note the following:
rrectne
– Install belt pulley/vibration damper (replace securing bolts)
⇒ page 44
ss
Specified torques
o
cial p
f in
form
mer
atio

om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
5 Oil circuit
⇒ “5.1 Removing and installing oil supply line to turbocharger,
120 kW and 132 kW engines”, page 170
⇒ “5.2 Removing and installing oil pressure line to turbocharger -
90 kW and 103 kW engine”, page 172
5.1 Removing and installing oil supply line

to turbocharger, 120 kW and 132 kW
engines
– Position engine with support bracket - 10o-lks222 A- as shown

wagen AG
and take up weight of engine in
swinstallation
agen AG
.V
position. does
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Note tho eo
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The securing bolts for the assembly mountings may only be re‐
nl
pt
du
moved if the engine is supported with support bracket - 10-222

an
itte
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A- !
erm
ab
ility
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Removing
, is n
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hole

spec
es, in part or in w

t to the co

– Remove right engine support ⇒ page 31 .
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 ➤
– Unbolt bracket -2- for oil supply line -1- from turbocharger.
lkswage es n
ot g
Vo oil supply line on upper turbocharger
– Loosen banjo bolt -2- d byfor ua
ran
-1-. o
ir se tee
th or
au ac
ss
ce
le
un
pt
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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
– Loosen banjo bolt -2- for oil supply line on lower turbocharger
rrectness of i
-1-.
l purpos
nform
mercia
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com
tion in
r
te o
thi
s
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t.
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– Unscrew bolt -2- for oil supply line bracket -1- through opening
co Vo
by lksw
cted
on assembly mounting -3-.
agen
Prote AG.
5. Oil circuit 171

Amarok 2011 ➤
– Unscrew banjo bolt -2- for oil supply line -1-.

. Volkswagen AG
– Collect escaping oil with a cloth. kswagen AG does
not
ol
yV gu
– Completely remove oil supplyed b line. ara
nte
ris
ho eo
Installing aut ra
c
ss
ce
le
un
pt
an
d
itte
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rm
ab
Note
pe
ility
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wit
, is n
h re
Procedure must be adhered to, this ensures that the oil supply
hole
line is installed stress-free.
spec
es, in part or in w
t to the co
– Renew seals, gaskets and self-locking nuts.
rrectness of i
– Fit new double seal -2- onto the respective line connection
-1- and secure by screwing in the corresponding banjo bolt
l purpos
-3-.
nform
ercia
m
a
– Install right engine support ⇒ page 31 .
com
tion in
r
– Install charge air pipe ⇒ page 250 .

te o
thi
s
iva
do
– Install air filter housing ⇒ page 368 .
r
rp
cum
fo
Specified torques
en
ng
t.
yi Co
op py
♦ ⇒ “2.1 Removing and installing assembly mountings”, t. C rig
gh ht
page 31 yri
p by
o Vo
by c lksw
cted
♦ ⇒ “1.1 Assembly overview - charge air system”, page 250
agen
Prote AG.
♦ ⇒ “7.1 Assembly overview - air filter”, page 368

♦ ⇒ “2.1 Assembly overview - turbocharger, 120 kW and 132 kW
engines”, page 260
5.2 Removing and installing oil pressure line

to turbocharger - 90 kW and 103 kW en‐
gine

Amarok 2011 ➤

Note
The securing bolts for the assembly mountings may only be re‐
moved if the engine is supported with support bracket - 10-222
A- !
Removing
– Remove right engine support ⇒ page 31 .
– Remove securing bolt -2-.

– Remove banjo bolts -1 and 3-.
– Collect escaping oil with a cloth.
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
ho eo
– Remove bolts -1- and remove oil pressure line. aut ra
c
ss
– Collect escaping oil with a cloth.
ce
e
nl
pt
du
an
itte
Installing
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
Procedure must be adhered to, this ensures that the oil pressure
line is installed stress-free.
– Renew seals, gaskets and self-locking nuts. 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.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
5. Oil circuit 173

Amarok 2011 ➤
– Fit new seals -2- onto the respective line connection -3- and
secure by screwing in the corresponding banjo bolt -1-.
– Install right engine support ⇒ page 31 .
– Install charge air pipe ⇒ page 250 . n AG. Volkswagen AG do
lkswage es n
o ot g
– Install air filter housing ⇒ page 368 . d byV ua
ran
ir se tee
Specified torques autho
or
ac
ss
ce
e
nl
page 31
pt
du
an
itte
y li
♦ ⇒ “1.1 Assembly overview - charge air system”, page 250 erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
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o
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f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
19 – Cooling
1 Cooling system, coolant
⇒ “1.1 Coolant hose schematic diagram”, page 175
⇒ “1.2 Assembly overview - coolant hoses”, page 178
⇒ “1.3 Checking cooling system for leaks”, page 180
⇒ “1.4 Draining and filling coolant”, page 182
1.1 Coolant hose schematic diagram
1.1.1 Coolant hose schematic diagram for vehicles with supplementary heater,
engine codes CDCA and CDBA
1 - Expansion tank
2 - Heat exchanger for heater
unit
3 - Union on rear of cylinder
head
❑ With coolant tempera‐
ture sender - G62-
4 - Cylinder head
6 - 4/2-way valve
❑ With thermostat.
❑ Can only be renewed AG. Volkswagen AG d
complete. agen oes
olksw not
yV gu
❑ Removing and installing ised b ara
nte
⇒ page 191 . ut
hor eo
a ra
s c
7 - Circulation pump - V55- s
ce
e
nl
pt
❑ Assembly overview
du
an
itte
⇒ page 189 .
y li
erm
ab

ility
ot p
⇒ page 200 .
wit
, is n
h re
8 - Auxiliary heater
hole
spec
❑ Depending on equip‐
es, in part or in w
t to the co
ment.
9 - Radiator
rrectness of i
❑ Renew coolant after re‐

placing.
l purpos

⇒ page 204 .
nform
ercia
10 - Coolant pump
m
at
om
11 - Continued coolant circula‐

on
c
tion pump - V51-

in t
or
his
te

a
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Cooling system, coolant 175

Amarok 2011 ➤
12 - Continued coolant circulation pump - V51-

13 - Radiator outlet coolant temperature sender - G83-
14 - Exhaust gas recirculation cooler
❑ Removing and installing ⇒ page 392 . AG. Volkswagen AG d
agen oes
15 - Thermostat (Y-piece) olksw not
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d by ara
e nte
16 - Coolant temperature sender - G62- horis
eo
aut ra
ss c
ce
e
nl
pt
du
1.1.2 Coolant hose schematic diagram, vehicles with auxiliary heater, engine co‐
an
itte
y li
erm
des CSHA and CNEA (emission standards EU 4 and EU 5)
ab
ility
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wit
, is n
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1 - Expansion tank
hole
spec
es, in part or in w
t to the co
unit
rrectness of i
head
l purpos
ture sender - G62-

4 - Cylinder head
nf
ercia
orm
m
atio
om
n in
6 - 4/2-way valve
or c
thi
e
t
sd
iva
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cu
❑ Can only be renewed
o
m
f
complete.
en
ng
t.
yi Co
op
7 - Circulation pump - V55-
C py
t. rig
gh ht
yri by
8 - Coolant pump
op Vo
by c lksw
cted agen
Prote AG.
ment.
10 - 2-way valve for coolant
shut-off valve - N147-
11 - Radiator
placing
12 - Exhaust gas recirculation
cooler changeover valve -
N345-
13 - Continued coolant circula‐
tion pump - V51-
14 - Radiator outlet coolant
temperature sender - G83-
16 - Thermostat (Y-piece)
176 Rep. gr.19 - Cooling

Amarok 2011 ➤
1.1.3 Coolant hose schematic diagram, vehicles with auxiliary heater, engine co‐
des CDBA and CNFA (emission standards EU 3, EU 4 and EU 5)
1 - Expansion tank
unit
head
ture sender - G62-
4 - Cylinder head
AG. Volkswagen AG d
agen
5 - Engine oil cooler Volksw
oes
not
gu
by ara
d
6- Circulation pump orise- V55- nte
eo
th
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7- 4/2-way valve
ss a c
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nl
pt
du
an
itte
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erm
ab
complete.
ility
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8 - Coolant pump
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
ment.
10 - 2-way valve for coolant
shut-off valve - N147- rrectness of i
11 - Radiator
l purpos

placing
nform
ercia

m
at
om
cooler
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 ➤
1.2 Assembly overview - coolant hoses

wage es n
1 - Expansion tank yV
olks ot g
ua
d b
❑ Checking cooling sys‐ o
ir se
ran
tee
tem for leaks with cool‐ auth or
ac
ing system tester - ss
V.A.G 1274- and adapt‐
ce
le
un
pt
er - V.A.G 1274/8-
an
d
itte
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⇒ page 180 . erm
ab
ility
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wit
ture display sender -
is n
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G32- .
ole,
spec
t to the co
❑ Hose clip pliers - VAS
6340- or hose clip pliers
- VAS 6362- are recom‐
rrectne
mended for installation
of spring-type clips.
ss
3 - Coolant line
o
cial p
f in
form
mer
atio
m
4 - Retaining clip
o
n
c
i
or
n thi
e
5 - T piece
t
sd
iva
o
r
❑ To heat exchanger
p
cum
r
fo
en
ng
6 - Connection
t.
yi Co
op py
t. C rig
gh ht
yri
with coolant tempera‐ p by
co Vo
ture sender - G62-
by lksw
cted agen
Prote
⇒ page 196
AG.
7 - Y-thermostat
8 - Coolant pipe
9 - Coolant line
10 - Bolt
❑ 9 Nm
11 - Ball thermostat (4/2-way valve)
❑ Thermostat is installed in valve.
❑ Renew completely.
12 - O-ring
13 - Coolant pipe
14 - Coolant pipe
15 - Coolant line
❑ Coolant hose schematic diagram ⇒ page 175 .
16 - Coolant line
❑ Secured to top of radiator.

Amarok 2011 ➤
17 - Upper coolant hose

18 - Coolant hose
19 - Radiator
❑ Renew coolant after replacing
20 - Coolant hose at bottom with T piece
23 - Retaining clip
25 - Coolant line
27 - Bracket
28 - Coolant line
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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ho eo
aut ra
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un
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d
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rm
ab
pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤ AG. Volkswagen AG d
4-cylinder diesel agen (2.0 l engine,
engine common
oes rail) - Edition 04.2013
olksw not
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by ara
ed nte
ris
1.3 Checking cooling system for leaks
au
tho eo
ra
ss c
ce
e
nl
pt
du
an
itte
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equipment required
erm
ab
ility
ot p
♦ Cooling system tester -
wit
V.A.G 1274 B-
, 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.
Test prerequisite
• Engine is at operating temperature
• Perform leakage test of cooling system using cooling system
tester - V.A.G 1274- and adapters adapter - V.A.G 1274/8- and
adapter - V.A.G 1274/9- .
Test sequence:
WARNING
Hot steam may escape when expansion tank is opened. Place

cloth over cap and open with caution.
– Open filler cap on coolant expansion tank.

– Screw adapter for cooling system tester - V.A.G 1274/8- into
coolant expansion tank.
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/8- .

Amarok 2011 ➤
– 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- , reduction of the pressure is essential. 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:
AG. Volkswagen AG d
agen oes
– Find leaks and rectify. olksw not
byV gu
ara
d
Check pressure relief valve in filler cap horise nte
eo
aut ra
– Screw cap into adapter for cooling system tester
s - V.A.G
s c
1274/9- .
ce
e
nl
pt
du
an
itte
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
y li
erm
ab
system tester - V.A.G 1274/9- .
ility
ot p
– Join connection piece - V.A.G 1274 B/1- to cooling system
wit
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h re
tester - V.A.G 1274 B- using connecting hose supplied.
hole
spec
– Using hand pump on cooling system tester, build up a pres‐
es, in part or in w
sure of approx. 1.6 bar.
t to the co
The pressure relief valve must not open.
rrectness of i
If the pressure relief valve opens prematurely:
l purpos
– Renew cap.
– Increase pressure to over 1.6 bar.
nf
ercia
o
The pressure relief valve must open.
rm
m
atio
m
If the pressure relief valve does not open:

o
n in
or c
thi
– Renew cap.
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sd
iva
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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.

Amarok 2011 ➤
1.4 Draining and filling coolant

equipment required
- VAS 6208-
6340-
♦ Cooling system charge unit
- VAS 6096-
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Draining ility
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WARNING
hole
spec
es, in part or in w
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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.
rrectness of i
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by
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Prote AG.

Amarok 2011 ➤
AG. Volkswagen AG d
– Open cap -2- on expansion
lksw
agen tank -1-. oes
not
o
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– Remove underbody ris
ed b
guard, if fitted ⇒ General body repairs,
ara
nte
exterior; Rep.
uth gr. 66 ; Underbody guard .
o eo
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a 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
– Remove spring-type clip -2- and pull lower coolant hose -1- off
radiator -3-.
rrectness
Note
o
cial p
f inform
Observe environmental regulations for disposal.
mer
atio
om
n
Filling
c
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Caution
p
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fo
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Only distilled water may be used for mixing with coolant addi‐ Cop py
tives. The use of distilled water ensures optimum protection
t. rig
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against corrosion.
p by
co Vo
by lksw
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Prote AG.

Amarok 2011 ➤
Note
♦ Use only coolant additives which conform with the ⇒ Elec‐

tronic Parts Catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the engine.
♦ The correct coolant solution ratio helps prevent damage due
to freezing and corrosion as well as scaling. Moreover, the
boiling temperature is raised. Therefore, the cooling system
must be filled all year round with coolant
wage
additive.
n AG. Volkswagen AG
does no ks
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♦ Because of its higher boiling
ed point, the coolant improves en‐
by ara
gine reliability under heavy
ho loads, particularly in countries with
ris nte
eo
tropical climates. s a ut ra
c
s
♦ Frost protection must be guaranteed down to about -25 °C (in
ce
e
nl
pt
du
countries with Arctic climates, down to about -36 °C).
an
itte
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♦ The coolant concentration must not be reduced by adding wa‐
ility
ot p
ter even in warmer seasons and in warmer countries. The
wit
, is n
coolant additive concentration must be at least 40 %.
h re
hole
♦ If a stronger anti-freeze mixture is necessary due to harsher
spec
weather conditions, the coolant additive content can be in‐
es, in part or in w
t to the co
creased. But only to 60 %, or the antifreeze protection will be
reduced again and the cooling effect will be impaired.
♦ ONLY refractometer - T10007 A- may be used for determining
rrectness of i
current anti-freeze density.
l purpos
♦ Read anti-freeze figures from respective scale for type of anti-

freeze added. nf
ercia
♦ Do not reuse old coolant.

rm
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atio
om
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c
Recommended mixture ratios:

or
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a
Frost protection Coolant additive Coolant ad‐ Distilled wa‐

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to portion ditive 3) ter3)

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t.
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-25 °C 40 % 5.0 l 7.5 l
Co
op py
-36 °C 50 % 6.25 l 6.25 l
t. C rig
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co
3) The quantity of coolant can vary depending upon vehicle equipment. by lksw
cted agen
Prote AG.
Procedure:
– Unscrew cap -2- from expansion tank -1-.

– Pull off coolant hose -3- on 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.

Amarok 2011 ➤
– 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.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
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
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rp
cu
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m
f
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 ➤
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
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote
186
AG.
Rep. gr.19 - Cooling
Amarok 2011 ➤
2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - coolant pump/ball thermostat (4/2-
way valve)”, page 187
⇒ “2.2 Assembly overview - Continued coolant circulation pump
V51 ”, page 188
⇒ “2.3 Assembly overview - circulation pump V55 ”, page 189
⇒ “2.4 Removing and installing coolant pump”, page 190
⇒ “2.5 Removing and installing 4/2-way valve with thermostat”,
page 191
⇒ “2.6 Removing and installing coolant temperature sender G62
”, page 196
⇒ “2.7 Removing and installing coolant temperature sender at ra‐
diator outlet G83 ”, page 197
⇒ “2.8 Removing and installing continued coolant circulation
pump V51 ”, page 198
⇒ “2.9 Removing and installing Y-thermostat”, page 199
⇒ “2.10 Removing and installing recirculation pump V55 ”,
page 200
2.1 Assembly overview - coolant pump/ball thermostat (4/2-way valve)

AG. Volkswagen AG d
agen
1 - Cylinder block Volksw
oes
not
gu
by ara
d
2 - O-ring orise nte
eo
th
❑ Renew after
ss a removing
u ra
c
ce
le
3 - Bolt
un
pt
an
d
itte
❑ 15 Nm
y li
erm
ab
4 - Ball thermostat (4/2-way

ility
ot p
valve)
wit
is n
h re

ole,
spec
⇒ page 191 .
t to the co
5 - O-ring
rrectne
6 - Coolant pump
s
⇒ page 190 .
s o
cial p
f in
7 - Bolt
form
mer
❑ 15 Nm
atio
om
8 - Oil sump
c
i
or
n thi
te
9 - Bolt
sd
iva
o
pr
❑ 15 Nm
um
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t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.
2. Coolant pump, regulation of cooling system 187

Amarok 2011 ➤
2.2 Assembly overview - Continued coolant circulation pump - V51-
1 - Coolant hose
❑ Return flow to exhaust
gas recirculation cooler
3 - Bolt
❑ 4.5 Nm
4 - Bolt
❑ 1.2 Nm
5 - Bracket
❑ For continued coolant
circulation pump - V51- .
❑ For continued coolant AG. Volkswagen AG d
agen oes
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circulation pump - V51-
by
Vol not
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ara
wiring harness. rised
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6 - Continued coolant
ss
au circula‐ ra
c
tion pump - V51-
ce
le
un
pt
an
d
itte
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⇒ page 198 .
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7 - Coolant hose
ot
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❑ Feed line from radiator h re

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spec
es, in part or in w
t to the co
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Cop py
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by c lksw
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Prote AG.

Amarok 2011 ➤
2.3 Assembly overview - circulation pump - V55-
1 - Bracket
❑ Secured on left wheel
housing
2 - Bolt
❑ 8 Nm
3 - Rubber bush
4 - Circulation pump - V55-
⇒ page 200 .
6 - Coolant hose
❑ To heater cooler.
7 - Coolant hose
❑ From cylinder head
AG. Volkswagen AG d
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t to the co
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cial p
f inform
mer
atio
om
n
c
i
or
n thi
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pr
cum
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fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
2.4 Removing and installing coolant pump

equipment required
- VAS 6208-
1331-
AG. Volkswagen AG d
♦ Spring-type clip pliers - agen oes
olksw not
VAS 6362- ed by
V gu
ara
ris nte
ho eo
aut ra
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ce
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un
pt
an
d
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ab
pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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 c lksw
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Prote AG.
Removing
– Unscrew securing bolts -1- of coolant pump -2- and carefully
remove coolant pump.
Installing
• Always renew gaskets, seals and O-rings.

Amarok 2011 ➤
AG. Volkswagen AG d
– Moisten new O-ring -3- with coolant. agen oes
olksw not
y V gu
d b ara
– Insert coolant pump -2- into cylinder block and tighten
orise securing nte
bolts -1-. auth eo
ra
ss c
ce
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nl
pt
du
Note
an
itte
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erm
ab
ility
Coolant pump sealing plug faces downwards.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Specified torques
l purpos
♦ ⇒ “2.1 Assembly overview - coolant pump/ball thermostat (4/2-

nf
ercia
o
rm
m
atio
om
n in
2.5 Removing and installing 4/2-way valve with thermostat
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
equipment required
t.
yi Co
Cop py
t.
rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote
- V.A.G 1331-
AG.

6340-

Amarok 2011 ➤

Removing
Note
Thermostat is located within the 4/2-way valve and cannot be re‐

placed individually.

agen AG olksw
– Disconnect battery ⇒ Electrical
swa
gensystem;
AG. V Rep. gr. do27
es .
olk not
yV gu
– Drain coolant ⇒ page ed b182 . ara
nte
ris
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
– Unscrew securing bolts -3- for coolant pipe -2-.

es, in part or in w
t to the co
– Remove coolant hose -1- at 4/2-way valve and lay aside.

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.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Unscrew bolts -3- for left engine support -1-.
Caution

be renewed.
Note
Coolant pipe is still installed in illustration!
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
– Unscrew securing bolt -1- for charge air pipe.

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
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rp
cu
o
m
f
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 ➤
– Unscrew securing bolt from charge air pipe bracket -2- on

coolant pipe -1-.
– Remove throttle valve module - J338- with throttle valve po‐
tentiometer - G69- and intake manifold flap motor - V157-
⇒ page 357 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
– Detach connector -1- for Hall sender - G40- . s
ce
e
nl
pt
du
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐
an
itte
y li
ing and installing alternator .
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
– Remove coolant hoses -1- at coolant pipe branch-off -2-.
for
en
ng
t.
yi Co
– Remove oil filter bracket ⇒ page 151 . . Cop py
rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Loosen clamp for coolant hose -1- and pull off coolant hose
-1-.
– Loosen clamp for coolant pipe -4- and pull coolant pipe -4- out
at union -2-.
– Unscrew securing bolt -3- for coolant pipe bracket.

Amarok 2011 ➤
– Pull heat shield -2- up slightly from coolant hose -1-.

– Loosen clamp -3- and pull coolant hose -1- off.
– Unscrew bolts -3- for coolant pipes -4- at cylinder block.
Note
Separate all electrical cableswarequired

gen AG to remove
. Volkswagen AG 4/2-way valve
does
and lay aside. yV
olks not
gu b ara
ed nte
oris e
th or
au ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
– Pull coolant hoses off unions -A and C-. wit

is n
h re
ole,
– Pull coolant pipe out of connection -B-.

spec
– Unscrew securing bolts -3- for 4/2-way valve -2-.

t to the co
– Pull valve out of cylinder block and then to the left to separate
connection -C- from coolant pipe.
rrectne
Installing
s

s o
cial p
f inform
mer
Note
atio
om
n
c
Renew gaskets and seals.

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 ➤
– First position 4/2-way valve with connection -B- on coolant

pipe.
– Install 4/2-way valve.
– Screw in and tighten securing bolts -3-.
– Connect coolant hoses as follows:
♦ -A-: Bypass line to cylinder head
♦ -C-: Radiator return line AG. Volkswagen AG d
agen oes
lksw not
– Fill cooling system ⇒ page d182 by .
Vo gu
ara
ise nte
r
– Install throttle valve module
ut
ho - J338- with throttle valve poten‐ eo
ra
tiometer - G69- andssintake manifold flap motor - V157-
a c
ce
le
– Install alternator ⇒ Starter, current supply, CCS; Rep. gr. 27 ;

un
pt
an
d
Removing and installing alternator .

itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
Specified torques
spec
♦ ⇒ “2.1 Assembly overview - coolant pump/ball thermostat (4/2-
t to the co
♦ ⇒ “5.1 Assembly overview - intake manifold”, page 354
rrectne
2.6 Removing and installing coolant temper‐
ss
ature sender - G62-
o
cial p
f inform
mer
atio
m

o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
– Briefly open filler cap for coolant expansion tank in order to
reduce pressure in cooling system.
Note
Place several cloths under the screw connection to absorb es‐

caping coolant.

Amarok 2011 ➤
– Disconnect connector -2- at coolant temperature sender -

G62- -1-.
Note
Components for coolant temperature sender - G62- are difficult

to see. A small hand-held mirror is required to unscrew and insert
coolant temperature sender - G62- .
– Pull off retaining clip and pull coolant temperature sender -

G62- -1- out of union -3-.
Installing
– Install coolant temperature sender - G62- with new O-ring on‐
ly.
. Volkswagen AG
repairs, exterior; Rep. gr. 66 ; Underbody guard . swa
gen AG does
k not
Vol gu
d by ara
e
2.7 Removing and installing coolant temper‐ ris nte
utho eo
ra
ature sender at radiator outlet - G83-
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Hose clamps up to 25 mm - 3094-
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
m

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Place several cloths under the screw connection to absorb
escaping coolant.

Amarok 2011 ➤
– Detach connector -2- from radiator outlet coolant temperature

sender - G83- .-1-.
– Pinch off coolant hoses with hose clamps, up to 25 mm dia. -
3094- .
– Pull off retaining clip -3- and pull radiator outlet coolant tem‐
perature sender - G83- out of union.
Installing
– Check coolant level ⇒ page 182 .
n AG. Volkswagen A
2.8 Removing and installing continued
Vol
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age coolant circulation
G do
es n
ot g pump - V51-
by ua
ed ran
oris tee
th
Special tools and workshop au
or
ac
equipment required ss
ce
le
un
pt
♦ Hose clamps up to 25 mm -
an
d
itte
y li
3094-
rm
ab
pe
ility
ot
wit
, is n
- V.A.G 1331-
h re
hole
spec
es, in part or in w
6362-
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 ➤
Removing
– Pinch off coolant hoses -1 and 4- with hose clamps, up to 25
mm dia. - 3094- .
– Remove coolant hoses -1 and 4- from continued coolant cir‐
culation pump - V51- . To do this, loosen spring-type clips.
– Collect escaping coolant with a cloth.
– Unscrew bolts -2- and remove continued coolant circulation
pump - V51- .
– Loosen clip -2- for wiring harness -1- at bracket -3-.

– Disconnect connector -4- at continued circulation coolant
pump - V51- .
Installing
– Install continued coolant circulation pump - V51- -3- and se‐

cure with bolts -2-.
– Tighten bolts -2-.
– Secure coolant hoses -1 and 4- to continued
gen AG coolant circula‐
. Volkswagen AG
does
swa
tion pump - V51- -3- using spring-type
yV
olk clips. not
gu b ara
ed
– Clip connector onto continued
ho
ris circulation coolant pump - V51- nte
e
and secure wiring harnessaut to bracket. or
ac
s s
ce

le
un
pt

an
d
itte
y li
rm
ab

pe
ility
ot
wit
Specified torques
, is n
h re
hole
♦ ⇒ “2.2 Assembly overview - Continued coolant circulation

spec
pump V51 ”, page 188

es, in part or in w
t to the co
2.9 Removing and installing Y-thermostat

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
199
cted agen
Prote AG.
2. Coolant pump, regulation of cooling system
Amarok 2011 ➤
AG. Volkswagen AG d
agen
♦ Hose clip pliers - VAS 6340- Volksw
oes
not
by gu
d ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
l purpos

– Remove underbody guard, if fitted ⇒ Rep. gr. 66 .
nform
ercia
– Detach coolant hoses with clamps up to 25 mm - 3094- .

m
a
com
tion in
– Remove spring-type clip -1- with hose clip pliers - VAS 6340- .
r
te o
thi
– Open retainer -4-.

s
iva
do
r
rp
cum
– Disconnect coolant hoses -2-, -3- and -6- from Y-thermostat.

fo
en
ng
t.
yi Co
Installing t. Cop py
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Installation is carried out in the reverse order; note the following: pyri by
Vo
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by c lksw
cted agen
– Check coolant level ⇒ page 182 . Prote AG.
2.10 Removing and installing recirculation

pump - V55-

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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aut ra
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nl
pt
du
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erm
Removing
ab
ility
ot p

wit
, is n

h re
hole
spec
– Place several cloths under circulation pump - V55- to absorb

es, in part or in w
escaping coolant.
t to the co
– Separate connector -2- at circulation pump - V55- -1-.

rrectness of i
– Pinch off coolant hoses -3- with hose clamps, up to 25 mm dia.

- 3094- at union.
l purpos
– Release clamps with hose clip pliers - VAS 6362- .

nform
ercia
– Unscrew bolt -4- and remove circulation pump - V55- -1- with
bracket.
m
at
om
io
Installing
n
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or
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e

at
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Cop py
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Prote AG.

Amarok 2011 ➤
3 Radiator, radiator fan

⇒ “3.1 Assembly overview - radiator/ radiator fan V7 ”,
page 202
⇒ “3.2 Assembly overview - radiator cowl and radiator fan V7 ”,
page 204
⇒ “3.3 Removing and installing radiator”, page 204
⇒ “3.4 Removing and installing radiator cowl with radiator fan V7
”, page 207
3.1 Assembly overview - radiator/ radiator fan - V7-
1 - Radiator upper mounting

2 - Radiator
placing
⇒ page 204 .
3 - Charge air cooler
4 - Upper cowling wage
es n
olks ot g
5 - Condenser byV ua
d ran
ir se tee
o
6 - Cap auth or
ac
ss
❑ Check using cooling
ce
le
un
system tester - V.A.G
pt
an
d
1274- and adapter for

itte
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rm
cooling system tester -
ab
pe
ility
V.A.G 1274/9- .
ot
wit
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❑ Test pressure 1.4…1.6
h re
bar
hole
spec
es, in part or in w
7 - Connector
8 - Bolt t to the co
❑ 5 Nm
rrectness of i
9 - Expansion tank
l purpos
❑ Checking cooling sys‐

tem for leaks with cool‐
nform
ercia
ing system tester -

V.A.G 1274- and adapt‐
m
er - V.A.G 1274/8-
com
tion in
⇒ page 180 .
r
te o
thi

s
iva
do
ture display sender -

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cum
G32- .
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10 - Bolt Cop py
t. rig
gh
❑ 5 Nm
ht
pyri by
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cted
11 - Radiator cowl with radiator fan - V7-
agen
Prote AG.

12 - Bolt
❑ 4 Nm
13 - Breather line
❑ Secured to top of radiator.

Amarok 2011 ➤
❑ Hose clip pliers - VAS 6340- or hose clip pliers - VAS 6362- are recommended for installation of spring-
type clips.
15 - Bolt
❑ 1.2 Nm
16 - Bracket
❑ For continued coolant circulation pump - V51- .
17 - Bolt
❑ 4.5 Nm
19 - Coolant hose
20 - Bracket
21 - Radiator outlet coolant temperature sender - G83- agen
AG. Volkswagen AG d
oes
olksw not
❑ Coolant hose schematic diagram ⇒ page 175 . d by
V gu
ara
ise nte
r
22 - Bracket ut
ho eo
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s a c
s
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nl
pt
du
an
24 - Radiator lower mounting
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
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om
n in
or c
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o
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Cop py
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pyri by
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by c lksw
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Prote AG.
3. Radiator, radiator fan 203

Amarok 2011 ➤
3.2 Assembly overview - radiator cowl and radiator fan - V7-
1 - Radiator
2 - Radiator fan
3 - Bolt
❑ 5 Nm
4 - Bolt
❑ 5 Nm
5 - Locking lug
❑ Must be engaged in ra‐
diator.
6 - Radiator cowl
AG. Volkswagen AG d
agen oes
olksw not
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pt
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erm
ab
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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m
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c
3.3 Removing and installing radiator

or
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o
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♦ Socket set 1/4", 22-piece - VAS 5528-

t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.

Amarok 2011 ➤
Removing
– Remove bolts -2- for securing radiator to lock carrier -1-.
– Remove lock carrier ⇒ General body repairs, exterior; Rep.
gr. 66 ; Lock carrier .
– Remove radiator cowl ⇒ page 207 .
⇒ page 11 .
– If fresh air supply system is present, partially remove
⇒ page 116 .
– Remove coolant hose -1- at radiator -3- and remove connect‐

ing hose -2-.
– Remove right connecting hose leading to turbocharger from
chair air cooler and place to one side.
– Remove air duct mounting ⇒ Item 23 (page 369) .
– Unclip left radiator fastening -2- at condenser -3-.

– Unclip right radiator fastening as well and pull condenser -3-
off radiator -1-.
Caution
lkswage es n
Vo ot g
• Do not bend oredstretch the refrigerant lines excessively.
by ua
ran
ir s te
o
• During further
auth removal work, make sure that the refriger‐e or a
ant linesssare not bent or stretched excessively. c
ce
le
un
pt
an
d
itte
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– Support condenser, e.g. with cable ties.

erm
ab
ility
ot p
– Do not bend or stretch the refrigerant lines excessively.

wit
is n
h re
– Carefully remove radiator upwards together with charge air

ole,
spec
cooler. When doing so, take the radiator -2- past the refrigerant
lines.
t to the co
rrectne
Note
s
♦ If the radiator -1- is to be replaced, undo bolts of charge air

s o
cooler and remove it from radiator.

cial p
f inform
♦ Undo and remove bolt -2- on right and left (not shown in illus‐
mer
tration) at radiator.
atio
om
n
c
i
or
n thi
Installing
te
sd
iva
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p
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
Note
Before installing radiator, check that radiator mountings -1- are

correctly seated on front part of car -2- and, if necessary, reposi‐
tion:
– Insert radiator mounting into lock carrier -2- at bottom -1-, do‐
ing so transversely to the direction of travel, and then turn it
90".
lkswage es n
o ot g
byV ua
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u or
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un
pt
an
d
itte
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erm
ab
ility
ot p
– Insert top radiator mountings -1- on right and left into the
wit
is n
h re
mounting on radiator -2- appropriately.

ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
– When installing the radiator, make sure that the catches -1- of
or
n thi
e
the radiator mounting on the left and right at the top have en‐
t
sd
iva
gaged completely in the lock carrier.

pr
cum
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fo
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t.
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Caution Cop py
t. rig
gh ht
pyri by
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tightened to 5.5 Nm. If the torque is too low or too high, the Prote AG.
operation.

Amarok 2011 ➤
4-cylinder
wage ndiesel
AG. Volengine (2.0
kswagen AG
dol
e engine, common rail) - Edition 04.2013
ks s no
Vol t gu
by a
– Fit condenser -3- on radiator
ris
e -1- on
d
left and right so that it en‐ rante
gages securely in theaucatches
tho -2-. eo
ra
ss c
ce
e
nl
Caution
pt
du
an
itte
y li
erm
ab
• Do not bend or stretch the refrigerant lines excessively.
ility
ot p
wit
, is n
h re
hole
– Install radiator cowl ⇒ page 207 .
spec
es, in part or in w
– Filling with coolant ⇒ page 182
t to the co
– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
50 ; Lock carrier .
rrectness of i
Specified torques
l purpos
♦ ⇒ “3.1 Assembly overview - radiator/ radiator fan V7 ”,

page 202
nf
ercia
or
♦ ⇒ “3.2 Assembly overview - radiator cowl and radiator fan V7
m
m
atio
”, page 204
om
n in
or c
thi
e
3.4 Removing and installing radiator cowl

t
sd
iva
o
r
with radiator fan - V7-

rp
cu
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Removing t. Cop py
rig
gh ht
– Remove underbody guard, if fitted ⇒ General body repairs, yri
p by
o Vo
c by lksw
cted agen
Prote AG.
– Unclip coolant hose -1- from brackets -2-.
– Unscrew securing bolts -3- for radiator cowl -4-.
– Disconnect connector -1- from radiator cowl -2-.

Amarok 2011 ➤
– Unscrew securing bolts -1- for radiator cowl -3-.

– Completely unclip bleeder hose -5- from radiator cowl -3-, and
lay it to one side.
– Unclip and unscrew coolant hose -4- with radiator outlet cool‐
ant temperature sender - G83- and continued coolant circula‐
tion pump - V51- -3- from radiator cowl.
– Unscrew bolts -2- and remove continued coolant circulation

pump - V51- with hoses.
– Loosen clip -2- for wiring harness -1- at bracket -3-.

– Disconnect connector -4- at continued circulation coolant
pump - V51- .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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ris nte
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an
– Release radiator cowl -2- at left and right. To do this, press

d
itte
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retaining lever -1- forwards using a screwdriver, and raise ra‐

erm
ab
diator cowl -2- slightly.

ility
ot p
wit
is n
– Remove radiator cowl upwards, together with radiator fan.

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
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
208
Prote AG.
Rep. gr.19 - Cooling
Amarok 2011 ➤
AG.4-cylinder diesel
Volkswagen AG do engine (2.0 l engine, common rail) - Edition 04.2013
agen es n
olksw ot g
y V ua
– Unscrew bolts ris
ed -arrows- and remove radiator fan -1-.
b ran
tee
tho
or
Installing s au ac
s
ce
e

nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
Specified torques
, is n
h re
hole
spec
”, page 204
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
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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.

Amarok 2011 ➤
20 – Fuel supply system

AG. Volkswagen AG d
agen oes
ksw
1 Procedure when filling with incorrect
ol not
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d by ara
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fuel ris nte
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⇒ “1.1 Procedure when filling with incorrect fuel”, page 210
ce
le
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⇒ “1.2 Engine is not running”, page 210

itte
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rm
ab
⇒ “1.3 Engine is running”, page 211
pe
ility
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wit
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1.1 Procedure when filling with incorrect fuel
h re
hole
spec
es, in part or in w
Caution
t to the co
Irreparable damage to high-pressure components, especially
the high-pressure pump, due to lack of lubrication though die‐
rrectness of i
sel can occur when filling fuel tank with incorrect fuel. Damage
l purpos
due to seizure and metal particles can be expected. These

metal particles will probably cause further damage to pressure
regulating valves and injectors.
nform
mercia
a
com
tio
Here are the solutions for two different cases of filling with incor‐
n in
r
rect fuel:
te o
thi
s
iva
do
♦ 1. 1st case: filling with incorrect fuel was detected BEFORE
r
rp
cum
starting the engine and the engine was NOT started

fo
en
g
⇒ page 210 .
n
t.
yi Co
Cop py
t.
♦ 2. 2nd case: filling with incorrect fuel was detected AFTER
rig
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yri by
starting the engine. Impurities or incorrect type of fuel has en‐ op Vo
by c lksw
tered the fuel system and has reached the high-pressure cted agen
Prote AG.
system ⇒ page 211 .
1.2 Engine is not running

♦ Fuel extractor - VAS 5190-
♦ Hose - VAS 6550/1-

Procedure
– Do not switch ignition on.
– Raise vehicle.
210 Rep. gr.20 - Fuel supply system

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 fuel extractor - VAS 5190- via the opening.
– Re-attach connecting hose -1- of filler neck to fuel tank, using
clamp -2-. wage
es ks not
Vol gu
d by ara
e nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Press the circlip to release the fuel line and then detach the
ility
ot p
fuel supply line -3-.
wit
, is n
– Connect pressure gauge pipe -VAS 6550/1- to the fuel supply
h re
hole
line -3-.
spec
es, in part or in w
– Guide open end of line into a suitable container.
t to the co
– Connect ⇒ Vehicle diagnostic tester and carry out “Check
electric fuel pump(s)”.
rrectness of i
l purpos
Note
nf
ercia
Fuel pump is now activated for 30 seconds.
orm
m
atio
om
– Repeat this procedure until fuel tank is completely empty.
n in
or c
thi
e
– Fill fuel tank with 5 litres of diesel fuel. Then, carry out “Guided
t
sd
iva
Fault Finding, Checking electrical fuel pump(s)” again to emp‐

o
r
rp
ty the tank. cu
o
m
f
en
ng
t.
yi Co
– Reconnect fuel supply line. Cop py
t. rig
gh ht
yri
– Fill fuel tank completely with diesel fuel. p by
o Vo
by c lksw
cted agen
– Perform road test. Prote AG.
1.3 Engine is running

♦ Hose - VAS 6550/1-

Procedure
– Do not switch ignition on.
– Raise vehicle.
1. Procedure when filling with incorrect fuel 211

Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine,. Vcommon
olkswage rail) - Edition 04.2013
AG n AG d
agen oes
lksw n
– Thoroughly clean area around y Vfiller neck -1- on fuel tank -4-. ot gu
o
d b ara
e nte
ris
– Loosen clamp -2- for connecting
utho hose -1- of filler neck on fuel eo
ra
tank -4- and pull connecting
ss a
hose off. c
ce
le
– Extract fuel with fuel extractor - VAS 5190- via the opening. un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Press the circlip to release the fuel line and then detach the
rrectne
fuel supply line -3-.
s
– Connect pressure gauge pipe -VAS 6550/1- to the fuel supply
s o
line -3-.
cial p
f inform
– Guide open end of line into a suitable container.
mer
atio
m

o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
Note
en
ng
t.
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op py
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted
– Repeat this procedure until fuel tank is completely empty.
agen
Prote AG.
– Remove fuel delivery unit ⇒ page 236 .

– Check fuel tank for dirt and filings.
– If necessary, clean fuel tank.
– Replace fuel delivery unit and install fuel tank ⇒ page 229 .
– Fill fuel tank with 5 litres of diesel fuel.
– Renew fuel filter ⇒ page 239 .
– Renew following high-pressure components:
♦ High-pressure pump ⇒ page 347 .
♦ High-pressure lines ⇒ page 338 .
♦ High-pressure accumulator (fuel rail) including fuel pressure
regulating valve - N276- and fuel pressure sender - G247-
⇒ page 340 .
♦ Injectors ⇒ page 327 .
♦ Fuel return lines (overflow oil lines).
– Reconnect fuel supply line.
– Fill fuel tank completely with diesel fuel.
– Fill/bleed fuel system ⇒ page 316 .
– Perform road test.

Amarok 2011 ➤
2 Checking low-pressure fuel system

⇒ “2.1 Checking fuel low-pressure at high-pressure pump”, page
213
⇒ “2.2 Checking flow rate at high-pressure pump”, page 215
⇒ “2.3 Checking fuel low-pressureVoahead of fuel filter”,
. lkswagen AG
page 218 swa
gen AG does
k not
y Vol g
⇒ “2.4 Checkingseflow
d b rate ahead of fuel filter”, page 222
ua
ran
ri tee
ho
2.1 ut
Checking fuel low-pressure at high-
or
a ac
ss
pressure pump
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Note
ot p
wit
, is n
h re
♦ The adapter lines/leads 1 to 4 listed below are not required for
hole
spec
the test.
es, in part or in w
t to the co
♦ Hose - VAS 6551/1-
♦ Hose - VAS 6551/2-
rrectness of i
♦ Test lead - VAS 6551/3-
l purpos
nf
ercia
orm
m
Note
atio
om
n in
or c
To perform test, use ⇒ Vehicle diagnostic tester in conjunction

thi
te
sd
with test instrument box - VAS 6356- .

iva
o
r
rp
cu
o
m
f
en
ng

t.
yi Co
Cop py
♦ Pressure gauge - VAS 6551-
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Adapter set - VAS 6551/5-
2. Checking low-pressure fuel system 213

Amarok 2011 ➤

♦ Laptop, vehicle diagnosis (remote head) - VAS 6150 A-
♦ Instrument box - VAS 6356-
Test prerequisites
• Fuses must be OK.
• Battery voltage at least 12 V
• Ignition switched off
• There must be at least 10 l of fuel in the fuel tank.
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
AG. Volkswagen AG d
• The fuel lines must not be kinked or damaged. lksw
agen oes
not
Vo gu
by ara
d
ise nte
WARNING uthor eo
ra
s a c
s
Fuel supply lines are under pressure! Wear eye protection and
ce
e
nl
pt
du
protective clothing to avoid eye injuries and skin contact. Be‐
an
itte
y li
fore loosening hose connections, wrap a cloth around the
erm
ab
connection. Then release pressure by carefully pulling hose off
ility
ot p
connection.
wit
, is n
h re
hole
Procedure spec
es, in part or in w
t to the co
WARNING
rrectness of i
♦ Read rules for cleanliness and the instructions for working

l purpos
on the fuel system ⇒ page 8 .

♦ Always follow these rules for cleanliness and instructions
nform
ercia
before starting work and while working on the fuel system.

m
at
♦ Wrap a clean cloth around the connection before opening

om
io
the fuel system, then carefully loosen the connection to

n
c
in t
r
release the pressure.

o
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 ➤
– Loosen spring-type clip -2- of fuel supply line -1-.

– Pull fuel supply line -1- off high-pressure pump.
. Volkswage
– Collect escaping fuel gen AaG cleaning cloth.
awith
n AG d
oes
ksw n ol ot g
yV ua
edb ran
ris tee
tho 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
– Connect pressure tester - VAS 6551- -1- with hoses from
adapter set - VAS 6551/5- .
t to the co
– Connect hose -VAS 6551/2- as well as connection fitting -VAS
6551/5-1- from adapter set - VAS 6551/5- to fuel supply line
rrectne
-3- and connection -A - of pressure tester - VAS 6551- .
– Open shut-off tap -A-.
ss o
– Connect hose »-2« from adapter set - VAS 6551/5- to open
cial p
f in
connection on high-pressure pump -2- and connection -B- of
form
mer
pressure tester - VAS 6551- .
atio
m
– Close shut-off taps -B- and -C-.

o
n
c
i
or
n thi
– Switch on pressure tester - VAS 6551- by pressing on/off
te
sd
va
pushbutton.
i
o
pr
cum
r
fo
en
– Carefully open shut-off tap -B-.

ng
t.
yi Co
op py
– Connect ⇒ Vehicle diagnostic tester to test instrument box -
. C rig
ht ht
rig
VAS 6356- . py by
co Vo
by lksw
cted agen
– Activate fuel pump using guided function “Fuel pump activa‐
Prote AG.
tion”.
– The fuel pump is activated.
• Specification: ≥ 3.5 bar.
If the specified value is not reached: check fuel low-pressure
ahead of fuel filter ⇒ page 218 .
♦ If the pressure ahead of fuel filter is “OK”:
♦ Renew fuel filter ⇒ page 239 .
2.2 Checking flow rate at high-pressure

pump
Note

the test.
♦ Hose - VAS 6551/1-
♦ Hose - VAS 6551/2-

Amarok 2011 ➤
Note
AG. Volkswagen AG d
agen oes
olksw not
To perform test, ⇒ Vehicle diagnostic tester d b may be used in con‐
y V gu
ara
junction with test instrument box - VAS horis6356-
e
. nte
eo
ut ra
s a c
s
ce
le
un
pt
an
♦ Pressure gauge - VAS 6551- 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.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Transparent measuring beaker ≥ 1.5 litre

Test prerequisites

Amarok 2011 ➤

must be switched off. wage
es ks not
Vol gu
• The fuel lines must not be kinked or damaged.
ed
by ara
nte
ris
utho eo
ra
a
WARNING ss c
ce
le
un
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Collect escaping fuel with a cleaning cloth.
– Loosen spring-type clip -2- of fuel supply line -1-.

– Pull fuel supply line -1- off high-pressure pump.
– Connect pressure tester - VAS 6551- -1- with hoses from

adapter set - VAS 6551/5- .
– Connect hose -VAS 6551/2- as well as connection fitting -VAS
6551/5-1- from adapter set - VAS 6551/5- to fuel supply line
-3- and connection -A - of pressure tester - VAS 6551- .
– Open shut-off tap -A- of pressure tester - VAS 6551- .
– Close shut-off tap -C- of pressure tester - VAS 6551- .

Amarok 2011 ➤
– Connect hose »-2« -1- from adapter set - VAS 6551/5- to con‐
nection -B- of pressure tester - VAS 6551- .
– Hold open end of hose into measuring beaker -2-.
– Close shut-off tap -B-.
pushbutton.
Note
A 2nd mechanic is needed to check the flow rate in the vehicle.
– Connect ⇒ Vehicle diagnostic tester to test instrument box -

VAS 6356- .
tion”.
– Carefully open shut-off tap -B- until specified value of 3.5 bar
is displayed on pressure tester - VAS 6551- .
– Empty measuring beaker.
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olks
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– Activate fuelaupump
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Specification: ≥ 550 ml
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2.3 Checking fuel low-pressure ahead of

h re
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fuel filter
es, in part or in w
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Note
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the test.
♦ Hose - VAS 6551/1-
nform
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♦ Hose - VAS 6551/2-

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To perform test, use ⇒ Vehicle diagnostic tester in conjunction
co lksw
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with test instrument box - VAS 6356- . Prote AG.

Amarok 2011 ➤
AG. V(2.0
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es, in part or in w
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rrectness of i
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nf
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♦ Vehicle diagnostic tester Prote AG.

Test prerequisites

Amarok 2011 ➤
WARNING
connection.
Procedure
WARNING

– Separate quick-release coupling of “black”

n AG. Vfuel
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-3- from fuel filter -1-. lkswage does
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To do this, press locking mechanism on quick-release coupling.

du
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– Collect escaping fuel with a cleaning cloth.

ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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ion
c
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or
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for
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Amarok 2011 ➤
olkswagen AG
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– Connect hose »-3« from adapter set - VAS 6551/5- ris
e to open nte
thopressure tester
fuel line (from fuel tank) and connection -A -auof eo
ra
- VAS 6551- . ss c
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nl
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connection on fuel filter and connection -B- of pressure tester
ot p
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- VAS 6551- .
, is n
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hole
– Open shut-off tap -B- of pressure tester - VAS 6551- .
spec
es, in part or in w
t to the co
pushbutton.
rrectness of i
– Connect ⇒ Vehicle diagnostic tester or laptop, vehicle diag‐
l purpos
nosis (remote head) - VAS 6150 A- to test instrument box -

VAS 6356-
nf
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tion”.
m
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♦ If the specification has been reached and the fuel low-pressure cop Vo
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low-pressure downstream of fuel filter must be checked.
♦ If the fuel low-pressure on the high-pressure pump has already
been checked and the specification has not been reached, re‐
new fuel filter ⇒ page 239 .
– Connect fuel supply line -3- to connection on fuel filter -1-.

– Separate quick-release coupling of fuel supply line -2- from
fuel filter -1-.
Note
To do this, press locking mechanism on quick-release coupling.

Amarok 2011 ➤

connection on fuel filter and connection -A- of pressure tester
- VAS 6551- .
fuel supply line leading to high-pressure pump -B- of pressure
tester - VAS 6551- .
– Open shut-off tap -B- of pressure tester - VAS 6551- .
pushbutton.
– Carefully open shut-off tap -B-.
VAS 6356- wage
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– Activate fuel pump eusing
db
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gu
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– The fuel pump
ss is activated.
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If the specified value is not attained: y li

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♦ Renew fuel filter ⇒ page 239 . wit

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hole
spec
2.4 Checking flow rate ahead of fuel filter

es, in part or in w
t to the co
Note
rrectness of i

l purpos
the test.
♦ Hose - VAS 6551/1-
nform
ercia
♦ Hose - VAS 6551/2-

m
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To perform test, ⇒ Vehicle diagnostic tester may be used in con‐ by c lksw
cted agen
junction with test instrument box - VAS 6356- . Prote AG.

Amarok 2011 ➤
♦ Pressure gauge - VAS 6551-
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♦ Transparent measuring beaker ≥ 1.5 litre

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Test prerequisites
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• Ignition switched off Prote
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agen


Amarok 2011 ➤
WARNING
connection.
Procedure
WARNING

– Disconnect “black” fuel supply line -3- from fuel filterge-1-.

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To do this, press locking mechanism on hose coupling.
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es, in part or in w
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m
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Prote AG.

Amarok 2011 ➤
– Connect hose »-3« from adapter set - VAS 6551/5- -4- to fuel
supply line (from fuel tank) -5- and connection -A - of pressure
tester - VAS 6551- -1-.
– Connect hose »-3« from adapter set - VAS 6551/5- -2- to con‐
nection -B- of pressure tester - VAS 6551- .
– Hold open end of hose into measuring beaker -3-.
– Close shut-off tap -B- of pressure tester - VAS 6551- .
pushbutton.
Note
A 2nd mechanic is needed to check the flow rate in the vehicle.

VAS 6356-
tion”.
– Carefully open shut-off tap -B- until the specified value of
3.5 bar is displayed on pressure tester - VAS 6551- .
– Empty measuring beaker.
– Hold hose from adapter set - VAS 6551/5- -2- into measuring
beaker -3- again.
olkswagen AG
en AG. V
– Activate fuel pump using
olks guided function “Fuel pump
wag does
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– The fuel pump
au
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Specification: ≥ 550 ml
ce
le
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itte
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ility
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es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
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tion in
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te o
thi
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Cop py
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Prote AG.

Amarok 2011 ➤
3 Fuel tank
⇒ “3.1 Assembly overview - fuel tank”, page 226
AG. Volkswagen AG d
⇒ “3.2 Assembly overview - fuel lines”, page 228 lkswagen oes
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⇒ “3.3 Removing and installing fuel tank”,ripage
se d b 229 ara
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⇒ “3.4 Removing and installing filler neck”,
au page 232 ra
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3.1 Assembly overview - fuel tank nl
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Caution
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The fuel pump must not be allowed to run when the fuel tank
hole
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is empty, as this may cause deflagrations.
es, in part or in w
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The fuel tank must contain at least 5 litres of fuel.
rrectness of i
1 - Seal
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❑ Moisten with fuel when
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2 - Union nut
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❑ Remove and install us‐
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❑ For vehicles with addi‐
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Prote AG.
82 .
❑ Check for secure seat‐
ing.
ing.
5 - Connecting hose
6 - Screw-type clip
7 - Bolt
❑ 5 Nm
8 - Panel nut
9 - Filler neck
10 - Bolt
❑ 2 Nm
11 - Fuel tank
❑ When removing, sup‐
port using engine and
gearbox jack - V.A.G 1383 A- .
❑ Drain fuel tank using fuel extractor - VAS 5190-

Amarok 2011 ➤
12 - Bolt
❑ 8 Nm
13 - Cap
14 - Seal
15 - Tank flap unit
16 - Securing strap
17 - Return line
❑ Blue or with blue marking.
❑ Clipped onto fuel tank.
❑ To pull off flange, press release button on connecting piece.
18 - Nut
❑ 20 Nm
19 - Supply line
❑ To fuel filter ⇒ Item 1 (page 238) .
❑ Clipped onto fuel tank.
❑ Black
❑ To pull off flange, press release button on connecting piece.
20 - Bolt
❑ 30 Nm
wage es n
21 - Protective cover Vol
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❑ For bottom oforfuel ise tank.
ran
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❑ Depending s a on equipment.
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22 - Supply line
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❑ For vehicles with additional heater ⇒ Rep. gr. 82 .

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23 - Fuel delivery unit

, is n
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hole
❑ Note installation position on fuel tank ⇒ page 228 .

spec
es, in part or in w
❑ To remove, first remove fuel tank ⇒ page 229 .

t to the co
❑ Removing and installing fuel gauge sender ⇒ page 237 .

rrectness of i

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25 - Metering pump - V54-

nf
ercia
or
26 - Mounting for metering pump - V54-

m
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3. Fuel tank 227

Amarok 2011 ➤
Installation position of fuel gauge sender lkswage es n
o ot g
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Arrow on sender flange -1- must align with mark
ir se on fuel tank
d b ran
tee
-arrows-. utho
or
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Connections for blue or blue-marked return line and black supply
ce
le
line are marked with arrows on fuel gauge sender flange.
un
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ility
Note ot p
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After installing fuel gauge sender, check whether fuel supply and
ole,
spec
return lines are still clipped onto fuel tank.
t to the co
3.2 Assembly overview - fuel lines
rrectne
1 - Supply line
ss o
❑ To high-pressure pump
cial p
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mer
ing.
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2 - Return line
i
or
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❑ From high-pressure
t
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pump.
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3 - Fuel temperature sender - yri
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Prote AG.
❑ Fitting location
⇒ page 307
4 - Bracket
5 - Return line
❑ From the injectors
ing.
6 - Return line
ing.
7 - Bracket
8 - Fuel filter with bracket
complete.
⇒ page 239 .
9 - Quick-release coupling
ing.
10 - Supply line
❑ From fuel tank.
11 - Return line
❑ To fuel tank.

Amarok 2011 ➤
12 - Return line
❑ Fuel return line from injectors to supply line leading to fuel filter
13 - Return line
❑ From high-pressure pump.
14 - Supply line
3.3 Removing and installing fuel tank
Caution

equipment required
♦ Union nut tool - 3217-
1331-
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
AG. Volkswagen AG d
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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
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t.
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Cop py
t. rig
gh ht
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229
cop Vo
by lksw
Prote
cted AG.
agen 3. Fuel tank
Amarok 2011 ➤
Removing
Note
Fuel tank must be drained. Use the fuel extractor - VAS 5190- to
do this.
– Note safety precautions before starting installation work

⇒ page 3 .
– Observe rules for cleanliness ⇒ page 8 .
Note
Before carrying out further work, disconnect battery earth strap.

For this reason, first check whether a coded radio
n AGis
. Vfitted.
olkswagObtain
en AG
anti-theft coding first if necessary. olks
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– Thoroughly clean area aroundtho filler neck
r
-1- on fuel tank -4-. eo
s au ra
c
– Loosen clamp -2- for connecting hose -1- of filler neck on fuel s
ce
e
tank -4- and pull connecting hose off.

nl
pt
du
an
itte
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– Extract fuel with fuel extractor - VAS 5190- via the opening.
erm
ab
ility
ot p
Vehicles with lower protective cover
wit
, is n
h re
– Unbolt protective cover on bottom of fuel tank
hole
⇒ Item 21 (page 227) .
spec
es, in part or in w
t to the co
– Support fuel tank with engine and gearbox jack - V.A.G 1383
A- .
rrectness of i
l purpos
– Disconnect supply line -3- and return line -2-.

nform
ercia
Note
m
at
om
io
Press in buttons on hose couplings to do this.

n
c
in t
or
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ate
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riv
– Unscrew bolt -arrow- for securing fuel tank -1- on left cross
p
cum
or
member.
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– Loosen securing straps in succession: . Cop py
rig
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rig by
copy Vo
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Prote AG.
– Unscrew bolt -arrow- for front securing strap -2- for fuel tank
-1-.

Amarok 2011 ➤
– Unscrew bolt -arrow- for rear securing strap -2- for fuel tank
-1-.
– Unscrew bolts -arrows- for securing straps -2- for fuel tank
-1-.
Vehicles with additional heater:
– Pull fuel line -2- off at metering pump - V54- -1-.

– Unclip wiring harness -3- at supply line -arrow-.
– Only lower fuel tank with engine and gearbox jack - V.A.G
1383 A- until filler neck and breather line can be removed.
AG. Volkswagen AG d
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– Loosen clamp -2- for connecting hose -1- of filler neck on fuel y li
rm
tank -4- and pull connecting hose off. ab

pe
ility
ot
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– Unclip breather line -3- on fuel tank -4-.

h re
hole
spec
es, in part or in w
Note
t to the co
Immediately seal all openings on fuel tank with clean cloths.

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.
3. Fuel tank 231

Amarok 2011 ➤
– Continue lowering fuel tank with engine and gearbox jack -

V.A.G 1383 A- until connector -2- can be pulled off fuel delivery
unit -1-.
– Press in securing clip to release fuel lines.
– Unclip fuel lines -2 and 3- from fuelodelivery
lksw
age unit -1-. es n
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yV ua
– Carefully lower fuel tank. db ran
ir se tee
ho
ut or
Installing ss
a ac
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un
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Caution
pe
ility
ot
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
Push hose -1- of filler neck onto connection on fuel tank -3-.
l purpos
Position clamp -2- at assembly markings -arrows- using hose clip

pliers - VAS 6362- . nform
mercia
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tion in
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te o
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– Push on breather line -3- and engage securely. cted agen
Prote AG.
♦ Connections for breather and fuel lines must engage audibly

when reconnected.
♦ 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 .
Specified torques
♦ ⇒ “3.1 Assembly overview - fuel tank”, page 226
3.4 Removing and installing filler neck


Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
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ility
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spec
Removing
t to the co
– Remove fuel tank ⇒ page 229 .
– Unscrew bolt -2- for filler neck -1- on underbody.
rrectne
– Open tank flap and clean inside tank flap unit thoroughly.
– Unscrew cap.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
– Unscrew bolt -2- from tank flap unit. opyri
gh by
Vo
ht
c
– Unclip tank flap unit and remove completely.
by lksw
cted agen
Prote AG.
3. Fuel tank 233

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
– Thread filler neck -1- in through wheel housing and position at

top of tank flap unit cut-out with nuts -2-.
– Tighten nuts -2-.
– Renew speed nut in cross member on underbody AG. Volkswagen AG d
⇒ Item 8 (page 226) . agen oes
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ility
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– Tighten bolt -2-.
h re
ole,
spec
– Installing fuel tank:
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
– Push hose -1- of filler neck onto connection on fuel tank -3-.
te
sd
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– Position clamp -2- at assembly markings -arrows- using hose

p
cum
r
fo
clip pliers - VAS 6362- .

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

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

♦ Connections for breather and fuel lines must engage audibly
when reconnected.
♦ 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.
Specified torques
AG. Volkswagen AG d
agen oes
olksw not
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ise nte
or eo
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nl
pt
du
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erm
ab
ility
ot p
wit
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
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ate
do
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for
en
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Prote AG.
3. Fuel tank 235

Amarok 2011 ➤
4 Fuel delivery unit, fuel gauge sender

⇒ “4.1 Removing and installing fuel delivery unit”, page 236
⇒ “4.2 Removing and installing fuel gauge sender G ”,
page 237
4.1 Removing and installing fuel delivery

unit
♦ Union nut tool - 3217-
Removing
– Unclip fuel lines -2 and 3- from fuel delivery unit -1-.
Vehicles with additional heater:
– Pull fuel line for metering pump - V54- off at fuel delivery unit.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
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un
pt
an
d
itte
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erm
ab
ility
ot p
– Unscrew union nut with union nut tool - 3217- .

wit
is n
h re
– Take fuel delivery unit out of the fuel tank.

ole,
spec
Installing
t to the co

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
– Install fuel delivery unit so that mark on flange of fuel delivery

unit -1- is aligned with mark on fuel tank -arrows-.
Specified torques
4.2 Removing and installing fuel gauge

sender - G-
Removing
– Remove fuel delivery unit ⇒ page 236 .
– Free lines -2- and unclip fuel gauge sender - G- to side
-arrows-.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
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un
pt
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rm
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pe
ility
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– Remove fuel gauge sender - G- -1- in -direction of arrow-. h re

hole
spec
es, in part or in w
– Release connectors on fuel gauge sender - G- .

t to the co
Installing
rrectness of i
– Insert fuel gauge sender - G- into guides on fuel pump and

l purpos
press downwards until it engages.

Specified torques
nform
ercia

m
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com
tion in
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te o
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Prote AG.
4. Fuel delivery unit, fuel gauge sender 237

Amarok 2011 ➤
lkswage es n
o ot g
yV
5 Fuel filter d b ua
ran
ir se tee
tho
u or
⇒ “5.1 Assembly overview - fuel filter”, page 238ss a ac
ce
e
nl
⇒ “5.2 Removing and installing fuel filter”, page 239
pt
du
an
itte
y li
⇒ “5.3 Checking fuel filter”, page 239
erm
ab
ility
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5.1 Assembly overview - fuel filter
wit
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hole
spec
1 - Supply line es, in part or in w
t to the co
❑ From fuel tank
ing.
rrectness of i
2 - Supply line
l purpos
nform
ercia

ing.
m
at
om
io
3 - Fuel filter
n
c
in t
or
his
ate
complete.
do
priv
cum
or

f
en
g
⇒ page 239 .
n
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op py
t. C rig
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4 - Gasket
co lksw
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cted agen
Prote
AG.
5 - Water drain screw

❑ Loosen and allow ap‐
prox. 100 cm3 fluid to
drain

Amarok 2011 ➤
5.2 Removing and installing fuel filter

Removing and installing fuel filter
Removing
– Unclip fuel lines -2 and 3- from fuel filter -1- and pull fuel filter
out of bracket in -direction of arrow-.
Note
Press in buttons on hose couplings to do this.
Installing
Install in reverse order.
5.3 Checking fuel filter

♦ Pressure tester - VAS 6551-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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♦ Hose - VAS 6551/3-
hole
spec
es, in part or in w
♦ Hose - VAS 6551/4-

t to the co
Test prerequisites
rrectness of i

l purpos

nf
ercia

orm
m
atio

om
n in

or c
thi
te
sd
iva
WARNING
r
rp
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f
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t.
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Co
Cop py
protective clothing to avoid eye injuries and skin contact. Be‐ ht. rig
rig ht
fore loosening hose connections, wrap a cloth around the py by
co Vo
by lksw
cted agen
Prote
connection.
AG.
5. Fuel filter 239

Amarok 2011 ➤
Procedure
WARNING AG. Volkswagen AG d

agen oes
o lksw not
y V gu
d b ara
♦ Always read rules for cleanliness and instructions
orise for nte
working on fuel system ⇒ page 8 . th eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
the fuel system, then carefully loosen the connection to ot
wit
, is n
h re
hole
spec
es, in part or in w
– Pull fuel supply line -2- off fuel filter.
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
– Connect connection -A- of pressure tester - VAS 6551- with
en
ng
t.
yi
line -VAS 6551/3- to open end of fuel filter.
Co
Cop py
t. rig
gh ht
– Connect connection -B- of pressure tester - VAS 6551- to‐ yri
p by
o Vo
gether with line -VAS 6551/4- to open line of high-pressure
c by lksw
cted agen
pump.
Prote AG.
– Switch on pressure tester - VAS 6551- by pressing On/Off

button.
– Close shut-off tap “C” of pressure tester - VAS 6551- .
– Carefully open shut-off valves -A- and -B-.
– Start engine.
• Take specification reading: at least 3.5 bar on pressure tester
- VAS 6551-
If the specified value is attained, the fuel system is OK.
If the specified value is not attained:
– Connect fuel supply line -2- to fuel filter again.
– Pull fuel supply line -3- off fuel filter.


AG. Volkswagen AG d
lksw
agen oes
no Amarok 2011 ➤
o
4-cylinder
d by
V
diesel engine (2.0 l engine,t gcommon
ua
ran rail) - Edition 04.2013
e
oris tee
th or
– Connect connection -A- sof
au pressure tester - VAS 6551- with ac
line -VAS 6551/3- to open end of fuel filter. s
ce
le
un
pt
– Connect connection -B- of pressure tester - VAS 6551- to‐
an
d
itte
y li
gether with line -VAS 6551/4- to open line of fuel tank.
rm
ab
pe
ility
– Switch on pressure tester - VAS 6551- by pressing On/Off
ot
wit
, is n
button.
h re
hole
spec
– Close shut-off tap “C” of pressure tester - VAS 6551- .
es, in part or in w
t to the co
– Carefully open shut-off valves -A- and -B-.
– Start engine.
rrectness of i
• Take specification reading: at least 3.5 bar on pressure tester
- VAS 6551-
l purpos
If specification is attained:
nform
ercia
– Renew fuel filter.

m
a
com
If the specified value is not attained:
tion in
r
te o
– Check fuel pump ⇒ page 242 .
thi
s
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do
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fo
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t.
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pyri by
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Prote AG.
5. Fuel filter 241

Amarok 2011 ➤
6 Fuel pump
⇒ “6.1 Checking fuel delivery rate of fuel pump (fuel low pressure)
”, page 242
⇒ “6.2 Checking voltage supply of fuel pump (fuel low pressure)”,
page 245
6.1 Checking fuel delivery rate of fuel pump

(fuel low pressure)
Note
♦ Hose - VAS 6551/1-

♦ Hose - VAS 6551/2-
♦ Test lead - VAS 6551/3- AG. Volkswagen AG d
agen oes
olksw not
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♦ Test lead - VAS 6551/4- ised b ara
nte
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Adapter lines/leads 1-4 are ut not required for test
h
♦ a ra
c
ss
ce
le
un
pt
an
d
itte
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♦ Pressure tester - VAS 6551-
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

com
tion in
r
te o
thi
s
iva
do
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cum
fo
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t.
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Prote AG.

♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
Test prerequisites

Amarok 2011 ➤

• Low-pressure fuel system checked ⇒ page 213 .
• Fuel filter checked ⇒ page 239 .
• Ensure that fuel lines are not blocked.
WARNING
connection. Then release pressure by carefully pulling
AG. Volkshose
wagenoff
AG do
agen
connection. Volksw es n
ot
by gu
ara
ed nte
oris eo
th
Procedure ss
au ra
c
ce
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nl
pt
du
an
WARNING
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
l purpos
nf
ercia
Note
orm
m
atio
m
A 2nd mechanic is needed to check the fuel delivery rate in the

o
n in
vehicle.
or c
thi
te
sd
iva
– Disconnect “black” fuel supply line -3-.

r
rp
cu
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f
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t.
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op py
Note
. C rig
ht ht
rig by
copy Vo
by lksw
To do this, press catches on hose couplings. Prote
cted AG.
agen
6. Fuel pump 243

Amarok 2011 ➤
– Connect pressure tester - VAS 6551- to open ends of fuel

supply line -3- using lines/hoses from adapter set - VAS
6551/5- .
– Connect connection -A- of pressure tester - VAS 6551- to end
of fuel supply line from fuel tank using lines/hoses from adapt‐
er set - VAS 6551/5- and open shut-off tap -A-.
– Connect connection -B- of pressure tester - VAS 6551- to end
of fuel line to fuel tank using lines/hoses from adapter set -
VAS 6551/5- .
– Close shut-off tap -B- of pressure tester - VAS 6551- .
– Put the line leading from connection -C- into a ≥ 3 litre meas‐
uring container -3- and hold there.
pushbutton.
– Connect test instrument/DSO adapter (5-pin) - VAS 5565- to
fuel delivery unit.
Note
G. Volkswagen AG d
Fuel pump is now activated for 30lkseconds.
swa
gen A oes
not
Vo gu
d by ara
e nte
– Carefully open shut-off horvalve
is
-C- completely. eo
aut ra
– Slowly close the shut-off
ss tap -C- again while reading the pres‐ c
ce
e
sure shown on the pressure tester - VAS 6551- . Set specified

nl
pt
du
value 5 ± 0.2 bar by closing the shut-off tap carefully.

an
itte
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erm
ab
– Drain measuring container.

ility
ot p
wit
Repeat function “Checking electronic fuel pump(s)”.

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

Amarok 2011 ➤
Note
♦ Amount of fuel delivered by fuel pump depends on voltage at

fuel delivery unit.
♦ Therefore, also connect multimeter - V.A.G 1526- to outputs
-1 and 5- of test instrument/DSO adapter 5-pin - VAS 5565- .
Test prerequisites
Volkswa
• At RT = room temperature or a fuel stemperature
agen
AG. of Tge=n (20
AG do+-
es n
k w
5) °C . by
Vol ot g
ua d ran
ise
• At a pressure of 5 ± 0.2 bar
tho at flange output
r tee
or
au ac
• ss
During the checking process, there must be voltages of 11 to
ce
e
15 volts at the fuel pump. Measured at the flange connector of

nl
pt
du
an
the delivery unit.
itte
y li
erm
ab
• If these voltages are not achieved, the fuel pump must be
ility
ot p
subjected to a voltage test ⇒ page 245 .
wit
, is n
h re
– Carry out in the guided function “Checking electronic fuel
hole
spec
pump(s)”
es, in part or in w
t to the co
*) Amount of fuel delivered in ml/30 s.
**) Voltage across fuel delivery unit (V) with engine at a standstill
and with pump running.
rrectness of i
Example:
l purpos
During the test, a voltage of 12.0 volts, for example, is measured

at the fuel delivery unit.
nf
ercia
orm
m
atio
m
The minimum amount of fuel delivered is therefore 1100 ml/30 s.

o
n in
or c
If the required amount of delivered fuel is achieved, or if more is

thi
te
sd
measured: Fuel pump ok.

iva
o
r
rp
cu
If the amount of fuel to be delivered by the fuel pump is not ach‐

o
m
f
en
ng
ieved, the following faults have occurred:

t.
yi Co
Cop py
t. rig
♦ Visual inspection of fuel delivery unit for dirt. opyri
gh by
Vo
ht
c lksw
♦ If voltages in the range of 11 to 15 volts were not achieved
by
cted agen
Prote
during the testing process, check the voltage supply.
AG.
Note
Check fuel system for leaks.
6.2 Checking voltage supply of fuel pump

(fuel low pressure)
6. Fuel pump 245

Amarok 2011 ➤
♦ Hand-held multimeter - V.A.G 1526D-
♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
♦ Vehicle diagnostic tester auth or
ac
ss
Test prerequisites
ce
e
nl
pt
du
an
itte
y li
erm
ab
• Battery voltage must be at least 12 V, if necessary connect a
ility
ot p
battery charger.
wit
, is n
• All electrical consumers, e.g. lights and rear window heating, h re

hole
must be switched off. spec

es, in part or in w
t to the co
• Visual check of cables OK.
Procedure:
rrectness of i
l purpos
Note
The fuel tank has to be lowered in order to be able to remove the

nf
ercia
connector from the flange of the fuel pump unit ⇒ page 229
rm
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 ➤
– Detach connector -2- from fuel delivery unit -1-.

– Connect test instrument adapter/DSO (5-pin) - VAS 5565- be‐
tween connector and flange.
– Connect hand-held multimeter - V.A.G 1526D- to contacts of
adapter.
Note
– Read voltage value on hand-held multimeter - V.A.G 1526D- :

specification = battery voltage (- 0.5 V OK).
If a voltage of 11 to 15 volts is not measured:
– Check cables/wires for breakage and short-circuiting.
Voltage supply OK.
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
247
Prote AG.
6. Fuel pump
Amarok 2011 ➤
7 Accelerator mechanism
⇒ “7.1 Function”, page 248
⇒ “7.2 Assembly overview - accelerator mechanism”, page 249
Volkswa AG. gen AG
agen does
7.1 Function db
yV
olksw not
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ara
rise nte
With the EPC system, the throttle valve is unot
tho operated by a cable eo
ra
from the accelerator There is no mechanical
ss a connection between c
the accelerator and the throttle valve.
ce
le
un
pt
an
d
Position of accelerator is transmitted to engine control unit by two
itte
y li
accelerator position senders (variable resistors together in one
erm
ab
ility
housing) connected to accelerator.
ot p
wit
is n
Position of accelerator (driver's requirement) is a main input value
h re
ole,
for engine control unit .
spec
Throttle valve is actuated by an electric motor (throttle valve po‐
t to the co
sitioner) in throttle valve module over full range of engine speeds
and load conditions.
rrectne
Throttle valve is operated by throttle valve positioner which is
controlled by engine control unit .
ss
When the engine is not running and the ignition is switched on,
o
cial p
f
the engine control unit moves the throttle valve exactly as pre‐
inform
scribed by the accelerator position sender . This means that when
mer
the accelerator is depressed half way, the throttle valve positioner
atio
m
opens the throttle valve to the same extent. The throttle valve is
o
n
c
i
then approx. half open.
or
n thi
te
sd
va
When the engine is running (under load), the engine control unit
i
o
pr
c
can open or close the throttle valve independently of the accel‐
um
r
fo
en
ng
erator position sender .

t.
yi Co
Cop py
This means that the throttle valve can already be completely open ht. rig
rig ht
even though the accelerator is only depressed half way. This has py by
co Vo
lksw
the advantage of preventing throttling losses at the throttle valve.
by
cted agen
Prote AG.
After evaluating the torque requirements of the various compo‐
nents (e.g. air conditioning system, automatic gearbox, ABS/
ESP, etc.), the engine control unit calculates the optimal throttle
valve opening angle for the respective situation.
This also results in significantly improved consumption and ex‐
haust emission values under certain load conditions.
“EPC” is a system comprising all components which contribute to
determining, controlling or monitoring the position of the throttle
valve (e.g. accelerator position sender , throttle valve control
module , EPC warning lamp , engine control unit ).

Amarok 2011 ➤
7.2 Assembly overview - accelerator mechanism
1 - Bearing bracket
❑ Removing and instal‐
ling: ⇒ Rep. gr. 46 .
2 - Connector
❑ 6-pin
3 - Nut
❑ 9 Nm
4 - Accelerator position sender
- G79-
❑ Not adjustable.
❑ The accelerator position
sender - G79- transmits
the driver's input to the
engine control unit
❑ Remove footwell cover
to remove sender. gen AG. Volkswagen AG
wa does
olks not
byV gu
ara
ed nte
ris
tho eo
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.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Accelerator mechanism 249

Amarok 2011 ➤
21 – Turbocharging/supercharging
1 Charge air system
⇒ “1.1 Assembly overview - charge air system”, page 250
⇒ “1.2 Removing and installing charge air cooler”, page 251
. Volkswagen AG
a gen AG does
⇒ “1.3 Removing and installing intake air temperature sender
Vol
ksw G42 not
gu
with charge air pressure sender G31 ”, page 254 ed by ara
nte
is
or eo
⇒ “1.4 Removing and installing exhaust gas aflap
ut
h
valve N220 ”, ra
page 255 ss c
ce
le
un
pt
⇒ “1.5 Checking charge air system for leaks”, page 256
an
d
itte
y li
erm
1.1 Assembly overview - charge air system
ab
ility
ot p
wit
is n
h re
Caution
ole,
spec
t to the co
tightened to 5.5 Nm. If the torque is too low or too high, the
operation.
rrectne
Assembly of hose connections ⇒ page 11 .
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
250 Rep. gr.21 - Turbocharging/supercharging

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
orise nte Amarok 2011 ➤
h eo
aut 4-cylinder diesel engine r a (2.0
c
l engine, common rail) - Edition 04.2013
ss
ce
le
1 - Clamp
un
pt
an
d
itte
❑ Follow installation in‐
y li
erm
ab
structions ⇒ page 11 .
ility
ot p
wit
2 - Bolt
is n
h re
ole,
❑ 2 Nm
spec
3 - Intake air temperature
t to the co
sender - G42- with charge air
pressure sender - G31-
rrectne
⇒ page 254 .
s
4 - O-ring
s o
cial p
f
❑ Renew if damaged or
inform
leaking.
mer
atio
5 - Connecting hose
om
n
c
i
❑ Note installation posi‐
or
n thi
e
tion ⇒ page 251 .

t
sd
iva
o
pr
c
6 - Connecting hose
um
r
fo
en
ng
t.
yi Co
op
tion ⇒ page 251 .
C py
t. rig
gh ht
yri by
7 - Charge air cooler
op Vo
by c lksw
cted agen
Prote AG.
⇒ page 251 .
8 - Connecting hose
tion ⇒ page 251 .
9 - Turbocharger
10 - Intake manifold
Installation position of connecting hoses

– Install connecting hose in such a way that marking -1- on con‐
necting hose is aligned with marking -2- on respective union.
1.2 Removing and installing charge air cool‐

er
1. Charge air system 251

Amarok 2011 ➤

agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
d by ua
ran
e
ris tee
utho 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
Removing
ht
pyri by
Vo
co lksw
by
cted
– Remove bolts -2- for securing radiator to lock carrier -1-.
agen
Prote AG.
– Remove lock carrier ⇒ General body repairs, exterior; Rep.

gr. 66 ; Lock carrier .
– Remove radiator cowl ⇒ page 207 .
⇒ page 11 .
⇒ page 116 .
– Remove coolant hose -1- and connecting hose -2-.

– Remove right connecting hose leading to turbocharger from
chair air cooler and place to one side.
– Remove air duct mounting ⇒ Item 23 (page 369) .
– Squeeze left catch -2- and pull condenser -3- forwards a little.

Amarok 2011 ➤
– Unclip right catch as well and pull condenser -3- off radiator
-1-.
Caution
• Do not bend or stretch the refrigerant lines excessively.

• During further removal work, make sure that the refriger‐
ant lines are not bent or stretched excessively.
– Support condenser, e.g. with cable ties.

– Do not bend or stretch the refrigerant lines excessively.
– Carefully remove radiator upwards together with charge air
cooler. When doing so, take the radiator -2- past the refrigerant
lines.
Note
♦ If the radiator -1- is to be replaced, undo bolts of charge air

cooler and remove it from radiator.
♦ Undo and remove bolt -2- on right and left (not shown in illus‐
tration) at radiator.
Installing
Note
AG. Volkswagen AG d
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olksw no
Before installing radiator,
ed by Vcheck that radiator mountings t-1- gu are
ara
correctly seated on horfront
is part of car -2- and, if necessary, reposi‐
nte
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tion: s aut ra
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un
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ility
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spec
t to the co
rrectness o
cial p
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atio
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or
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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
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olksw not
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nl
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erm
ab
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hole
spec
es, in part or in w
– When installing the radiator, make sure that the catches -1- of
t to the co
the radiator mounting on the left and right at the top have en‐
gaged completely in the lock carrier.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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ate
do
priv
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– Insert top radiator mountings -1- on right and left into the
f
en
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t.
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mounting on radiator -2- appropriately.
Co
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gh
– Install radiator cowl ⇒ page 207 .
ht
pyri by
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– Filling with coolant ⇒ page 182 cted agen
Prote AG.
– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.

50 ; Lock carrier .
Assembly of hose connections ⇒ page 11 .
Specified torques
♦ ⇒ “3.1 Assembly overview - radiator/ radiator fan V7 ”,
page 202
”, page 204
1.3 Removing and installing intake air tem‐

perature sender - G42- with charge air
pressure sender - G31-

Amarok 2011 ➤
Removing
– Release and pull off connector -1- for intake air temperature
sender - G42- together with charge air pressure sender - G31-
-1-.
– Undo and remove bolts for intake air temperature sender -
G42- and charge air pressure sender - G31- -1-.
– Pull intake air temperature sender - G42- together with charge
air pressure sender - G31- -1- out of union.
Installing olkswage es n
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Installation is carried out in the reverse order; note the ir sefollowing:
d ran
tee
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or
Specified torques ss
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nl
pt
du
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erm
ab
1.4 Removing and installing exhaust gas
ility
ot p
flap valve - N220-
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
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ate
do
priv
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t.
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Co
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t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
Removing
– Pull connector -3- and vacuum lines and pull off fuel pressure
regulating valve - N220- -1-.
– Remove spreader rivet -2- and exhaust gas flap valve - N220-
-1-.
Installing
Caution
Do not kink, twist or crush the vacuum lines when routing. This
may cause breakdowns.
Connect all hoses to stop or at least 10 mm on the relevant
connection piece.
1.5 Checking charge air system for leaks

♦ Charge air system tester - V.A.G 1687-
AG. Volkswagen AG d
agen oes
olksw not
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♦ Adapter - V.A.G 1687/10- ised b ara
nte
or eo
h
♦ Engine bung set - VAS aut6122- ra
ss c
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nl
pt
du
an
itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
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n in
or c
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by lksw
256
cted agen
Prote AG.
Rep. gr.21 - Turbocharging/supercharging
Amarok 2011 ➤
Procedure
– Remove connecting pipe -arrow-.
– Seal union with a bung -2- (diameter 28 mm) fro the engine
bung set - VAS 6122- and secure with a clip -1-.
– Remove intake hose -1- from air filter.

– Insert adapter - V.A.G 1687/10- into intake hose -1- and se‐
cure with a clip.
Prepare charge air system tester
en AG. V
olkswa-gV.A.G
en AG 1687- as follows:
wag does
olks not
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ara
ed nte
ris
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au ra
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ss
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un
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an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Unscrew pressure control valve -2- completely and close

valves -3- and -4-.
ss o
cial p
f inform
mer
Note
atio
om
n
c
To turn the pressure regulating valve -2- the knob must be pulled
i
or
n thi
upwards.
te
sd
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pr
cum
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fo
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t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.

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

V.A.G 1687/10- as shown.
– Connect compressed air hose -1- (compressed air supply) toagen AG. Volkswagen AG d
charge air system tester - V.A.G 1687- , using a standard Vocon‐
lksw
oes
not
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necting piece. ed by ara
n ris tee
utho or
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ss
Note
ce
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nl
pt
du
an
itte
Drain water in sight glass by removing drain plug -6-.
y li
erm
ab
ility
ot p
– Open valve -3-.
wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
The pressure must not exceed 0.5 bar! If the pressure is too
high, this can cause damage to the charge air system.
rrectness of i
l purpos
– Adjust pressure to 0.5 bar with pressure control valve -2-.

– Open valve -4- and wait until test circuit is full. If necessary, nform
ercia
adjust pressure to 0.5 bar.

m
at
– Check charge air system for leaks as follows:

om
ion
c
in t
r
♦ By listening
o
his
ate
do
riv
♦ By feeling
p
cum
for
en
g
♦ With leak detector spray

n
t.
yi Co
Cop py
♦ or with ultrasonic tester - V.A.G 1842- .
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ Slight leaks on the intake side of turbocharger are permissible,

as the intake hoses are not designed for high-pressure.
♦ A small amount of air escapes through the valves and enters
the engine. Therefore a holding pressure test is not possible.
♦ How to use the ultrasonic tester - V.A.G 1842- ⇒ operating
instructions
♦ Depressurise test circuit by detaching coupling from adapter -
V.A.G 1687/10- before removing adapter.

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
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
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pr
cum
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fo
en
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
259
agen
Prote AG.
2. Turbocharger
Amarok 2011 ➤
2 Turbocharger
⇒ “2.1 Assembly overview - turbocharger, 120 kW and 132 kW
⇒ “2.2 Assembly overview - turbocharger, 90 kW and 103 kW
⇒ “2.3 Removing and installing turbocharger - 120 kW and
132 kW engines”, page 267
⇒ “2.4 Removing and installing turbocharger - 90 kW and 103 kW
⇒ “2.5 Removing and installing charge pressure sender 2 G447
”, page 277
⇒ “2.6 Removing and installing regulating flap potentiometer
G584 and vacuum unit for turbocharger, 120 kW engine”,
page 278
⇒ “2.7 Removing and installing regulating flap potentiometer
G584 and vacuum unit for turbocharger, 132 kW engine”,
page 290
⇒ “2.8 Removing and installing charge pressure control solenoid
valve N75 ”, page 300
AG. Volkswagen AG d
agen oes
2.1 Assembly overview - turbocharger, 120 kW and 132 kW engines byV
olksw not
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Note ss c ce
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♦ Sealed bolts and nuts must not be loosened.

itte
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ab
♦ All hose connections are secured.

pe
ility
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♦ Charge air system must be free of leaks.

h re
hole
♦ Renew self-locking nuts.

spec
es, in part or in w
t to the co
♦ Before screwing on oil pressure line, fill turbocharger with engine oil through union.
♦ After installing turbocharger, allow engine to run at idling speed for about 1 minute to ensure that oil is
supplied to turbocharger.
rrectness of i
l purpos
1 - Heat shield
2 - Bolt
nform
ercia
❑ 9 Nm
m
a
com
3 - Vacuum unit
ion in
r

te o
thi
⇒ page 321 .
s
iva
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rp
cum
4 - Regulating flap potentiom‐

fo
en
ng
eter - G584-
t.
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op py
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ht ht
rig
⇒ page 278 . py by
co Vo
by lksw
cted agen
5 - Nut Prote AG.
❑ 9 Nm
6 - Exhaust gas temperature
sender 1 - G235-
❑ Grease thread of sender
using high-temperature
paste ⇒ Electronic
Parts Catalogue (ET‐
KA) .

Amarok 2011 ➤
❑ Sender must not be bent when removing and installing.
❑ Sender must not contact any other component when installed.
❑ Black connector
❑ 45 Nm
7 - Nut
• Tightening sequence ⇒ page 263 .
• Installation sequence:
♦ Bolts ⇒ Item 11 (page 261) and ⇒ Item 12 (page 261) must be loosened at bracket.
♦ Fit turbocharger on studs on cylinder head.
n AG. Volkswagen A ge G do
swa es
♦ Tighten turbocharger
by
Vol bolts ⇒ Item 9 (page 261) in
k not
gspecified
ua sequence.
d ran
se
♦ First, tighten ho bolt by hand. Then, tighten ⇒ Item 11 (pagee261)
ri te and ⇒ Item 12 (page 261) . After that, tighten
ut or
bolts to sspecified
s a torque. ac
❑ 25 Nm
ce
le
un
pt
an
d
itte
8 - Gasket
y li
erm
ab
ility
ot p
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9 - Exhaust manifold with turbocharger
h re
ole,
❑ Renew complete only.
spec
❑ Before removing, connecting pipes must be removed ⇒ page 250 .
t to the co
❑ Always renew oil return line when it has been removed or opened in area of hose connection.
❑ Check oil supply lines for damage before installing them ⇒ Item 16 (page 261) .
rrectne
❑ Note tightening sequence and installation procedure ⇒ page 263 .
❑ When turbocharger and connecting pipes are being assembled, it is essential that the correct repair kit
ss
⇒ ETKA (Electronic Parts Catalogue) is used.

o
cial p
f i
❑ Installation position of connecting hose at turbocharger ⇒ page 263

nform
mer

atio
om
10 - Bracket
n
c
i
or
n thi
e
11 - Bolt
t
sd
iva
o
pr

um
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fo
en
ng
❑ Observe tightening sequence and procedure ⇒ page 263 .

t.
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op py
❑ 40 Nm
. C rig
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rig by
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12 - Bolt
co lksw
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Prote
❑ 40 Nm
AG.
13 - Banjo bolt
❑ 30 Nm
14 - Double seal
❑ Remember that there are various sizes
15 - Banjo bolt
❑ 24 Nm
16 - Oil supply line
❑ To remove oil supply line completely, engine support and starter must first be removed.
2. Turbocharger 261
Amarok 2011 ➤
Note
♦ Risk of damage when removing

and installing turbocharger.
♦ Check oil supply line for damage
after removing (kinks in hose).
Oil supply line must be renewed
if damaged.
♦ Check oil supply line for damage
(kinks in hose) after installing tur‐
bocharger.
♦ Removing and installing
⇒ page 170 .
17 - Banjo bolt
❑ 60 Nm
18 - Seal
19 - Bolt
❑ 25 Nm
20 - Seal
21 - Banjo bolt
❑ For oil return line
❑ 60 Nm
22 - Oil return line
❑ Oil return line must always be renewed after removing turbocharger.
AG. Volkswagen AG d
agen
23 - Bolt olksw
oes
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❑ 11 Nm rised ara
nte
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ut
24 - Gasket ss a ra
c
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un
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25 - Bolt
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ab
❑ 15 Nm
pe
ility
ot
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26 - Oil return line

h re
hole
❑ Oil return line must be renewed after removing turbocharger.

spec
es, in part or in w
27 - Clip
t to the co
28 - Bolt
❑ 9 Nm
rrectness of i
29 - Pulsation damper
l purpos
30 - O-ring
nform
ercia
❑ Not available as replacement part.

❑ Included in ⇒ Item 29 (page 262) .
m
a
com
tion in
31 - Banjo bolt
r
te o
thi
❑ 30 Nm
s
iva
do
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rp
32 - Seal
um
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
33 - Line to charge pressure sender 2 - G447-

34 - Retaining clamp
35 - Bolt
❑ 3 Nm
36 - Bolt
❑ 9 Nm
37 - Charge pressure sender 2 - G447-
Tightening sequence and installation procedure

♦ Position exhaust manifold together with turbocharger on studs
on cylinder head.
♦ Only screw bolt ⇒ Item 7 (page 261) loosely into turbocharger.
♦ Tighten nuts -1- to -8- to 25 Nm in specified sequence. Then
tighten nuts to 25 Nm again in specified sequence.
♦ Tighten bolt ⇒ Item 11 (page 261) .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Installation position
horis of connecting hose at turbocharger nte
eo
aut ra
– Fit connecting
ss hose in such a way that the “rib” -1- of the con‐ c
necting hose is aligned with the middle of the nameplate -2-.
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
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f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Turbocharger 263
Amarok 2011 ➤
2.2 Assembly overview - turbocharger, 90 kW and 103 kW engines
Note
♦ Sealed bolts and nuts must not be loosened.

♦ All hose connections are secured.
♦ Charge air system must be free of leaks.
wage e n
♦ Before screwing on oil pressure line, fill turbocharger
byV
olks
with engine oil through sunion.
ot g
ua
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♦ After installing turbocharger, allow enginethto
o run at idling speed for about 1 minute to tensure ee
or
that oil is
supplied to turbocharger. au ac
ss
ce
e
nl
pt
du
an
itte
y li
1 - Turbocharger
erm
ab
ility
ot p
wit
, is n
❑ Connecting pipes must
h re
be removed before re‐
hole
spec
moving ⇒ page 250 .
es, in part or in w
t to the co
❑ Check oil pressure lines
for damage before in‐
stalling them.
rrectness of i
❑ Note tightening se‐
quence and installation
l purpos
procedure ⇒ page 263 .

❑ When turbocharger and
nform
ercia
connecting pipes are

being assembled, it is
m
at
om
essential that the cor‐
ion
c
rect repair set ⇒ ETKA
in t
or
his
e
(Electronic Parts Cata‐

at
do
riv
logue) is used.
p
cum
or
❑ Installation position of
f
en
ng
t.
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connecting hose at tur‐
Co
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bocharger ⇒ page 264 t. C rig
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❑ Removing and installing cop Vo
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⇒ page 272 . cted agen
Prote AG.
2 - Bolt
❑ No replacement part
available
3 - Position sender for charge
pressure positioner - G581-
4 - Heat shield
5 - Bolt
❑ 9 Nm
sender 1 - G235-
using high-temperature paste ⇒ Electronic Parts Catalogue (ETKA) .
❑ Exhaust temperature sender 1 - G235- must not be bent or twisted when removing and installing.
❑ Exhaust temperature sender 1 - G235- must not contact any other component on installation.
❑ Black connector
❑ 45 Nm

Amarok 2011 ➤
7 - Bolt
❑ M10 x 35
8 - Bolt
❑ M10 x 18
9 - Support
10 - Nut
❑ No replacement part available
11 - Bolt
❑ M10 x 30
12 - Nut
• Installation sequence:
♦ Position turbocharger on studs on cylinder head.
♦ First tighten nut finger-tight, then tighten nut to prescribed torque ⇒ page 266 .
♦ Tighten turbocharger bolts ⇒ page 266 in specified sequence.
❑ 25 Nm
13 - Exhaust manifold with turbocharger
❑ Tightening sequence ⇒ page 266 .
14 - Gasket
15 - Gasket
16 - Oil pressure line
❑ Supply and return. lkswage es n
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❑ Oil pressure line must be
ir serenewed after removing turbocharger. ant
d b r
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Note ss
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nl
pt
du
♦ Risk of damage when removing

an
itte
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and installing turbocharger.

erm
ab
ility
ot p
♦ Always renew oil pressure line

wit
, is n
after removing.
h re
hole
spec
♦ Check oil pressure line for dam‐

es, in part or in w
age (kinks in hose) after instal‐

t to the co
ling turbocharger.
♦ Removing and installing
rrectness of i
⇒ page 170 .
l purpos
17 - Bolt
18 - Seal
nform
ercia

m
at
om
io
19 - Banjo bolt
n
c
in t
or
❑ 32 Nm
his
ate
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riv
20 - Seal
p
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for
en
g

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t.
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op py
21 - O-ring t. C rig
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❑ Renew after removing cop Vo
by lksw
cted agen
Prote AG.
2. Turbocharger 265
Amarok 2011 ➤
22 - Banjo bolt
❑ 60 Nm
23 - Bolt
❑ M6 x 16
24 - Bolt
25 - Connection
26 - Gasket
Tightening sequence and installation procedure

♦ Position exhaust manifold together with turbocharger on studs
on cylinder head.
. Volkswagen AG
gen AG does
♦ Tighten nut ⇒ Item 12 (page 265) finger-tight on stud.
Vol
ksw
a
not
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db ara
♦ Tighten nuts -1- to -8- to 25 Nm in specified osequence.
ris
e Then nte
tighten nuts to 25 Nm again in specified sequence.
au
th eo
ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
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h re
Installation position of connecting hose at turbocharger
hole
spec
es, in part or in w
– Fit connecting hose in such a way that the “rib” -1- of the con‐
t to the co
necting hose is aligned with the middle of the nameplate -2-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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do
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
2.3 Removing and installing turbocharger - 120 kW and 132 kW engines

equipment required
- V.A.G 1331-
Nm) - V.A.G 1332-
1410-
6122-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
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f
en
ng
t.
Caution Cop
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When a mechanical fault is found on the turbocharger, e.g. a pyri by
Vo
co
destroyed compressor impeller, it is not only sufficient to renew
by lksw
cted agen
Prote
the turbocharger. To avoid subsequent damage, the following
AG.
work must be carried out:

♦ Check air filter container, air filter element and intake ho‐
ses for dirt.
♦ Check the whole charge air path and charge air cooler for
foreign objects.
If foreign objects are found in the charge air system, the charg‐
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.
“Biturbo” is removed upwards.

Before the “biturbo” can be removed, the following parts must be
removed:
2. Turbocharger 267
Amarok 2011 ➤
♦ Exhaust pipe with catalytic converter

♦ Air filter with attachments
Removing
⇒ page 11 .
Note
♦ After lines and hoses have been removed, the open connec‐
tions are to be sealed immediately with a plug from the engine
bung set - VAS 6122- .
♦ Only use clean plugs.
– Remove air filter with attachments ⇒ page 368

– Remove connecting pipe ⇒ page 250
– Loosen bolt -2- in screw-type clip -1- for front exhaust pipe
-4- at turbocharger.
– Unscrew and remove bolts -3- in bracket for front exhaust pipe agen
AG. Volkswagen AG d
oes
-4-. olksw not
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rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Loosen screw-type clip -3- for front exhaust pipe -1-.
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
– Undo and remove bolts -3- for front exhaust pipe -2- at bracket
for
en
g
-1-.
n
t.
yi Co
Cop py
– Carefully remove front exhaust pipe upwards out of the engine
t. rig
gh ht
yri
compartment.
p by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Loosen screw-type clip -2- for connecting hose -1- and detach
connecting hose from pulsation damper.
Note
Seal opening in turbocharger with clean cloths or similar.
– Pull connector -1- off regulating flap potentiometer - G584-

-3- and lay to side. There is no need to disconnect connector
-1- on exhaust gas recirculation valve - N18- -2-.
Note
The described procedure doesn Anot . Vapply

olkswagto
e vehicles compliant
with the emission standard w ge 5Gas sensor nis
aEU AG do
secured
e perma‐
lks s n
nently to vehicle. d by Vo
ot g
ua
r e an
ris tee
utho or
a ac
ss
ce
e
nl
pt
du
an
itte
– Detach connector -2- from charge air pressure sender 2 -

y li
erm
ab
G447- -1-.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Remove bolts -2 and 3- for pipe -1- from exhaust gas recircu‐
m
at
lation cooler.
om
ion
c
in t
r
– Remove pipe from exhaust gas recirculation cooler.

o
his
ate
do
riv
– Remove oil supply line from turbocharger ⇒ page 170 .

p
cum
for
en
ng
t.
yi Co
Caution
t. Cop py
rig
gh ht
yri by
• Avoid damage to oil supply line. Observe notes.
cop Vo
by lksw
cted agen
Prote AG.
• When doing this, ensure that no pressure is exerted on the
rod.
• Do not hold onto the rod when removing the turbocharger.
• When carrying the turbocharger, always hold it by the
pipes and not by the rods.
Bent rods impair the functioning of the turbocharger.
– Loosen clamp ⇒ Item 27 (page 262) and disconnect oil return

line.
2. Turbocharger 269
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - oEdition
lksw
04.2013
AG. V agen AG
agen does
lksw not
– Undo and remove bolts -2- for oil return line db
yat
V bottom of tur‐
o gu
ara
bocharger -1-. 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
– Undo and remove bolt -2- for turbocharger -1- at lower bracket.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Release and detach connector -1- of exhaust gas temperature
op Vo
by c lksw
sender 1 - G235- on front right wheel housing -3- at the cou‐
cted agen
Prote AG.
pling point -2-. Then, free wiring harness from fittings and lay
it to one side.
– Undo and remove bolts -1- to -8- for exhaust manifold with
turbocharger.
– Remove turbocharger with exhaust manifold upwards.

Amarok 2011 ➤
– Undo and remove bolts -1- in bracket for coolant pipe -2- and
remove exhaust manifold gasket -3-.
Installing
– Renew all gaskets, O-rings and self-locking nuts.
– Install turbocharger with new oil return line.
– Fit new double seal -2- onto the respective line connection
-1- and secure by screwing in the corresponding banjo bolt
-3-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ar
d
– Check oil supply risline -arrow- for damage after installing ante
e
o
th 261) . eo
⇒ Item 16 (page
au ra
c
ss
– Install connecting pipes ⇒ page 250 .
ce
e
nl
pt
du
an
itte
y li
erm
Caution
ab
ility
ot p
wit
, is n
• Note tightening sequence and procedure when bolting

h re
turbocharger on ⇒ page 263 .

hole
spec
es, in part or in w
t to the co
Specified torques
rrectness of i
page 31
l purpos

nform
ercia

m
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.
2. Turbocharger 271
Amarok 2011 ➤
2.4 Removing and installing turbocharger - 90 kW and 103 kW engines

equipment required
- V.A.G 1331-
Nm) - V.A.G 1332-
1410-
6122-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Caution
When a mechanical fault is found on the turbocharger, e.g. a

rrectness of i
destroyed compressor impeller, it is not only sufficient to renew

the turbocharger. To avoid subsequent damage, the following
l purpos
work must be carried out:

♦ Check air filter container, air filter element and intake ho‐
nf
ercia
ses for dirt.

rm
m
atio
m
♦ Check the whole charge air path and charge air cooler for
o
n in
c
foreign objects.
or
thi
te
sd
a
If foreign objects are found in the charge air system, the charg‐
iv
o
r
rp
cu
ed air routing must be cleaned and the charge air cooler must
o
m
f
en
be renewed, if necessary.
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
“Turbocharger” is removed upwards.
cop Vo
by lksw
cted agen
Prote AG.
For removal of the “turbocharger”, the following parts must first
be removed:

Amarok 2011 ➤
♦ Exhaust pipe with catalytic converter

♦ Air filter with attachments
n AG. Volkswagen A
age G do
ksw es n
Removing by Vol ot g
ua
ed ran
ris
Observethorules for cleanliness ⇒ page 8 . tee
u or
a ac
Observe
ss instructions for hose connections with screw-type clips
ce
le
⇒ page 11 .
un
pt
an
d
itte
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rm
ab
pe
ility
Note
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove air filter with attachments ⇒ page 368
l purpos
– Remove connecting pipe ⇒ page 250

– Loosen bolt -2- in screw-type clip -1- for front exhaust pipe
nform
ercia
m
a
com
– Unscrew and remove bolts -3- in bracket for front exhaust pipe
-4-. 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.
-1-.
compartment.
2. Turbocharger 273
Amarok 2011 ➤
– Loosen screw-type clip -2- for connecting hose -1- and detach
connecting hose from pulsation damper.
Note
Seal opening in turbocharger with clean cloths or similar.
– Pull connector -1- off position sender for charge pressure po‐
sitioner - G581- -3- and lay to side. There is no need to
disconnect connector -1- on exhaust gas recirculation valve -
N18- -2-.
Note
The described procedure does not apply to vehicles compliant

with the emission standard EU 5 as sensor is secured perma‐
nently to vehicle.

G447- -1-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
– Remove bolts -2 and 3- for pipe -1- from exhaust gas recircu‐
wit
, is n
h re
lation cooler.
hole
spec
– Remove pipe from exhaust gas recirculation cooler.

es, in part or in w
t to the co
Caution
rrectness of i
• Avoid damage to oil pressure line. Observe notes.

l purpos
• When doing this, ensure that no pressure is exerted on the

rod.
nform
ercia
• Do not hold onto the rod when removing the turbocharger.

m
a
com
• When carrying the turbocharger, always hold it by the

ion in
pipes and not by the rods.

r
te o
thi
s
iva
Bent rods impair the functioning of the turbocharger.

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 ➤
– Unscrew nut -3- for support -2- of turbocharger -1-.
– Remove securing bolts -2 and 3- for support -1-.
– Loosen clamp -2- on oil pressure line pipe -1- and separate oil
pressure line.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
– Remove securing bolt and banjo bolt -1 and 2-.

ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Turbocharger 275
Amarok 2011 ➤

it to one side.
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
– Remove nuts -1- to -8- for exhaust manifold with turbocharger.
ility
ot p
wit
is n
– Remove turbocharger with exhaust manifold and oil line up‐
h re
ole,
wards.
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
– Undo and remove bolts -1- in bracket for coolant pipe -2- and
o
n
c
i
remove exhaust manifold gasket -3-.
or
n thi
te
sd
a
Installing
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
op
– Renew all gaskets, O-rings and self-locking nuts.
C py
t. rig
gh ht
yri by
– Install turbocharger with new oil pressure line. cop Vo
by lksw
cted agen
Prote AG.
– Fit new seals -2- onto the respective line connection -3- and
secure by screwing in the corresponding banjo bolt -1-.
– Install connecting pipes ⇒ page 250 .
Caution
• Note tightening sequence and procedure when bolting

turbocharger on ⇒ Item 12 (page 265) .
Specified torques
page 31

Amarok 2011 ➤
2.5 Removing and installing charge pres‐

sure sender 2 - G447-
Note
♦ On vehicles without particulate filter, the charge pressure

sender 2 - G447- can only be renewed together with bracket,
as one unit ⇒ Electronic parts catalogue (ETKA) .
♦ Charge air pressure sender 2 - G447- is integrated into turbo‐
charger and cannot be replaced on vehicles with a particulate
filter.

♦ Engine bung set - VAS 6122-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
Note
l purpos
♦ Due to risk of breakage, sensor is replaced complete with

bracket and hose.
nform
ercia
♦ The described procedure does not apply to vehicles compliant

m
at
with the emission standard EU 5 as sensor is secured perma‐

om
io
nently to vehicle.
n
c
in t
or
his
ate
do
priv
cum
or
Note
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
p by
co Vo
by lksw
bung set - VAS 6122- . cted agen
Prote AG.
2. Turbocharger 277
olkswagen AG
en AG. V
Amarok 2011 ➤ ksw
ag does
not
Vol
4-cylinder diesel engine (2.0 l engine,
ed by common rail) - Edition 04.2013gu
ara
ris nte
utho eo
– Release and pull connector -4-ss aoff charge air pressure sender ra
c
2 - G447- -1-.
ce
e
nl
pt
du
an
– Unscrew bolts -2- on bracket for charge air pressure sender 2
itte
y li
- G447- .
erm
ab
ility
ot p
– Remove banjo bolt -3- from turbocharger and remove charge
wit
, is n
air pressure sender 2 - G447- complete.
h re
hole
spec
Installing
es, in part or in w
t to the co
Install in reverse order.
rrectness of i
l purpos
2.6 Removing and installing regulating flap

potentiometer - G584- and vacuum unit
nf
ercia
or
for turbocharger, 120 kW engine
m
m
atio
om
n in
or c
thi
e
2.6.1 Removing and installing regulating flap potentiometer - G584-

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Special tools and workshop Cop py
equipment required
t. rig
gh ht
pyri by
Vo
o
♦ Hand vacuum pump - VAS
c by lksw
cted agen
6213- or hand vacuum
Prote AG.
pump - V.A.G. 1390- .

♦ Turbocharger tester -
V.A.G 1397A-
1783- with open end span‐
ner insert AF10 - V.A.G
1783/1-

Amarok 2011 ➤
Note
A spare-parts kit ⇒ ETKA (electronic parts catalogue) is available

for replacing the regulating flap potentiometer - G584- .
Removing
– Remove pipe -arrow- from cylinder head cover.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
– Detach hoses from connecting hose -3- bracket -arrow-.
erm
ab
ility
ot p
wit
, is n
ing harness -2- from connecting hose retainer -3-.
h re
hole
spec
– Open clips -1- and -4-.
es, in part or in w
t to the co
– Remove connecting hose -3-.
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.
2. Turbocharger 279
Amarok 2011 ➤
– Pull hose off regulating flap potentiometer - G584- -2-.
– Unclip connector -1- from regulating flap potentiometer -

G584- -2-.
Only for vehicles with charge air pressure sender 2 - G447- on
turbocharger.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
s a ac
s
ce
e
G447- -1-.
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
– Undo and remove bolts -2- securing bracket for charge air
pressure sender 2 - G447- -1- and place charge air pressure
nform
ercia
sender 2 - G447- to one side.

m
at
om

ion
c
in t
or
– Seal opening -3- of turbocharger with a suitable cover.

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 ➤
– Undo and remove bolts -2- securing heat shield -1- and re‐
move heat shield.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Undo and completely remove nut -2- securing control rod.
wit
, is n
– Counterhold lock nut -3- with open-end spanner.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
– Working from below, undo and remove nuts securing regulat‐
n
c
in t
or
ing flap potentiometer - G584- -1- together with bracket -2- to

his
ate
mounting of turbocharger (2 nuts).

do
priv
cum
or
– Remove regulating flap potentiometer - G584- upwards to‐

f
en
ng
t.
gether with bracket. Cop
yi Co
py
t. rig
Installing gh ht
pyri by
Vo
co lksw
by
Installation is carried out in the reverse order; note the following: Prote
cted AG.
agen
Caution
Use only new bolts and nuts from the spare-parts kit if the reg‐
ulating flap potentiometer - G584- is being replaced complete‐
ly!
New part
– If necessary, remove lower nut securing the control rod of the
new regulating flap potentiometer - G584- .
Note
Lock nut must have been screwed onto control rod.
Old part
– Remove lock nut from control rod and carefully remove the
sealing paint from the control rod completely.
– Screw new lock nut from spare-parts kit onto control rod again.
Continuation for all
2. Turbocharger 281
Amarok 2011 ➤
– Carefully clean touching surfaces of regulating flap potenti‐

ometer - G584- -3- and bracket -2-.
– Carefully clean mounting for regulating flap potentiometer -
G584- on turbocharger.
– Insert regulating flap potentiometer - G584- -3- in such a way
that the location marker -1- fits into the hole in the bracket
-2-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
– Install regulating flap potentiometer - G584- and guide control
utho eo
ra
a
rod -1- through adjusting lever on turbocharger as shown ss in c
the illustration.
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
– Fit regulating flap potentiometer - G584- on the turbocharger
l purpos
mounting with new nuts from the spare-parts kit -4- and tighten
nuts to 8 Nm.
nf
ercia
o
– Screw nuts -2- onto control rod by hand in direction of vacuum
rm
m
atio
unit.
om
n in
or c
thi
te
sd
a
Note
iv
o
r
rp
cu
o
m
f
en
ng
Make sure that the guiding element -1- of the flap lever moves
t.
yi Co
easily along the control rod. Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho e o Amarok 2011 ➤
aut ra
4-cylinder
ss diesel engine (2.0 l engine, common rail) -c Edition 04.2013
ce
e
nl
pt
du
– Attach connector -1- to regulating flap potentiometer - G584-
an
itte
y li
-2-.
erm
ab
ility
ot p
Connect ⇒ Vehicle diagnostic tester.
wit
, is n
h re
Selecting operating mode:
hole
spec
– Press button on display for “Vehicle self-diagnosis”.
es, in part or in w
t to the co
Selecting vehicle system:
– Press button “01 - Engine electronics” on display.
rrectness of i
The display indicates the control unit identification and the coding
l purpos
of the engine control unit.

Selecting diagnostic function:
nform
ercia
– Press button for “011 - Measured values” on the display.

m
at
om
io
– The display shows the individual components.
n
c
in t
or
his
e
– Select “Bypass Valve, Turbocharger, High Pressure Turbine

at
do
riv
Input, Input Voltage” and confirm entry with Q .

p
cum
for
en
g
– Connect turbocharger tester - V.A.G 1397A- and hand vac‐

n
t.
yi Co
uum pump - VAS 6213- or hand vacuum pump - V.A.G. 1390- Cop py
ht. rig
to vacuum connection -1- of regulating flap potentiometer - py
rig by
ht
G584- using a T-piece to do so. co Vo
by lksw
cted agen
Prote
Switch on turbocharger tester - V.A.G 1397A- and move sliding
AG.
switch on device to position II.
– Apply a vacuum of 500 ± 50 mbar to regulating flap potenti‐

ometer - G584- .
– Move flap lever -1- on turbocharger in -direction of arrow- to

“Closed” position and hold it there.
– Screw securing nut -3- in direction of vacuum unit until it con‐
tacts flap lever -1-.
– Continue turning securing nut -3- until a voltage of 0.75 volt ±
0.02 volt of regulating flap potentiometer - G584- is reached.
– Tighten lock nut -2- to 8 Nm.
Note
Make sure that control rod -1- does not turn by counterholding on
nut -2-.
2. Turbocharger 283
Amarok 2011 ➤
Slowly reduce vacuum. Flap lever -1- now moves in

-direction of arrow- “Open”.
ometer - G584- again.
– Check voltage setting (0.75 volt ± 0.02 volt) of regulating flap
potentiometer - G584- and, if necessary, reset.
Slowly reduce vacuum.
Note
Flap lever -1- must now be resting against the stop. If the flap
lever is not resting against the stop, the setting procedure must
be repeated until the setting values agree with each other.
– After this, secure the nuts and lock nuts with sealing paint from
the replacement-parts kit.
– Press securing clip from replacement-parts kit onto control rod

and turn 90° in -direction of arrow-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
– Tighten securing bolts -2- for heat shield -1-.
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 ➤
2.6.2 Removing and installing vacuum unit for turbocharger

equipment required
♦ Universal dial gauge brack‐
et - VW 387-
pump - V.A.G. 1390- .
V.A.G 1397A-
♦ Dial gauge set, 4-part - VAS
6341-
1783/1-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
Note
iva
o
r
rp
cu
o
m
f
A spare-parts kit ⇒ ETKA (electronic parts catalogue) is available

en
ng
t.
yi Co
for replacing the vacuum unit. t. Cop py
rig
gh ht
pyri by
Removing
co Vo
by lksw
cted agen
Prote AG.
2. Turbocharger 285
Amarok 2011 ➤
– Detach vacuum hoses from connecting hose -3- bracket

-arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
– Undo and remove bolts -2- securing heat shield -1-.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Pull hose -1- off vacuum unit -2-.

– Undo and completely remove lower nut -3- of control rod -5-.

Amarok 2011 ➤
– Undo nuts of vacuum unit -1- and remove vacuum unit -2-.
Installing
Caution
Only use new nuts from the spare-parts kit!
– Carefully cleaning touching surfaces of vacuum unit.
– If necessary, remove lower securing nut -3- of the control rod

from the new vacuum unit -2-.
olkswagen AG
en AG. V
– Install new vacuum unit -2- and push ksw control rod -5- throughes not
ag do
Vol
adjusting lever on turbocharger
ed
b as shown in illustration.
y gu
ara
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Note
ce
e
nl
pt
du
an
itte
Location marker on vacuum unit must fit into mounting on turbo‐
y li
erm
ab
charger.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Fit vacuum unit -2- in place and fit nuts -1-, tighten nuts to 8
t to the co
Nm.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Screw nuts -3- onto control rod by hand in direction of vacuum

f
en
ng
t.
yi
unit.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
Note Prote
cted AG.
agen
Make sure that the guiding element of the flap lever moves easily
along the control rod.
2. Turbocharger 287
Amarok 2011 ➤
– Connect turbocharger tester - V.A.G 1397A- -2- and hand

vacuum pump - VAS 6213- or hand vacuum pump - V.A.G.
1390- -3- to vacuum connection of vacuum unit -1- using a T-
piece to do so.
Switch turbocharger tester - V.A.G 1397A- on and move sliding
– Apply a vacuum of 390 ± 10 mbar to vacuum unit.
Caution
The following adjusting work must be carried out with extreme

care and precision as, otherwise, there is a risk that the turbo‐
charger will be damaged.

“Closed” position.
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
– Screw nut -3- in direction of vacuum unit until it is touching the
an
d
itte
y li
flap lever, while applying a tightening torque of 8 Nm to the
erm
ab
lock nut -2- at the same time.
ility
ot p
wit
is n
h re
ole,
Note
spec
t to the co
the nut -3-.
rrectne
– Reduce vacuum again and apply a vacuum of 390 ± 10 mbar
to vacuum unit again.
ss o
cial p
f in
Note
form
mer
atio
m
Flap lever must now be resting against the stop (closed position).
o
n
c
i
or
n thi
te
sd
a
– Check set value and, if necessary, reset.

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Note t. Cop py
rig
gh ht
yri by
The check must be repeated at least 3 to 5 times in order to ensure cop Vo
by lksw
that the vacuum unit has been set precisely and in order to avoid
cted agen
Prote AG.
possible damage to the turbocharger.
Repeat this procedure approx. 3-5 times.

– Reduce vacuum again.

Amarok 2011 ➤
– Secure dial gauge - VAS 6079- together with universal dial

gauge bracket - VW 387- to turbocharger with a suitable bolt
-1- (as shown in illustration) and move gauge to end of control
rod -2-.
Note
The dial gauge rod and the control rod of the vacuum unit must
be in line with each other.
– Operate hand vacuum pump - VAS 6213- until the turbocharg‐

er tester - V.A.G 1397A- indicates 390 ± 10 mbar.
– Set dial gauge, 0-30 mm - VAS 6341/1- to 0.
– Operate hand vacuum pump - VAS 6213- until turbocharger
tester - V.A.G 1397A- indicates 410 ± 10 mbar.
wage
– Read value on dial gauge - VAS 6079- . yV
olks es n
ot g
b ua
ed ran
– Make sure that value on dial gauge - VAS 6079-
horis does not tee
change. aut or
ac
ss
– If the value has changed, correct the setting of the vacuum unit
ce
le
un
pt
and repeat the measurement until the setting agrees with the
an
d
itte
y li
specified values.
erm
ab
ility
ot p
– Secure securing nut and lock nut with sealing paint from the
wit
spare-parts kit.
is n
h re
ole,
spec
– Press retaining clip from spare-parts kit onto control rod and
turn 90° in the -direction of the arrow-.
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
– Tighten bolts -2- securing heat shield -1- to 9 Nm.

r
fo
en
ng
t.
yi Co
Further assembly is carried out in the reverse order of removal. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Turbocharger 289
Amarok 2011 ➤
2.7 Removing and installing regulating flap

potentiometer - G584- and vacuum unit
for turbocharger, 132 kW engine
2.7.1 Removing and installing regulating flap potentiometer - G584-

equipment required
pump - V.A.G. 1390- .
V.A.G 1397A-
1783/1-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
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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
Note
rrectness of i
A replacement-parts kit for replacing the regulating flap potenti‐

l purpos
ometer - G584- is available in the ⇒ ETKA (electronic parts

catalogue) .
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
290
Prote AG.
Rep. gr.21 - Turbocharging/supercharging
Amarok 2011 ➤
Removing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Detach hoses from retainer -arrow- on connecting hose -3-.
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.
– Unclip connector -1- from regulating flap potentiometer -

G584- -2-.
2. Turbocharger 291
Amarok 2011 ➤
– Undo and remove bolts -2- securing heat shield -1- and re‐
move heat shield.
– Lever off retaining clamp.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
– Loosen and completely unscrew securing nut -2- for control
du
an
itte
rod.
y li
erm
ab
ility
– Counterhold lock nut -3- with open-end spanner.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Working from below, unbolt regulating flap potentiometer -

G584- -1- together with bracket -2- from mounting of turbo‐
m
at
charger (3 nuts).
om
ion
c
in t
r
– Remove regulating flap potentiometer - G584- upwards to‐

o
his
te
gether with bracket.

a
do
priv
cum
or
Installing
f
en
ng
t.
yi Co
Installation is carried out in the reverse order; note the following: Cop py
t. rig
gh ht
pyri by
Vo
co
Caution
by lksw
cted agen
Prote AG.
Use only new bolts and nuts from the replacement-parts kit if
the regulating flap potentiometer - G584- is being renewed
completely!
New part
– If necessary, remove lower securing nut on control rod of new
regulating flap potentiometer - G584- .
Note
The lock nut must be screwed onto control rod.
Old part
– Unscrew lock nut from control rod and carefully remove seal‐
ing paint from control rod completely.
– Screw new lock nut from replacement-parts kit onto control
rod.
Continuation for all

Amarok 2011 ➤
– Carefully clean contact surfaces of regulating flap potentiom‐

eter - G584- -3- and bracket -2-.
– Carefully clean mounting for regulating flap potentiometer -
G584- on turbocharger.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
– Install regulating flap potentiometer - G584- and
aut guide control ra
c
rod -1- through adjusting lever on turbocharger
ss
as shown in
ce
e
illustration.
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
– Fit regulating flap potentiometer - G584- on the turbocharger

mounting with new nuts from the replacement-parts kit -4- and
tighten nuts to 8 Nm.
nf
ercia
orm
– Screw securing nut -2- onto control rod by hand in direction of
m
atio
m
vacuum unit.
o
n in
or c
thi
te
sd
iva
Note
o
r
rp
cu
o
m
f
en
ng
Make sure that the guiding element -1- of the flap lever moves
t.
yi Co
op
easily along the control rod.
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Turbocharger 293
AG. Volkswagen AG d
agen oes
olksw not
Amarok 2011 ➤ d by
V gu
ara
e nte
4-cylinder diesel engine (2.0 l engine, commonhoris
rail) - Edition 04.2013 eo
aut ra
ss c
– Attach connector -1- to regulating flap potentiometer - G584-
ce
e
nl
-2-.
pt
du
an
itte
y li
Connect ⇒ Vehicle diagnostic tester.
erm
ab
ility
ot p
Selecting operating mode:
wit
, is n
h re
– Press button on display for “Vehicle self-diagnosis”.
hole
spec
es, in part or in w
Selecting vehicle system:
t to the co
– Press button “01 - Engine electronics” on display.
The display indicates the control unit identification and the coding
rrectness of i
of the engine control unit.
l purpos
Selecting diagnostic function:

– Press button for “011 - Measured values” on the display.
nf
ercia
orm
– The display shows the individual components.
m
atio
om
– Select “Bypass Valve, Turbocharger, High Pressure Turbine
n in
or c
Input, Input Voltage” and confirm entry with Q .
thi
te
sd
iva
o
r
– Connect turbocharger tester - V.A.G 1397A- and hand vac‐

rp
cu
o
m
uum pump - VAS 6213- or hand vacuum pump - V.A.G. 1390-
f
en
ng
t.
yi
to vacuum connection -1- of regulating flap potentiometer -
Co
op py
G584- using a T-piece to do so. t. C rig
gh ht
pyri by
Switch on turbocharger tester - V.A.G 1397A- and move sliding
o Vo
by c lksw
cted
agen
Prote AG.

ometer - G584- .

“Closed” position and hold it there.
– Screw securing nut -3- in direction of vacuum unit until it con‐
tacts flap lever -1-.
– Continue turning securing nut -3- until a voltage of 0.75 volt ±
0.02 volt of regulating flap potentiometer - G584- is reached.
– Tighten lock nut -2- to 8 Nm.
Note
nut -2-.

Amarok 2011 ➤
Slowly reduce vacuum. Flap lever -1- now moves in

-direction of arrow- “Open”.
ometer - G584- again.
– Check voltage setting (0.75 volt ± 0.02 volt) of regulating flap
potentiometer - G584- and, if necessary, reset.
Slowly reduce vacuum.
Note
Flap lever -1- must now be resting against the stop. If the flap
lever is not resting against the stop, the setting procedure must
be repeated until the setting values agree with each other.
– After this, secure the nuts and lock nuts with sealing paint from
the replacement-parts kit.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut ra
– Press
ss a securing clip from replacement-parts kit onto control
c rod
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

Further assembly is carried out in the reverse order of removal.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Turbocharger 295
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
lksw not
2.7.2 Removing and installing vacuum unit for turbocharger
o
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
Special tools and workshop s
ce
le
equipment required
un
pt
an
d
itte
y li
♦ Universal dial gauge brack‐
rm
ab
et - VW 387-
pe
ility
ot
wit
♦ Hand vacuum pump - VAS , is n
h re
hole
spec
pump - V.A.G. 1390- .
es, in part or in w
t to the co
V.A.G 1397A-
♦ Dial gauge set, 4-part - VAS
rrectness of i
6341-
l purpos

nform
ercia

1783/1-
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.
Note
A replacement-parts kit for replacing the vacuum unit is available

in the ⇒ ETKA (electronic parts catalogue) .
Removing

Amarok 2011 ➤
– Detach vacuum hoses from retainer -arrow- on connecting

hose -3-.
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
– Undo and remove bolts -2- securing heat shield -1-.
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.
– Pull hose -1- off vacuum unit -2-.

– Loosen and completely unscrew lower securing nut -3- of con‐
trol rod -5-.
2. Turbocharger 297
Amarok 2011 ➤
– Unscrew nuts of vacuum unit -1- and remove vacuum unit

-2-.
Installing
Caution
Use only new nuts from the replacement-parts kit!
– Carefully clean contact surfaces of vacuum unit.
– If necessary, unscrew lower securing nut -3- of control rod

from new vacuum unit -2-.
– Install new vacuum unit -2- and push control rod -5- through
adjusting lever on turbocharger as shown in illustration.
Note
Location marker on vacuum unit must fit into mounting on turbo‐

charger.
– Fit vacuum unit -2- in place and fit nuts -1-, tighten nuts to 8
Nm.
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
– Screw securing nut -3- onto control rod by hand in direction of

rm
ab
vacuum unit.
pe
ility
ot
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
Make sure that the guiding element of the flap lever moves easily
along the control rod.
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 ➤
– Connect turbocharger tester - V.A.G 1397A- -2- and hand

vacuum pump - VAS 6213- or hand vacuum pump - V.A.G.
1390- -3- to vacuum connection of vacuum unit -1- using a T-
piece to do so.
Volkswagen AG
Switch turbocharger tester - V.A.G 1397A- on and move agesliding
n AG. does
ksw
switch on device to position II. by
Vol not
gu
ara
d
se nte
– Apply a vacuum of 390 ± 10 mbar to vacuum
tho
ri unit. eo
au ra
c
ss
ce
e
Caution
nl
pt
du
an
itte
y li
The following adjusting work must be carried out with extreme erm
ab
ility
care and precision as, otherwise, there is a risk that the turbo‐
ot p
wit
charger will be damaged.
, is n
h re
hole
spec
es, in part or in w
t to the co
“Closed” position.
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.
– Screw nut -3- in direction of vacuum unit until it is touching the
yi Co
op py
flap lever, while applying a tightening torque of 8 Nm to the t. C rig
gh ht
lock nut -2- at the same time. yri
p by
co Vo
by lksw
cted agen
Prote AG.
Note
The control rod -1- must not turn. Therefore, counterhold on se‐
curing nut -3-.
– Reduce vacuum again and apply a vacuum of 390 ± 10 mbar

to vacuum unit again.
Note
Flap lever must now be resting against the stop (closed position).
– Check set value and, if necessary, reset.
Note
The check must be repeated at least 3 to 5 times in order to ensure

that the vacuum unit has been set precisely and in order to avoid
possible damage to the turbocharger.
Repeat this procedure approx. 3-5 times.

– Reduce vacuum again.
2. Turbocharger 299
Amarok 2011 ➤
– Secure dial gauge - VAS 6079- together with universal dial

gauge bracket - VW 387- to turbocharger with a suitable bolt
-1- (as shown in illustration) and move gauge to end of control
rod -2-.
Note
The dial gauge rod and the control rod of the vacuum unit must
align with each other.
– Operate hand vacuum pump - VAS 6213- until the turbocharg‐

er tester - V.A.G 1397A- indicates 390 ± 10 mbar.
– Set dial gauge, 0-30 mm - VAS 6341/1- to 0.
– Operate hand vacuum pump - VAS 6213- until turbocharger
tester - V.A.G 1397A- indicates 410 ± 10 mbar. agen
AG. Volkswagen AG d
oes
ksw not
– Read value on dial gauge - VAS 6079- . Vol gu
d by ara
e nte
ris
– Make sure that value on dial gauge - VAS 6079-
tho does not eo
au ra
change. ss c
ce
le
un
– If value has changed, correct setting of vacuum unit and repeat
pt
an
d
measurement until setting complies with specified values.

itte
y li
erm
ab
– Secure securing nut and lock nut with sealing paint from re‐
ility
ot p
placement-parts kit.
wit
is n
h re
ole,
spec
– Press securing clip from replacement-parts kit onto control rod
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.
Further assembly is carried out in the reverse order of removal.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2.8 Removing and installing charge pres‐

sure control solenoid valve - N75-

Amarok 2011 ➤
AG. Volkswagen AG d
agen 4-cylinder diesel oengine
es n (2.0 l engine, common rail) - Edition 04.2013
olksw ot g
y V ua
d b ran
e
♦ Torque wrenchhoris - V.A.G 1410- tee
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Pull connector -2- and vacuum lines off charge pressure con‐
trol solenoid valve - N75- -1-.
– Remove spreader rivet -3- and charge pressure control sole‐
noid valve - N75- -1-.
Installing
Caution
connection piece.
2. Turbocharger 301
Amarok 2011 ➤
23 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Schematic overview - fuel system”, page 302
⇒ “1.2 Fitting location overview - injection system”, page 304
⇒ “1.3 Assembly overview - fuel system”, page 311
⇒ “1.4 Checking fuel system for leaks”, page 316
⇒ “1.5 Filling/bleeding fuel system”, page 316
1.1 Schematic overview - fuel system
WARNING
♦ Read through the rules for cleanliness and the instructions

for working on the fuel system ⇒ page 7 .
♦ If components of the fuel system between the fuel tank
and the high-pressure pump are removed or renewed, the
fuel system must be filled to be bled ⇒ page 316 . (It is
important not to allow the high-pressure pump to run while
still empty.)

♦ If components of the fuel system between the fuel tank and AG. Volkswagen AG d
the high-pressure pump are removed or renewed, it is neces‐ olkswagen oes
not
sary for the fuel system to be bled. To do this, perform thed by V gu
ara
oris
e nte
eo
tester ⇒ page 316 . auth
ra
ss c
ce
le
un
pt
total of 3 times in this case. The process must not be termi‐ an
d
itte
nated prematurely.
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.
302 Rep. gr.23 - Mixture preparation - injection

Amarok 2011 ➤
1 - Fuel tank
❑ With fuel system pres‐
surisation pump - G6- .
2 - Fuel filter
❑ With pre-heating valve.
❑ Assembly overview -
fuel filter ⇒ page 238 .
⇒ page 239 . AG. Volkswagen AG d
agen oes
olksw not
3 - Fuel temperature sender - d by V gu
ara
G81- orise nte
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4 - High-pressure pump ss a c
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nl
pt
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⇒ page 347 .
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5 - Fuel metering valve - N290-
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DANGER!
hole
spec
Valve
• must not be re‐
es, in part or in w
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moved.
❑ Valve is not available as
rrectness of i
separate part.
l purpos
6 - Fuel pressure regulating

valve - N276-
nform
ercia

⇒ page 362 .
m
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io
7 - High-pressure accumulator
n
c
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(fuel rail)
o
his
ate
do
riv
8 - Fuel pressure sender -

p
cum
or
G247-
f
en
ng
t.
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Co
op py
⇒ page 365 . t. C rig
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9 - Restrictor
co Vo
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❑ Cannot be renewed separately
AG.
10 - Injectors
❑ Injector, cylinder 1 - N30-
1. Injection system 303

Amarok 2011 ➤
1.2 Fitting location overview - injection system
1 - Intake manifold pressure

sender - G71-
⇒ page 307
2 - Air mass meter - G70-
⇒ page 307
eter - G584-
❑ “Position sender for
charge pressure posi‐
tioner” in vehicles with
single turbo engine -
G581- .
⇒ page 308
4 - Vacuum unit for exhaust
flap
❑ In vehicles with “biturbo
engine” only.
⇒ page 308
5 - Injectors
❑ Injector, cylinder 1 -
N30-
❑ Injector, cylinder 2 - AG. Volkswagen AG d
agen
N31- Volksw
oes
not
gu
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❑ Injector, cylinder 3 - rised
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N32- ut
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❑ Injector, cylinder 4 - ss
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N33-
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Prote AG.

Amarok 2011 ➤
⇒ page 307
⇒ page 327 .
❑ Fitting location ⇒ page 304
7 - Fuel pressure sender - G247-
8 - Fuel pressure regulating valve - N276-
10 - Engine speed sender - G28-
11 - Glow plugs
❑ Glow plug 1 - Q10-
12 - Throttle valve module - J338- with throttle valve potentiometer - G69- and intake manifold flap motor -
V157-
13 - Fuel temperature sender - G81-
gen AG
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swa does
❑ Fitting location ⇒ page
y V 307
olk not
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ed nte
14 - Engine controlthunit
or
is - J623-
e or
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ss
a
⇒ page 306 ac
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15 - Intake air temperature sender - G42- with charge air pressure sender - G31-
rm
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hole

spec
es, in part or in w
t to the co
17 - Fuel metering valve - N290-

rrectness of i
18 - Hall sender - G40-

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nform
ercia
19 - Exhaust gas recirculation valve - N18- with exhaust gas recirculation potentiometer - G212-
m
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tion in

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❑ Adaptation must be carried out after renewing.

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Prote AG.

Amarok 2011 ➤
22 - Coupling point
❑ For exhaust gas temperature sender 1 - G235- ⇒ Item 6 (page 260) (black connector) at coupling point
of air filter
❑ For exhaust gas temperature sender 3 - G495- ⇒ Item 5 (page 377) (brown connector) at coupling point
of air filter
❑ For exhaust gas temperature sender 4 - G648- ⇒ Item 6 (page 377) (orange connector) at coupling point
of air filter
23 - Charge pressure control solenoid valve - N75-
24 - Exhaust gas flap valve - N220-
25 - Exhaust gas recirculation cooler changeover valve - N345-
A - Brake light switch on brake master cylinder - F-
B - Clutch pedal switch - F36-
C - Accelerator position sender - G79-
D - Exhaust temperature sender 1 - G235- or exhaust Atemperature sender
G. Volkswagen A 2 - G448-
agen G do
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❑ Installed in exhaust manifold/turbocharger.
by
Vol o t gu
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E - Exhaust gas temperature sender t3ho-ri G495- tee
or
au ac
❑ Fitting location ⇒ Item 5 (page
ss 377)
ce
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nl
F - Exhaust gas temperature sender 4 - G648- pt

du
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itte
❑ Fitting location ⇒ Item 6 (page 377) y li

erm
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G - Lambda probe - G39- wit

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❑ Fitting location ⇒ Item 3 (page 377)

h re
hole
spec
H - Particulate filter
es, in part or in w
t to the co

rrectness of i
Engine control unit - J623-

l purpos
Location: in engine compartment on left.

1- Securing bolts/shear bolts
nform
ercia
2- 60-pin connector - T60-

m
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io
3- 94-pin connector - T94-

n
c
in t
or
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4- Engine control unit - J623-

at
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cum
for
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t.
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Cop py
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Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
Mounting locations on right on top of engine

1- Intake manifold pressure sender - G71-
2- Exhaust gas recirculation valve - N18- with exhaust gas re‐
circulation potentiometer - G212-
3- Air mass meter - G70-
Mounting locations on top of engine

1- Fuel pressure sender - G247-
2- Injector, cylinder 1 - N30-
6- Fuel pressure regulating valve - N276- AG. Volkswagen AG d
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Mounting locations on top of engine (continued)
ce
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1- Glow plug 1 - Q10-

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spec
5- Fuel temperature sender - G81-
t to the co
rrectness o
Mounting locations on top of engine (continued)
cial p
f inform
1- Fuel temperature sender - G81-

mer
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n
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Prote AG.

Amarok 2011 ➤
Components on top of turbocharger

1- Regulating flap potentiometer - G584-
n AG . Volkswagen AG
2- “Position sender for charge pressure positioner” in vehicles wage does
with single turbo engine - G581- . Volks not
gu
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3- Vacuum unit for exhaust flap tho eo
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ss
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spec
Intake air temperature sender - G42- with charge air pressure
sender - G31-
t to the co
1- Intake air temperature sender - G42- with charge air pres‐
sure sender - G31-
rrectne
2- Connector
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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Mounting locations on top of engine on left

p
cum
r
fo
en
ng
1- Throttle valve module - J338- with throttle valve potentiom‐

t.
yi Co
op
eter - G69- and intake manifold flap motor - V157- C py
ht. rig
rig ht
py by
2- Fuel metering valve - N290- co Vo
by lksw
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3- High-pressure pump
AG.
Charge pressure sender 2 - G447- -arrow-

Amarok 2011 ➤
Solenoid valves at air filter

♦ Changeover valve for exhaust gas recirculation cooler - N345-
-1-
♦ Exhaust gas flap valve - N220- -2-
♦ Charge pressure control solenoid valve - N75- -3-
Hall sender - G40-
Vacuum unit for exhaust flap

1- Vacuum hose
2- Vacuum unit wfor
ageexhaust
n AG. Volkflap
swagen AG
doe
ks s no
Vol t gu
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ss
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nl
pt
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erm
ab
ility
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hole
Regulating flap potentiometer - G584-

spec
es, in part or in w
1- Electrical line connection

t to the co
2- Vacuum hose
rrectness of i
3- Vacuum unit for wastegate

l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
Coolant temperature sender G62

1- Coolant temperature sender - G62-
2- Electrical line connection
3- Connection
Engine speed sender - G28-

Installation location of engine speed sender - G28- -2- below the
oil filter holder -1-.
AG. Volkswagen AG d
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rise nte
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Brake light switch on brake master cylinder
aut - F- ra
c
ss
Brake light switch - F- with brake pedal switch - F47- -1- is fitted
ce
e
nl
pt
du
underneath the brake master cylinder.

an
itte
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spec
es, in part or in w
t to the co
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Clutch pedal switch - F36-

1- Connector
nform
ercia
2- Clutch pedal switch - F36-

m
at
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ion
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or
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ate
do
priv
cum
for
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t.
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Cop py
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Prote AG.

Amarok 2011 ➤
Radiator outlet coolant temperature sender - G83-

Coolant temperature sender at radiator outlet - G83- : Installed at
the bottom on the left in front of the radiator.
AG. Volkswagen AG d
agen oes
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1.3 Assembly overview - fuel system ss c
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nl
pt
du
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WARNING
erm
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ility
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♦ Read through the rules for cleanliness and the instructions
, is n
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for working on the fuel system ⇒ page 7 .
hole
spec
es, in part or in w
t to the co
♦ If components of the fuel system between the tank and the
high-pressure pump are removed or renewed, the fuel
rrectness of i
system must be filled to be bled ⇒ page 316 . (It is im‐

portant not to allow the high-pressure pump to run while
l purpos
still empty.)
nf
ercia

rm
m
atio

om
n in
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thi
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a

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op py
♦ If components of fuel system between fuel tank and high-pres‐
. C rig
ht ht
rig
sure pump are unbolted, removed or renewed, “Bleeding fuel py by
co Vo
system” function must be carried out to bleed fuel system us‐
by lksw
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Prote
ing ⇒ Vehicle diagnostic tester.
AG.

total of 3 times in this case. The process must not be termi‐
nated prematurely.

Amarok 2011 ➤
1 - Return line
❑ From high-pressure
pump.
❑ General diagram of fuel
lines leading to engine
⇒ page 228
2 - Supply line
❑ To high-pressure pump.
❑ General diagram of fuel
lines leading to engine
⇒ page 228
3 - Bolt
❑ 10 Nm
4 - Hose
❑ Connection to return
lines of the injectors
5 - Hose
❑ Around high-pressure
accumulator (fuel rail) AG. Volkswagen AG d
agen oes
6 - Return line olksw not
V gu
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❑ To fuel tank. orise nte
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7 - Supply line ss a c
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nl
pt
du
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8 - Return line
erm
ab
❑ To fuel filter
ility
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9 - High-pressure line
h re
hole
❑ Between high-pressure
spec
es, in part or in w
accumulator (common t to the co

rail) and injectors
❑ Install so that compo‐
nent is not stressed.
rrectness of i

l purpos
General diagram of fuel lines leading to engine ⇒ page 228

nform
ercia
Note
m
at
om
io
♦ The high-pressure lines may be

n
c
in t
or
re-used after the following

his
ate
checks:
do
priv
cum
or
♦ Check taper seat of high-pres‐

f
en
ng
t.
sure line for deformation and
yi Co
op
cracks.
C py
t. rig
gh ht
yri by
♦ The line hole must not be de‐
op Vo
by c lksw
formed, constricted or damaged.
cted agen
Prote AG.
♦ Corroded lines should no longer

be used.
❑ 30 Nm
10 - Clamp
❑ For high-pressure line ⇒ Item 26 (page 314)
11 - Bolt
❑ 10 Nm

Amarok 2011 ➤
12 - High-pressure accumulator (fuel rail)

❑ Removing and installing ⇒ page 340 . AG. Volkswagen AG d
agen oes
lksw not
13 - Seal by
Vo gu
ara
ed
❑ Renew after removing horis nte
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14 - Fuel pressure regulating valve
s - N276-
s c
ce
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nl
❑ Cannot be re-installed.
pt
du
an
itte
❑ 80 Nm
y li
erm
ab
ility
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15 - O-ring
h re
hole
spec
es, in part or in w
16 - Injectors (piezo injectors or solenoid valves)
t to the co
❑ Do not interchange!
❑ When removing and installing, always renew the following components and seals/O-rings: “copper seal”
rrectness of i
⇒ Item 17 (page 313) and ⇒ Item 19 (page 313) , “O-ring for injector bore”, ⇒ Item 15 (page 313) , “O-
ring for injector return connection” ⇒ Item 15 (page 313) and “bolt for clamping plate”
l purpos
⇒ Item 21 (page 313) .

❑ Before re-using high-pressure lines ⇒ Item 9 (page 312) , perform visual check of taper seals for damage,
nf
ercia
o
e.g. transverse scores or corrosion. Always renew if damaged.
rm
m
atio
❑ If piezo injectors, high-pressure lines ⇒ Item 9 (page 312) and clamping plates ⇒ Item 20 (page 313)
om
which were removed are to be reinstalled, they must always be re-fitted in their original positions (i.e. on
n in
or c
the same cylinder).
thi
te
sd
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f
17 - Copper washer
en
ng
t.
yi Co
op
❑ Renew after removing C py
t. rig
gh ht
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18 - O-ring op Vo
by c lksw
cted agen
❑ Renew after removing Prote AG.
19 - Copper washer
20 - Clamping plates
❑ Reusable.
21 - Bolt
❑ 8 Nm +180°
22 - Fuel return line
❑ To fuel tank.
❑ The fuel return line must not be kinked, damaged or blocked.
❑ The fuel return lines must not be dismantled.
❑ Release ⇒ page 315
❑ Check locks ⇒ page 315
❑ Attach ⇒ page 315
❑ Lock ⇒ page 316
23 - Restrictor
❑ Cannot be renewed separately
24 - Fuel pressure sender - G247-
❑ 100 Nm
25 - Bolt
❑ 22 Nm

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Amarok 2011 orise➤ nte
eo
h
4-cylinder
s a diesel engine (2.0 l engine, common rail) - Edition
ut ra
c 04.2013
s
ce
le
un
26 - High-pressure line
pt
an
d
itte
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❑ Secured with 3 clamps ⇒ Item 10 (page 312)
erm
ab
❑ Between high-pressure pump and high-pressure accumulator (fuel rail)
ility
ot p
wit
is n
h re
Note
ole,
spec
♦ The high-pressure lines may be
t to the co
re-used after the following
checks:
rrectne
♦ Check taper seat of high-pres‐
sure line for deformation and
cracks.
ss o
cial p
f
♦ The line hole must not be de‐
inform
formed, constricted or damaged.
mer
atio
♦ Corroded lines should no longer
om
n
be used.
c
i
or
n thi
te
sd
a
❑ 30 Nm
iv
o
pr
cum
r
fo
27 - High-pressure fuel pump
en
ng
t.
yi Co
❑ With fuel metering valve - N290- (must not be opened). Cop py
t. rig
gh
❑ After renewing, initial fuel filling must be carried out (never allow the pump to run while it is still empty)
ht
pyri by
Vo
o
⇒ page 316 .
c by lksw
cted agen
Prote AG.
28 - Bolt
❑ 20 Nm +180°
29 - Bolt
❑ 20 Nm +45°
30 - Bolt
❑ 23 Nm
31 - Hub
❑ With sender ring.
❑ Use counterhold tool - T10051- to loosen and tighten.
❑ To remove, use puller - T40064- .
32 - Nut
❑ 95 Nm
33 - Toothed belt pulley on high-pressure pump
34 - Fuel temperature sender - G81-

Amarok 2011 ➤
Release fuel return line

-arrow B-.
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
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itte
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erm
ab
ility
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Check locks
h re
hole
spec
es, in part or in w
Caution
t to the co
rrectness of i
l purpos

nf
ercia
orm
m
atio
m

o
n in
c

or
thi
te
sd
a
• The engine must not be run when the fuel return line is
iv
o
r
rp
cu

o
m
f
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.
Fit fuel return line

Amarok 2011 ➤
Lock fuel return line

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ce
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un
pt
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d
itte
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erm
ab
ility
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1.4 Checking fuel system for leaks
h re
ole,
spec
DANGER!
t to the co
♦ Observe safety precautions when working on the injection
system ⇒ page 4 .
rrectne
♦ Observe rules for cleanliness ⇒ page 8 .
ss
Follow these instructions before starting work and while work‐
o
cial p
f i
ing on system.
nform
mer
atio
om
n
– Allow engine to idle for a few minutes but do not accelerate.
c
i
or
n
Then switch off engine again. (Fuel system will bleed itself au‐
thi
te
sd
a
tomatically).
iv
o
pr
cum
r
fo
– Check entire fuel system for leaks.

en
ng
t.
yi Co
op
Renew the affected component if leakage still occurs after tight‐ C py
ht. rig
ening to the correct torque. rig ht
py by
co Vo
by lksw
– Then, road-test the vehicle for more than 20 km. Accelerate cted agen
Prote AG.
with full throttle at least once.
Note
If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off engine, erase event memory and then continue
road test.
– Then check high-pressure section again for leaks.
1.5 Filling/bleeding fuel system
Caution
After new or removed parts such as the fuel filter or fuel lines
have been fitted, the high-pressure pump must be filled with
fuel before the engine is started for the first time. Avoid allowing
the high-pressure pump to run dry under all circumstances.

Amarok 2011 ➤
Note
♦ When installing the high-pressure pump, it is essential to en‐

n AG. Volkswagen A
sure that no dirt enters the fuel
olks
wagesystem.
G do
es n
ot g
yV u
♦ Only remove sealing db
rise plugs immediately prior to installationaraofnte
fuel lines. tho eo
s au ra
c
♦ There must be sufficient fuel in the tank.
s
ce
e
nl
pt
du
an
itte
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Proceed as follows to fill high-pressure pump with fuel.
erm
ab
ility
ot p
wit
, is n
h re
– Connect ⇒ Vehicle diagnostic tester, and carry out function
hole
“Bleed fuel system”.
spec
es, in part or in w
t to the co
Note
rrectness of i
This process takes 130 seconds. Fuel pumps are actuated a total
of 3 times in this case. The process must not be terminated pre‐
l purpos
maturely.
nform
ercia
– Then, start the engine.

m
at
om
– After filling fuel system, leave engine running at moderate
ion
c
speed for a few minutes and then switch off again.
in t
or
his
te
– Check fuel system for leaks.

a
do
priv
cum
or
– Read event memory and, if necessary, delete event memory

f
en
ng
t.
entry. Cop
yi Co
py
t. rig
– Then, road-test the vehicle for more than 20 km. Accelerate gh ht
yri by
with full throttle at least once.
op Vo
by c lksw
cted agen
Prote AG.
Note
♦ If there is any air left in the fuel system, the engine may switch
to the backup mode ('emergency running' mode) during the
road test. Switch off the engine and erase the fault memory.
Then continue road test.
♦ Then check high-pressure part of fuel system again for leak‐
age.
– Read event memory again.

Amarok 2011 ➤
2 Vacuum system
⇒ “2.1 Schematic diagram - vacuum system”, page 318
⇒ “2.2 Testing vacuum system for leaks”, page 321
AG . Volkswage
⇒ “2.2.1 Checking vacuum hoses ksw
leading
agen to non-return
n AG d
ovalve,
es n
l
solenoid valves N220 and N75by V changeover valve N345 ”, ot gu
o
ara
page 322 ris
ed
nte
ho eo
ut
⇒ “2.2.2 Checking svacuum
sa hose leading to changeover valve for ra
c
exhaust gas recirculation cooler N345 ”, page 324
ce
e
nl
pt
du
an
⇒ “2.2.3 Checking vacuum hose to vacuum unit on turbocharger”,
itte
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page 324
erm
ab
ility
ot p
⇒ “2.2.4 Checking vacuum hose to vacuum unit on exhaust gas
wit
, is n
recirculation cooler”, page 325
h re
hole
spec
2.1 Schematic diagram - vacuum system
es, in part or in w
t to the co
Caution
rrectness of i
l purpos

nform
ercia
connection piece.
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 ➤

cooler changeover valve -
N345-
2 - Bracket
❑ Attach bracket to bottom
of air filter housing
⇒ page 320
3 - Bolt
❑ 1 Nm
4 - Connection to air filter
5 - Vacuum unit
❑ Vacuum unit is installed AG. Volkswagen AG d
on exhaust gas recircu‐ agen oes
olksw not
lation cooler. Both parts byV gu
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ed
can only be renewed to‐ horis nte
eo
gether. s aut ra
c
s
❑ Connection of vacuum
ce
le
un
pt
hose to vacuum unit
an
d
itte
⇒ page 320
y li
erm
ab
ility
6 - T-piece
ot p
wit
is n
❑ Installed between brake
h re
ole,
servo and vacuum
spec
pump.
t to the co
hose to T-piece
⇒ page 320
rrectne
eter - G584-
ss
❑ With vacuum unit with
o
cial p
f
potentiometer
inform
mer
❑ On turbocharger.
atio
m
o
n
c
hose to regulating flap ⇒ page 320 i

or
n thi
te
sd

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t.
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8 - Vacuum line
Co
Cop py
ht. rig
❑ Fastened with cable ties rig ht
py by
co Vo
by lksw
9 - Cylinder head cover Prote
cted AG.
agen
❑ Vacuum reservoir is installed in cylinder head cover. Both parts can only be renewed together.
❑ Connection of vacuum hose to cylinder head cover ⇒ page 320
10 - Exhaust gas flap valve - N220-
❑ 6 Nm
11 - To vacuum unit on turbocharger
❑ Vacuum unit not available as a separate part.
12 - Charge pressure control solenoid valve - N75-
❑ With individual air filter.
❑ 6 Nm
❑ Old fitting location ⇒ page 321
2. Vacuum system 319

Amarok 2011 ➤
❑ New fitting location: fastened to solenoid valve bracket
Secure bracket to bottom of air filter housing

– Insert bracket together with valves -1- at bottom into mount‐
ings on air filter housing -2-.
AG. Volkswagen AG d
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ab
ility
ot p
Secure bracket to top of air filter housing
wit
, is n
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hole
– Fit and tighten bolt holding bracket with valves -1- to top of air
spec
filter housing -2-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
Installation of vacuum lines on engine on right-hand side
or
his
ate
do
riv
1- Connect vacuum hose to vacuum unit of cooler for waste

p
cum
gas recirculation.
for
en
ng
t.
yi
2- Connect vacuum hose to regulating flap potentiometer -
Co
Cop py
G584- .
t. rig
gh ht
pyri by
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3- Connect vacuum hose of recirculation valve leading to cyl‐ by c lksw
cted agen
inder head cover.
Prote AG.
Installation of vacuum lines on engine on left-hand side

1- Connect vacuum hose to junction piece on vacuum pump.
2- Connect vacuum hose of recirculation valve leading to junc‐
tion piece.
3- Connect vacuum hose of junction piece leading to cylinder
head cover.

Amarok 2011 ➤
Charge pressure sender 2 - G447- -arrow-
2.2 Testing vacuum system for leaks

♦ Engine bung set - VAS 6122-
AG. Volkswagen AG d
agen oes
olksw not
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ise nte
or
♦ Hand vacuum pump - VAS 6213-
aut
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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
rrectness of i
l purpos
Caution
nform
ercia
m
at

om
ion
c
in t
r

o
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e
connection piece.
at
do
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for
en
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t.
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Checking vacuum hoses to non-return valve, exhaust gas flap
Co
Cop py
valve - N220- , charge pressure control solenoid valve - N75- ,
t. rig
gh ht
yri
changeover valve for exhaust gas recirculation cooler - N345- and p by
o Vo
by c lksw
vacuum reservoir ⇒ page 322 Prote
cted AG.
agen
Checking vacuum hose to regulating flap potentiometer - G584-

⇒ page 324
Checking vacuum hose to vacuum unit on turbocharger
⇒ page 324

Amarok 2011 ➤
Checking vacuum hose to vacuum unit onn Aexhaust

wage
G. Volkswgas
agen recircu‐
AG do
es n
lation cooler ⇒ page 325 y Volks ot g
u b ara
ed
2.2.1 Checking vacuum hoses leading to non- ris nte
tho e or
au
return valve, solenoid valves -N220- and
ac
ss
ce
e
-N75- changeover valve -N345-
nl
pt
du
an
itte
y li
erm
Test procedure
ab
ility
ot p
– Pull vacuum hose -3- off at outer connection of exhaust gas
wit
, is n
flap valve - N220- -4-.
h re
hole
spec
– Pull vacuum hose -2- off at outer connection of charge pres‐
es, in part or in w
sure control solenoid valve - N75- -1-.
t to the co
– Pull vacuum hose -6- off at outer connection of changeover
valve for exhaust gas recirculation cooler - N345- -5-.
rrectness of i
– Connect hand vacuum pump - VAS 6213- to the 3 valves one
l purpos
after the other and then generate a vacuum of 0.6 bar.

– Observe pressure gauge of hand vacuum pump - VAS 6213-
nf
ercia
for approx. 30 seconds.
orm
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atio
• Vacuum must not drop.
om
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or c
If vacuum drops:
thi
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– Replace valve if it does not seal properly.
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t.
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– Seal vacuum hoses -2, 3 and 6- with clean bungs from engine
Co
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t. C rig
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pyri by
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– Seal connecting piece -2- with a clean bung from engine bung
co lksw
by
cted agen
set - VAS 6122- . Prote AG.
– Pull vacuum hose -arrow- off vacuum reservoir. Seal opening

of vacuum hose with clean bung from engine bung set - VAS
6122- .

Amarok 2011 ➤
– Pull vacuum hose off T-piece -2-.

Volkswa
– Connect hand vacuum pump - VAS 6213- toswremoved
agen
AG. vacuum
gen AG
does
hose and generate a vacuum of 0.6 bar.
by
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se
– Observe pressure gauge of handthovacuum
ri pump - VAS 6213- tee
or
for approx. 30 seconds. ss au ac
ce
le
un
pt
an
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itte
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If vacuum drops:
erm
ab
ility
ot p
– Locate damage or leaking vacuum hose connection. To do
wit
this, pull individual vacuum hoses off from relevant connection
is n
h re
and check for leak to connected component.
ole,
spec
t to the co
– Pull off vacuum hoses -1- and -2- at connector -arrow- and
check non-return valve and vacuum hose to exhaust gas re‐
circulation cooler changeover valve - N345- .
rrectne
– Locate damage or leaking vacuum hose connection.
– Renew non-return valve or leaking vacuum hose.
ss o
cial p
f
– Reconnect all vacuum hoses to valves and to union -arrow-.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
– Pull vacuum hose -arrow- off vacuum reservoir. Seal opening

t.
yi Co
op
of vacuum hose with clean bung from engine bung set - VAS C py
ht. rig
6122- . rig ht
py by
co Vo
by lksw
– Connect hand vacuum pump - VAS 6213- to removed vacuum cted agen
Prote AG.
If vacuum drops:
– Replace vacuum hose if it leaks -1-.
If pressure does not drop:
– Connect hand vacuum pump - VAS 6213- to vacuum reservoir
and generate a vacuum of 0.6 bar.
If vacuum drops:
– Replace cylinder head cover if it leaks ⇒ page 93 .
– Check following vacuum hoses:
♦ Vacuum hose to regulating flap potentiometer - G584-
⇒ page 324
♦ Vacuum hose to vacuum unit on turbocharger ⇒ page 324
♦ Vacuum hose to vacuum unit on exhaust gas recirculation
cooler ⇒ page 325

Amarok 2011 ➤
2.2.2 Checking vacuum hose leading to

changeover valve for exhaust gas recir‐
culation cooler - N345-
Test procedure
• Vacuum hoses to non-return valve, exhaust flap valve -
N220- , charge pressure control solenoid valve - N75- , ex‐
haust gas recirculation cooler changeover valve - N345- and
vacuum reservoir must first have been checked for leaks
⇒ page 322 . wage
es ks not
Vol g
– Pull vacuum hose off at emiddle
db
y connection of exhaust gas flapuaran
valve - N220- . thoris tee
o
au ra
– Connect hand vacuum
ss pump - VAS 6213- to removed vacuum c
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
If vacuum drops:
spec
es, in part or in w
t to the co
rrectness of i
– Pull vacuum hose -arrow- off regulating flap potentiometer -
G584- . Seal opening of vacuum hose with clean bung from
l purpos
engine bung set - VAS 6122- .

– Connect hand vacuum pump - VAS 6213- to pulled-off vacuum nf
ercia
reservoir and generate a vacuum of 0.6 bar.

orm
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atio

om
n in

or c
thi
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sd

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If vacuum drops:
o
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f
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ng
t.
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– Renew leaking vacuum hose. Cop py
t. rig
gh ht
yri
If pressure does not drop: p by
co Vo
by lksw
cted agen
– Connect hand vacuum pump - VAS 6213- to potentiometer for Prote AG.
regulating flap - G584- and generate a vacuum of 0.6 bar.
If vacuum drops:
– Replace turbocharger ⇒ page 267 .
2.2.3 Checking vacuum hose to vacuum unit

on turbocharger
Test procedure
⇒ page 322 .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by Amarok a2011
ran ➤
ise
r tee
tho (2.0 l engine, common rail) - Edition 04.2013o
au ra
c
ss
– Pull vacuum hose off at middle connection of charge pressure
ce
e
nl
pt
du
control solenoid valve - N75- -1-.
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
– Connect hand vacuum pump - VAS 6213- to removed vacuum
nform
ercia
hose -2- and generate a vacuum of 0.6 bar.
m
at
om
ion
c
in t
or
his
te

a
do
priv
cum
or
If vacuum drops:
f
en
ng
t.
yi Co
– Remove underbody guard, if fitted ⇒ Rep. gr. 66 . t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Pull vacuum hose -1- from vacuum unit -2-. Seal opening of
vacuum hose with clean bung from engine bung set - VAS
6122- .
– Connect hand vacuum pump - VAS 6213- to pulled-off vacuum
If vacuum drops:
– Renew leaking vacuum hose.
– Connect hand vacuum pump - VAS 6213- to vacuum unit and
generate a vacuum of 0.6 bar.
If vacuum drops:
– Replace turbocharger ⇒ page 267 .
2.2.4 Checking vacuum hose to vacuum unit

on exhaust gas recirculation cooler
Test procedure
⇒ page 322 .

Amarok 2011 ➤
– Pull vacuum hose off at central connection of changeover

– Connect hand vacuum pump - VAS 6213- to removed vacuum
If vacuum drops:
– Bring lock carrier into service position ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Lock carrier service position .
– Pull off vacuum hose -arrow 2-. Seal opening of vacuum hose
with clean bung from engine bung set - VAS 6122- .
– Connect hand vacuum pump - VAS 6213- to pulled-off vacuum
If vacuum drops:
AG. Volkswagen AG d
– Renew leaking vacuum hose. agen oes
olksw not
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d by ara
If pressure does not drop: oris e nte
h eo
ut ra
– Connect hand vacuum pump
ss a - VAS 6213- to vacuum unit and c
generate a vacuum of 0.6 bar.
ce
le
un
pt
an
d

itte
y li

erm
ab
ility
ot p

wit
is n
h re
ole,
If vacuum drops:
spec
– Replace exhaust gas recirculation cooler ⇒ page 251 .

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

Amarok 2011 ➤
3 Injectors and high-pressure accumu‐

lator (rail)
⇒ “3.1 Overview of injectors”, page 327 n AG. Volkswagen AG do
lkswage es n
o ot g
⇒ “3.2 Injector delivery calibration”, page 327 d byV ua
ran
ir se tee
⇒ “3.3 Removing and installing injectors (piezo uth injectors)”,
o
or
page 328 ss
a ac
ce
le
un
⇒ “3.4 Removing and installing injectors (solenoid valves)”, page
pt
an
d
332
itte
y li
rm
ab
⇒ “3.5 Removing and installing high-pressure lines”, page 338 pe
ility
ot
wit
, is n
⇒ “3.6 Removing and installing high-pressure accumulator (rail)”,
h re
page 340
hole
spec
es, in part or in w
⇒ “3.7 Checking return flow rate of injectors with engine running”,
t to the co
page 343
3.1 Overview of injectors
rrectness of i
Engine codes Solenoid valves with Piezo injectors with
l purpos
restrictor pressure retention

valve
nform
ercia
CDBA, CDCA X
m
a
com
CNEA, CNFA, X
tion in
CSHA
r
te o
thi
s
iva
3.2 Injector delivery calibration
do
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rp
cum
fo
en
g

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
Check “injector delivery calibration” adaptation
c by lksw
cted agen
Prote AG.
The function “injector delivery calibration” serves to correct the
injection rates for each cylinder of a common rail system individ‐
ually across the entire map range.
The 7-digit adaptation values -1- (details in illustration are only an
example) are marked separately on each piezo injector. They
may consist of letters and/or numbers (ASCII code).
3. Injectors and high-pressure accumulator (rail) 327

Amarok 2011 ➤
Table of characters for reading the characters on the injector.

When a new injector is installed, the adaptation value for the new
injector must be written to the engine control unit.
When the engine control unit is renewed, the “injector delivery
calibration values” must be written into the new engine control
unit.
The work procedure for the adaptation is described in ⇒ Vehicle
diagnostic tester.
Also check that the “injector delivery calibration” values are cor‐
rectly entered for all the other injectors. Do NOT attempt to re-
enter these calibration values if the correct values are already
stored in the engine control unit.
Select “Adapt injector delivery calibration” ⇒ Vehicle diagnostic
tester.
3.3 Removing and installing injectors (piezo injectors)

equipment required
♦ Puller - T10055-
♦ Assembly sleeve - T10377-
♦ Socket - T40055-
- V.A.G 1331- agen
AG. Volkswagen AG d
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♦ Ratchet - V.A.G 1331/1- byV gu
ara
ed
ris nte
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aut ra
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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
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
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
♦ Puller - T10402-
Caution
• Do not interchange removed piezo injectors. . Volkswagen AG

gen AG does
swa
• When a new piezo injector is installed,
by
Volthe adaptation val‐
k not
gu
ue for the new injector must berientered
se
d in the engine ara
nte
control unit ⇒ Vehicle diagnostic
ut
ho tester. eo
ra
a c
ss
ce
e
nl
pt
du
Removing
an
itte
y li
erm
ab
– Pull off connector -1- at piezo injector to be removed.
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
e
Caution
at
do
priv
cum
or

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

Amarok 2011 ➤
. Volkswage
AG n AG d
agen oes
olksw not
– With engine switched off, carefully pull returndline by connections
V gu
ara
off at piezo injectors. To do this, press the two rise clips downwards nte
-arrow A- and, at the same time, pull the tho eo
au release bolt upwards ra
-arrow B-. ss c
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
wit
Ensure cleanliness. It must be assured that no dirt gets into the
, is n
h re
disconnected fuel return lines or the open connections of the pie‐
hole
spec
zo injectors.
es, in part or in w
t to the co
– Unscrew high-pressure line ⇒ Item 9 (page 312) between
high-pressure accumulator (fuel rail) and injectors to be re‐
moved.
rrectness of i
– Remove bolts ⇒ Item 21 (page 313) of the injectors to be re‐
l purpos
moved.
nform
mercia
a
com
tion in
– Place puller - T10055- with adapter - T10055/1- in position as
r
te o
thi
shown and pull injector out downwards with tapping move‐
s
iva
ments.
do
r
rp
cum
fo
Installing
en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– The 7-digit adaptation values -1- (details in illustration are only

an example) are marked separately on each piezo injector.
Read off and note down this value before installing new piezo
injector.
Important instructions for installation of piezo injectors:
• When removing and installing, always renew the following
components and seals/O-rings: “copper seal”, “O-ring for in‐
jector bore”, “O-ring for injector return connection”.
• Used piezo injectors may only be re-installed on the cylinder
they were removed from.
• Make sure that the piezo injector and the installation area are
clean before installing.
• Piezo injector must not be damaged in any way.
• Lubricate all O-rings with diesel before installing.
If a used piezo injector is being re-installed:

Amarok 2011 ➤
AG. Vo4-cylinder
lkswagen AGdiesel engine (2.0 l engine, common rail) - Edition 04.2013
agen does
o lksw not
V gu
– To removeedtheb old copper seal from the piezo injector,
y ara
nte
carefully
clampththe
o copper seal in a pair of pliers so the copper
ris
e o seal is
just sprevented
au from spinning. Then carefully pull and twist ra
c the
piezo injector out of the copper seal by hand.
s
ce
e
nl
pt
du
– Clean piezo injector tip and sealing surface.
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
– Fit new copper seal -1- on piezo injector -2- with help of as‐
sembly sleeve - T10377- . Use “narrow” side of assembly
l purpos
sleeve - T10377- for this.

– Carefully slide new O-ring over fuel return connection to avoid
nf
ercia
damaging O-ring.
orm
m
atio
– Clean sealing surface of injector in cylinder head and injector
om
n in
shaft.
or c
thi
te
sd
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o
r
WARNING
rp
cu
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f
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ng
t.
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Only cleaning set - VAS 6811- may be used for cleaning seal‐
Cop py
t. rig
gh ht
pyri by
Vo
o
For detailed information on how to use the cleaning set as well
by c lksw
cted agen
Prote AG.

6811- .
– Renew seal for injector shaft. Use assembly sleeve - T10377-

to do this.
– Push clamping plate onto piezo injectors.
Piezo injectors are installed “dry”. Therefore, do not install with
any fluid to facilitate assembly.
– Insert piezo injectors with clamping plate into injector bores
without exerting excessive force.
– Check O-rings for damage. Replace damaged O-rings.

Amarok 2011 ➤
AG. Volkswagen
– After fuel return line has been pushed won
agecompletely,
n
press
AG do
es n
olks
d by V ot g
ua
e ran
ris tee
– Install high-pressure linesu⇒
tho page 338 . or
a ac
ss
ce
le
un
pt
Note
an
d
itte
y li
rm
ab
After renewing one or more injectors, the “injector delivery cali‐
pe
ility
ot
bration” values for the new injectors must be written into the
wit
, is n
engine control unit with ⇒ Vehicle diagnostic tester ⇒ page 327 .

h re
hole
spec
es, in part or in w
Specified torques
t to the co
♦ ⇒ “1.3 Assembly overview - fuel system”, page 311

rrectness of i
l purpos
nform
mercia
3.4 Removing and installing injectors (sole‐

com
tion in
noid valves)
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
♦ Puller - T10055-
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
♦ Assembly sleeve - T10377-
AG. Volkswagen AG d
agen oes
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d b ara
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ss c
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pt
an
d
itte
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♦ Puller -T10415-
rm
ab
pe
ility
ot
Removing
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Caution
m
a
com
tion in
♦ Mark allocation of injectors to cylinders. They must always
r
te o
thi
be re-installed on the same cylinders.
s
iva
do
r
rp
c
♦ Observe rules for cleanliness when working on the injec‐
um
fo
en
g
tion system.
n
t.
yi Co
op py
♦ The open connections must be sealed with a suitable cap.
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Pull return line connections off injectors. To do this, press the
catches -1- and -2- downwards and, at the same time, pull the
release pin upwards -arrow-.

Amarok 2011 ➤
– Detach connectors -arrows- from injectors.
Caution
When releasing high-pressure line, counterhold high-pressure

connection using an open-ended spanner. Leaks occur if high-
pressure connection is released.
– Unscrew union nuts of relevant high-pressure line -1 to 4- and

remove corresponding high-pressure line.
– Unscrew bolt -1- of the clamping piece of the injector that is to
be removed.
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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Fit puller - T10055- with puller -T10415- and pull injector out
upwards using tapping movements.
Note
Pull injector out using rotary movements in order not to damage

sealing lip.
– Place the removed injectors on a clean cloth.

AG. Volkswagen AG d
Installing new injectors agen oes
olksw not
V gu
by ara
When a fitting a new injector, the following risemust
d be replaced: nte
ho eo
ut
♦ Copper seal ss a ra
c
ce
le
♦ O-ring 3 for shaft of injector

un
pt
an
d
itte
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♦ O-ring for fuel return connection
erm
ab
ility
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wit
is n
Note
h re
ole,
spec
♦ Observe cylinder specific markings when reusing high-pres‐
t to the co
sure lines.
♦ The high-pressure lines may be re-used after the following
checks:
rrectne
♦ Check taper seat of respective high-pressure line for defor‐
s
mation and cracks.
s o
cial p
f i
♦ The line hole must not be deformed, constricted or damaged.
nform
mer
♦ Corroded lines should no longer be used.
atio
om
n
c
i
or
n
Installing used injectors
thi
te
sd
va
When a used injector is re-fitted, the following must be replaced:

i
o
pr
cum
r
fo
en
ng
♦ Copper seal
t.
yi Co
Cop py
♦ O-ring 3 for shaft of injector
t. rig
gh ht
pyri by
Vo
o
♦ O-ring for fuel return connection by c lksw
cted agen
Prote AG.
– Spray tip of injector with an rust removal spray. Wait approx.
5 minutes and wipe off soot and oil particles with a cloth.
– If an injector is very dirty, the tip of the nozzle should also be
cleaned with a soft brass wire brush to make it easier to re‐
move the copper seal. Do not apply the wire brush to the bores
in the nozzle.
– To remove the old copper seal from the injector, clamp the seal
carefully in a vice so that it is just held between the jaws without
turning. Then carefully pull and twist the injector out of the
copper seal by hand.
– Use a scraper to clean off the deposits under the copper seal.
– Clean sealing surface of injector in cylinder head and injector
shaft.

Amarok 2011 ➤
WARNING
Only cleaning set - VAS 6811- may be used for cleaning seal‐
For detailed information on how to use the cleaning set as well
6811- .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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 ➤
– Replace O-ring for shaft of injector. Use assembly sleeve -

T10377- to do this.
– Install injectors.
Note
If any of the seals for injectors in cylinder head cover are dam‐
aged, replace the affected seal .
– Tighten union nuts of high-pressure lines hand-tight. Check

they are seated without stress.
– Tighten high-pressure lines to specified torque.
• Press return line connections carefully over the seals and onto
the injectors (first check seal for damage). The catch should
engage audibly. Then press release pin down carefully.
After one or more injectors has been replaced, the correction val‐
ues for the new injectors must be entered into the engine control
unit ⇒ Vehicle diagnostic tester.
Also check all the other injectors to find out whether the correct
correction values have been stored in the engine control unit. Do
not attempt to re-enter these values if the correct values are al‐
ready stored in the engine control unit.
Note
The high-pressure connections must not be opened for bleeding.

wage
– Start engine and run yV
o at idling speed for a few minutes,
lks es n
ot g then
switch off again. ir se
d b ua
ran
tee
tho
– Switch offs auignition. or
ac
s
– Check the complete fuel system and return line connections
ce
e
nl
pt
du
for leaks ⇒ page 316 .

an
itte
y li
erm
ab
Renew the affected component if leakage still occurs after tight‐

ility
ot p
ening to the correct torque.

wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
The return lines can only be renewed complete.

rrectness of i
– Then, road-test the vehicle for more than 20 km. Accelerate

with full throttle at least once. Then check high-pressure part
l purpos
of fuel system again for leakage.

nform
ercia
Note
m
at
om
ion
If there is any air left in the fuel system, the engine may switch to
c
in t
or
the backup mode ('emergency running' mode) during the road

his
ate
test. Stop engine and delete event memory ⇒ Vehicle diagnostic

do
priv
tester . Then continue the road test.

um
for
en
ng
t.
yi Co
op
Specified torques
C py
t. rig
gh ht
yri by
♦ ⇒ “1.3 Assembly overview - fuel system”, page 311 cop Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
3.5 Removing and installing high-pressure

lines
♦ Socket - T40055-
AG. Volkswagen AG d
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un
pt
an
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itte
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rm
ab
pe
ility
Removing
ot
wit
, is n
h re
hole
Caution
spec
es, in part or in w
t to the co
♦ Mark high-pressure lines to indicate which ones belong to

which cylinders. They must always be re-installed on the
same cylinders.
rrectness of i
♦ Open connections must be sealed immediately with a suit‐

l purpos
able cap.
♦ Do not crush or damage fuel return lines during removal
nform
ercia
or installation.
m
a
com
tio

n in
r

te o
thi
s
iva
do
r
rp
cum
fo
– Use socket - T40055- to unscrew high-pressure line between

en
ng
t.
yi
high-pressure accumulator (fuel rail) and injectors to be re‐
Co
Cop py
moved. ht. rig
rig ht
py by
o Vo
Installing by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
Caution
To position injection lines more easily and stress-free, loosen

and shift high-pressure accumulator (fuel rail) slightly if nec‐
essary. The lines must never be bent or tensioned. Tension
would otherwise cause the respective line to break in the long-
term.
Note
This section describes how toolkinstall

AG. V swagennew
AG doinjection lines. If the
injection lines which agen
olksw were previously fitted eare s no to be used again,
t gu
the points listed
ed by under ⇒ Item 9 (page 312) must
V
abe
ra checked
again. Apart
thori from that the procedure is identical. ntee
s
or
au ac
ss
Installing individual injection lines (cylinders 1…4, between high-
ce
e
nl
pt
pressure accumulator (fuel rail) and injector)
du
an
itte
y li
– Remove new injection line from its packaging. Remove seal‐
erm
ab
ility
ing plug and position line between high-pressure accumulator
ot p
(fuel rail) and injector (without laying down).

wit
, is n
h re
hole
– First, tighten the union nuts of the injection line hand-tight

without a tool. Ensure that line is correctly seated. spec
es, in part or in w
t to the co
– Proceed in the same way with other injection lines.
– Tighten high-pressure accumulator (fuel rail) bolts again, if
rrectness of i
necessary. Specified torque ⇒ Item 11 (page 312) .

l purpos
– Tighten union nuts of all new injection lines using torque

wrench (5...50 Nm) - V.A.G 1331- and socket bit - T40055- .
Specified torque ⇒ Item 9 (page 312) .
nf
ercia
orm
Installing fuel line between high-pressure pump and high-pres‐

m
atio
m
sure accumulator (fuel rail) or complete wiring harness

o
n in
or c
thi
te
sd
iva
Note
o
r
rp
cu
o
m
f
en
ng
t.
♦ If high-pressure lines are used again, bear in mind the mark‐
yi Co
op
ings you have already made on them.
C py
t. rig
gh ht
yri by
♦ High-pressure lines may be re-used after the following checks:
cop Vo
by lksw
cted agen
Prote AG.
♦ Check taper seat of respective high-pressure line for defor‐
mation and cracks.
♦ Line hole must not be deformed, constricted or damaged.
– Install high-pressure lines (without tension).

– If you have not yet done so, loosen the bolts of the high-pres‐
sure accumulator (fuel rail) to allow it to be moved.
– Then remove the packaging from the fuel line between high-
pressure pump and high-pressure accumulator (fuel rail). Re‐
move sealing plug and position the line without laying down
again.
– First, tighten the union nuts of the injection line hand-tight
without a tool. Ensure that line is correctly seated.
– If a complete wiring harness needs to be installed, adopt the
same procedure for all 4 injection lines.

Amarok 2011 ➤
– Fit all fastening clips to the fuel line. Make sure they are aligned
correctly.
– Screw in the screws -2- of the clips approx. 3 turns of the
screw.
– Tighten high-pressure accumulator (fuel rail) bolts again.
Specified torque ⇒ Item 11 (page 312) .
– Tighten clamp on top of intake manifold.
– Tighten union nuts of all new injection lines using torque

wrench (5...50 Nm) - V.A.G 1331- and n AGsocket
. Volkswbit
agen- AT40055-
G do .
Specified torque ⇒ Item 9 (page wage
olks 312) .
es n
guot V
d ara by
– Then, tighten 2 remaining
or
ise securing bolts. nte
h eo
ut ra
– Press return line connections
ss a carefully over the seals and onto c
the injectors and check seal for damage. You should hear
ce
e
nl
pt
them click into place. Then press the release pin downwards
du
an
itte
carefully.
y li
erm
ab
ility
– Filling fuel system ⇒ page 316 .
ot p
wit
, is n
Specified torques
h re
hole
spec
es, in part or in w
t to the co
3.6 Removing and installing high-pressure
accumulator (rail)
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.
♦ Socket - T40055-

Amarok 2011 ➤
Removing
wage es n
– Pull connector -2- off fuel pressure sender - G247- -1-. y V olks ot g
ua
d b ran
e
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Unscrew bolts -2- for fuel line -1-.
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
Disconnecting fuel return lines py by
co Vo
by lksw
cted agen
Prote AG.
Caution


Amarok 2011 ➤

-arrow B-.
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
– Pull all fuel return lines -1- off piezo injectors.

itte
y li
rm
ab
– Release connectors -2- and pull them off piezo injectors.
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
– Unscrew union nuts -1- from piezo injectors.

m
a
com
t
– Ensure cleanliness. No dirt must be allowed to get into the
ion in
disconnected fuel return lines or the open connections on the
r
te o
thi
piezo injectors.
s
iva
do
r
rp
c
– Unscrew bolts -2- from high-pressure accumulator (fuel rail).
um
fo
en
ng
t.
– Pull cable guide -3- from high-pressure accumulator (fuel rail).
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unclip connector -2- and pull off from fuel pressure regulating
valve - N276- -1-.
– Pull fuel hose -3- from high-pressure accumulator (fuel ail)
-4-.

Amarok 2011 ➤
olkswagen AG
en AG. V
– Remove high-pressure accumulator (fuel rail) ksw-1-. Guide high-
ag does
not
Vol
pressure accumulator (fuel rail) past fuel
ed
b return line and fuel
y gu
ara
lines. ho
ris nte
eo
t
au ra
– Ensure cleanliness. No dirt may
ss get into the injector holes on c
ce
le
un
pt
an
d
itte
Installing
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Observe instructions for installing high-pressure lines
es, in part or in w
⇒ page 338 .
t to the co
– The fuel system must first be filled with fuel before the engine
is started ⇒ page 316 .
rrectness of i
Specified torques
l purpos
nform
ercia
3.7 Checking return flow rate of injectors

m
a
with engine running
com
tion in
r
te o
thi
s
iva
do
r
rp
c
♦ Return flow meter - VAS 6684-
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Hose clamps, up to Ø 25 mm - 3094-
WARNING
Wear eye protection and protective clothing to avoid eye inju‐

ries and skin contact. Before loosening hose connections,
wrap a cloth around the connection. Then release pressure by
carefully pulling hose off connection.

Amarok 2011 ➤
Procedure
WARNING

Note
♦ Adhere strictly to the rules for cleanliness; no dirt must be al‐

lowed to get into the disconnected return lines and the open
return line connections.
♦ Clean all return line connections with commercially available
degreaser before removing them.
♦ Dry all cleaned parts.
Note
♦ The test sequence is described for the solenoid valves with

restrictor. The test sequence for piezo injectors with pressure
retention valve is the same.
♦ For checking the return flow rate of the solenoid valves the
“transparent” hoses of the return flow meter - VASag6684-
en AG. Vare agen AG doe
olksw
required. Volksw s no
tg
by ua
ed ran
oris tee
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au ac
Note ss
ce
le
un
pt
an
d
The hoses of the return flow meter - VAS 6684- must be of the
itte
y li
erm
same length.
ab
ility
ot p
wit
is n
– Carefully pull return line connections off injectors. To do this,

h re
ole,
press tabs -1- and -2- downwards and simultaneously pull re‐
spec
lease pin -arrow- upwards.

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

Amarok 2011 ➤
– Clamp off fuel return hose -arrow- using hose clamp up to

25 mm - 3094- .
– Connect the “transparent” hoses -2- of return flow meter - VAS
6684- -1- to the return line connections of all 4 injectors.
Caution
Risk of damage to injectors when return lines are pulledAGoff.

. Volkswagen n AG do
wage es n
♦ Do NOT press the accelerator during thisy test;
Vol the engine
ks ot g
ua
must only run at idling speed. ris
ed b ran
tee
tho
♦ If one of the inspection glasses isauabout to overflow, ter‐
or
ac
minate the measurement. ss
ce
le
un
pt
an
d
itte
y li
rm
ab
– Start engine and allow to idle for 3.5 minutes.
pe
ility
ot
wit
, is n
– When the engine is warm and running at idling speed the re‐
h re
hole
turn flow rates at each of the 4 injectors must not differ by more
spec
than a small amount -1-.
es, in part or in w
t to the co
– If the return flow rate of one injector is significantly higher than
the return flow rate of the other injectors -2-, renew the re‐
spective injector, ⇒ page 328 or ⇒ page 332 .
rrectness of i
Installing
l purpos
nform
mercia
Note
a
com
tion in
r
♦ The O-rings of all return line connections must be renewed.

te o
thi
s
iva
do
♦ Lubricate O-rings with engine oil or assembly oil before instal‐
r
rp
cum
ling.
fo
en
ng
t.
yi Co
Cop py
t. rig
gh
– Carefully fit return lines onto injectors and press down tabs on
ht
pyri by
Vo
o
side -arrows- until they engage audibly.
c by lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Then carefully press the release pin downwards -arrow-.

– Check fuel system for leaks ⇒ page 316 .
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 ➤
4 High-pressure pump
⇒ “4.1 Removing and installing high-pressure pump”, page 347
⇒ “4.2 Checking high-pressure pump”,
wage
page
n AG. V350
olkswagen AG
doe
olks s no
yV t gu
4.1 Removingrisand
ed
b
installing high-pressure ara
nte
pump s autho eo
ra
s c
ce
e
nl
pt
du
Caution
an
itte
y li
erm
ab
♦ Risk of irreparable damage to high-pressure pump if al‐
ility
ot p
lowed to run dry.
wit
, is n
h re
♦ The high pressure pump must be filled with fuel before the
hole
spec
engine is started the 1st time ⇒ page 316 . (It is important
es, in part or in w
not to allow the high-pressure pump to run while still emp‐
t to the co
ty.)
rrectness of i
l purpos

equipment required
nf
ercia
orm
m
atio
♦ Puller - T40064-
om
n in
or c
♦ Thrust piece - T40064/1-
thi
te
sd
iva

o
r
rp
cu
- V.A.G 1331-
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. High-pressure pump 347

Amarok 2011 ➤
♦ Pliers - 3314-
Removing
⇒ page 116 .
– Removing toothed belt from camshaft and high-pressure
pump ⇒ page 107 .
– Undo and remove bolts -2- for high-pressure line -1-.
– Remove union nuts and remove high-pressure line -1-.
– Place removed high-pressure line -1- on a clean
wage
n AGsurface.
. Volkswagen AG
doe
ks s no
Vol t gu
d by ara
e nte
ris
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
– Detach connector -arrow- from fuel metering valve - N290- .

spec
– Loosen clips from fuel hoses -1- and pull fuel hoses off high-
t to the co
pressure pump.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
– Unscrew bolts -arrows- for high-pressure pump toothed belt

i
o
pr
cum
r
pulley.
fo
en
ng
t.
yi Co
– Remove pulley from high-pressure pump. Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Hold hub of high-pressure pump with counterhold - T10051-

and undo nut -1-.
– Position puller - T40064- with thrust piece - T40064/1- and pin

- T40064/2- as shown and pull hub off high-pressure pump. If
necessary, use a 24 mm open-ended spanner as a counter‐
hold.
– Free wiring harness above high-pressure pump from fittings,
and lay it to one side.
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 ➤
– Unscrew bolts -arrows- of high-pressure pump.

– Remove high-pressure pump.
Installing
Caution
After new or removed parts such as the fuel filter or fuel lines
have been fitted, the high-pressure pump must be efilled . Vwith
olkswagen AG
g n AG
fuel before the engine is started for the first time.olkAvoid
swa allowing does
not
the high-pressure pump to run dry undereall d b circumstances.
y V gu
ara
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
– Install high-pressure lines ⇒ page 338 .
rrectness of i
l purpos
Note
nf
ercia
♦ High-pressure lines may be re-used after the following checks:
orm
m
atio
♦ Check taper seat of high-pressure line for deformation and
om
n in
cracks.
or c
thi
e
♦ Line hole must not be deformed, constricted or damaged.

t
sd
iva
o
r
rp
cu

o
m
f
en
ng
t.
yi Co
op py
Specified torques t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4.2 Checking high-pressure pump


Amarok 2011 ➤
♦ Socket - T40055-
♦ Ratchet - V.A.G 1331/1-
♦ High-pressure pump tester - VAS 6683-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
WARNING
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
351
cted agen
Prote AG.
4. High-pressure pump
Amarok 2011 ➤
Procedure
WARNING

Note
♦ Adhere strictly to rules of cleanliness. No dirt must be allowed

to get into the union nut and the disconnected high-pressure
line.
♦ Clean all high-pressure connections with commercially avail‐
able degreaser before removing them.
Specified torques
. Volkswagen AG
gen AG does
Component Nm
Vol
ksw
a
not
y gu
db ara
High-pressure line on injector rise 30 nte
tho eo
High-pressure line on fuel rail s au 30 ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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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Amarok 2011 ➤
– Unscrew union nut -2- of high-pressure line -1- from cylinder

1.
– Loosen union nut -4- of high-pressure line -1- from fuel rail by
2 turns.
– Connect high-pressure pump tester - VAS 6683- -3- to union
nut -2- of open high-pressure line, screw on nut “to stop” and
tighten it by hand.
– Screw union nut -4- of high-pressure line -1- “to stop” onto fuel
rail and tighten by hand.
– Using torque wrench - V.A.G 1331- , ratchet - V.A.G 1331/1-
and socket - T40055- , tighten union nuts -2- and -4- to
specified torque of 30 Nm.
– Disconnect the 4 connectors of the injectors.
– Start engine. wage
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• Fuel must be supplied to the high-pressure pump testered
by - VAS ua
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6683- . horis tee
ut or
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Note
pt
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If there is fuel in the high-pressure pump tester - VAS 6683- , the
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high-pressure pump is “OK”.
wit
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Installing
spec
es, in part or in w
t to the co
Note
rrectness of i
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♦ The high-pressure line may be re-used after the following

checks:
nform
ercia
♦ Check taper seat of high-pressure line for deformation and

cracks.
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io
♦ The line hole must not be deformed, constricted or damaged.
n
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or
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– Using torque wrench - V.A.G 1331- , ratchet - V.A.G 1331/1-

en
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t.
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and socket - T40055- , tighten high-pressure line to specified Cop py
torque of 30 Nm.
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Amarok 2011 ➤
5 Intake manifold
⇒ “5.1 Assembly overview - intake manifold”, page 354
⇒ “5.2 Removing and installing intake manifold”, page 354
⇒ “5.3 Removing and installing throttle valve module J338 with
throttle valve potentiometer G69 and intake manifold flap motor
V157 ”, page 357
5.1 Assembly overview - intake manifold
1 - Oil dipstick
2 - Seal
3 - Gasket
4 - Bolt
❑ 8 Nm
5 - Intake manifold
⇒ page 354 .
6 - Gasket
7 - Bolt
❑ 20 Nm
8 - Pipe
❑ To cylinder head n AG. Volkswagen AG do
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9 - Clamp d b ua
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❑ 5 Nm autho
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10 - Connection
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11 - Bolt
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❑ 8 Nm
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12 - Seal
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spec
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13 - Throttle valve module -

t to the co
J338- with throttle valve poten‐

tiometer - G69- and intake
manifold flap motor - V157-
rrectness of i

l purpos
⇒ page 357 .
14 - Bolt
nf
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❑ 8 Nm
orm
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15 - Bolt
om
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❑ 9 Nm
or
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16 - Clip
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5.2 Removing and installing intake manifold
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Amarok 2011 ➤
AG. Volkswagen AG d
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♦ Socket set, 22 piece - VAS 5528-
es, in part or in w
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♦ XZN 8 bit - T40159- or Torx T 30 bit - T10405- t. Cop py
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– Remove high-pressure accumulator (fuel rail) ⇒ page 340 .
agen
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– Pull connector off glow plugs ⇒ page 405 .

– Free fuel lines and engine wiring harness above intake mani‐
fold from fittings, and lay them to one side.
– Undo and remove bolts from charge air pipe bracket -2- at
coolant pipe -1-.
5. Intake manifold 355

Amarok 2011 ➤
– Loosen screw-type clip -2- and pull charge air pipe -1- off
throttle valve control module - J338- together with throttle
valve potentiometer - G69- and intake manifold flap motor -
V157- .
AG. Volkswagen AG d
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– Pull connector -2- off throttle valve module - J338- together
pt
du
an
with throttle valve potentiometer - G69- and intake manifold
itte
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flap motor - V157- .
ab
ility
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Note
hole
spec
es, in part or in w
Bolt -1- for oil dipstick has already been removed!
t to the co
rrectness of i
l purpos
nf
– Continue releasing oil dipstick by forcing off the spreader clip
ercia
o
with removal lever - 80 - 200- .
rm
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– Loosen clip -1- and remove screws -2-.

– Remove connecting pipe.

Amarok 2011 ➤
– Undo and remove bolts holding intake manifold in place

-arrows- in diagonal sequence from the outside to the inside
with XZN 8 bit - T40159- or Torx T30 bit - T10405- .
– Carefully remove intake manifold upwards.
Installing AG. Volkswagen AG d
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Installation is carried out in the reverse order; note the following: by
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Renew all gaskets and seals.
itte
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ility
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– Tighten bolts holding intake manifold in place -arrows- in di‐
, is n
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agonal sequence from the inside to the outside with XZN 8 bit hole
- T40159- or Torx T30 bit - T10405- .
spec
es, in part or in w
t to the co
– Observe instructions for installing high-pressure lines
⇒ page 338 .
rrectness of i
– The fuel system must first be filled with fuel before the engine
l purpos
is started ⇒ page 316 .

Specified torques
nf
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orm
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5.3 Removing and installing throttle valve
o
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module - J338- with throttle valve poten‐
en
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t.
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op
tiometer - G69- and intake manifold flap
C py
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motor - V157-
p by
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Removing
Removing screw-type clips ⇒ page 11 .
5. Intake manifold 357

Amarok 2011 ➤
– Loosen clamp -1- and detach connecting pipe.
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– Pull connector -2- off throttle valve module - J338- together
ole,
with throttle valve potentiometer - G69- and intake manifold
spec
flap motor - V157- .
t to the co
– Undo bolts -arrows- and remove throttle valve module - J338-
together with throttle valve potentiometer - G69- and intake
manifold flap motor - V157- -4-.
rrectne
Installing
ss
o
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f inform
Specified torques
mer
atio
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o
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Prote AG.

Amarok 2011 ➤
6 Senders and sensors

⇒ “6.1 Removing and installing air mass meter G70 ”, page 359
⇒ “6.2 Removing and installing exhaust pressure sensor 1 G450
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⇒ “6.3 Removing and by
ed installing fuel pressure regulating valve
ua
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⇒ “6.4 Checking
ss fuel pressure regulating valve N276 ”,
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⇒ “6.5 Removing and installing fuel pressure sender G247 ”, page
erm
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365
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6.1 Removing and installing air mass meter
h re
hole
- G70-
spec
es, in part or in w
t to the co
rrectness of i
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– Pull off connector -3- for air mass meter - G70- . Prote AG.
– Loosen screw-type clip -4- and remove intake hose from air
mass meter - G70- .
6. Senders and sensors 359

Amarok 2011 ➤
– Unscrew bolts -arrows- from air mass meter - G70- and care‐
fully pull air mass meter - G70- -1- out of air filter housing
guide.
Installing
To ensure the proper function of the air mass meter - G70- , it is
important to observe the following notes and instructions. agen
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♦ If the air filter element is very dirty or wet, dirt or water could
ce
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un
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reach the air mass meter - G70- and affect the air mass value.
an
d
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This would lead to loss of power, since a smaller injection
y li
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quantity is calculated.
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♦ Always use genuine part for air filter element.
is n
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ole,
♦ Use a lubricant (silicon) to amount the air intake hose.
spec
t to the co
– Check for salt residues, dirt and leaves in air mass meter -
G70- and air intake hose (pure air side).
rrectne
– Check intake channel for contamination as far as air filter el‐
ement. If contamination is found, remove salt residues, dirt
and leaves from top and bottom part of air filter housing by
ss
rinsing out or using a vacuum cleaner if necessary.
o
cial p
f inform
Specified torques
mer
atio
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o
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6.2 Removing and installing exhaust pres‐

t
sd
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sure sensor 1 - G450-
um
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Amarok 2011 ➤
Removing
Note
Some connectors are difficult to see. A small hand-held mirror is

required to unscrew and insert the threaded connection.
Note
Exhaust pressure sensor 1 - G450- -arrow- is located on rear left

engine bracket.
– Release connector -2- and pull off from exhaust gas pressure
sensor 1 - G450- -1-.
– Undo and remove bolt -3- in bracket
en AG.-4-
Volkand
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gas pressure sensor 1 - VG450-wag-1-. does
olks not
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– Open spring-type clips -1- and pull hoses off -2 and 3-.
es, in part or in w
t to the co
rrectness of i
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Prote AG.

Amarok 2011 ➤
– Undo and remove bolt -2- on line retainer -1- and detach line
retainer -1- from vacuum pump -3-.
– Completely remove exhaust gas pressure sensor 1 - G450- .
Installing
wage
Installation is carried out in the reverse olks order; note the following:
es n
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Note ss
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If exhaust pressure sensor 1 - G450- is renewed, then adaptation
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must be carried out using ⇒ Vehicle diagnostic tester.
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ility
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Specified torques
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spec
es, in part or in w
t to the co
6.3 Removing and installing fuel pressure
regulating valve - N276-
rrectness of i
l purpos
The fuel pressure regulating valve is located in the high pressure

accumulator. The valves ensure that pressure is constant in the
high pressure accumulator and in the injector lines (fuel high
nform
ercia
pressure circuit).
m
at
om
If pressure is too high in the fuel high pressure circuit, the regu‐
ion
c
lating valve will open. A small amount of fuel from the high
in t
or
pressure accumulator will thereby make its way back to the fuel his
ate
tank via the return line.

do
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cum
or
If pressure is too low in the fuel high pressure circuit, the regulat‐
f
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ng
t.
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ing valve will close. The valve seals the high pressure side against
Co
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the low pressure side in this way.
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Procedure
co lksw
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Prote AG.
Note
Fuel pressure regulating valve - N276- must be renewed each

time after removing.
Caution
Read through the rules for cleanliness and the instructions for
working on the fuel system ⇒ page 7 .
ing on the fuel system.
– Clean threaded area around the regulating valve with com‐

mercially available degreaser, for example, before removing
it. Under no circumstances may dirt enter the hole of the high-
pressure accumulator (fuel rail).
Note
Clean carefully; cleaning solvent must not enter the electrical

connector.
– Dry fuel pressure regulating valve - N276- .

Amarok 2011 ➤
– Remove high-pressure accumulator (fuel rail) ⇒ page 340 .

– Clamp high-pressure accumulator (fuel rail) in a vice with pro‐
tective jaws.
– Counterhold at 36 mm hexagon -3- and loosen 30 mm union
nut -2-. Then unscrew regulating valve by hand.
– Use suction device to extract dirt from high-pressure accumu‐
lator bore (threads and sealing surface). Do not use any
mechanical tools to do this.
Note
Seal off high-pressure accumulator hole immediately with a suit‐

able plug to prevent dirt from entering.
Installing
WARNING
agen
AG. Volkswagen AG d
oes
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For vehicles with solenoids,
orise the learnt values from the fuel sys‐ ante
d
tem must be reset following
au
th the renewal of the fuel pressure eo
ra
regulating valve - N276-
ss ⇒ Vehicle diagnostic tester. c
ce
le
un
pt
an
d
itte
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ab
ility
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Note
wit
is n
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ole,
♦ The fuel pressure regulating valve - N276- has a deformable

spec
sealing lip and no separate seal; it can therefore be used only
once. t to the co
♦ Check that sealing surfaces (deformable sealing lip) and
threads on fuel pressure regulating valve - N276- are undam‐
rrectne
aged.
♦ Check the sealing surface of the high-pressure accumulator
ss
hole as well.
o
cial p
f inform
♦ Thread on fuel pressure regulating valve - N276- must be free

mer
of oil and grease.

atio
om
n
c
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or
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Amarok ir se 2011 ➤
d ran
tee
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4-cylinder
auth diesel engine (2.0 l engine, common rail) or -
ac Edition 04.2013
ss
ce
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– Renew seal -1-.
nl
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– Tighten union nut -2- by hand.
erm
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ility
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Note
h re
hole
spec
Connector connection piece must point vertically upwards.
es, in part or in w
t to the co
– Align fuel pressure regulating valve - N276- so that connector
connection piece points vertically upwards.
rrectness of i
– Counterhold at housing hexagon -3- and tighten union nut
l purpos
-2-.
– Bleeding fuel system ⇒ page 316 .
nform
ercia
– After mounting, leave engine running at moderate speed for a

m
at
om
few minutes and then switch off again.
ion
c
in t
or
his
ate
do
riv

p
cum
for
en
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– Then test drive the vehicle, accelerating to full throttle at least

n
t.
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once. Check high pressure part of fuel system again for leaks. Cop py
t. rig
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– Read event memory again. p by
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Specified torques Prote AG.
6.4 Checking fuel pressure regulating valve

- N276-
♦ Transparent measuring beaker ≥ 500 ml
WARNING

Procedure
WARNING


Amarok 2011 ➤
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♦ Adhereaustrictly
th to the rules for cleanliness; no dirt muste obe r a al‐
lowedssto get into the disconnected return line and the open c
return line connection.
ce
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un
pt
an
d
itte
♦ Clean all return line connections with commercially available
y li
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ab
degreaser before removing them.
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is n
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ole,
spec
– Release spring-type clip -arrow- and pull fuel return hose off
fuel rail.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
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– Seal the open fuel return hose -1- with a clean sealing plug.
um
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fo
en
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t.
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– Connect an auxiliary hose -2- to return connection of fuel rail
Co
op py
-3-.
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rig by
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– Hold auxiliary hose in measuring beaker -4- to measure return
co Vo
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flow rate. Prote AG.
– Start engine and run at idling speed for 30 seconds.
Note
The fuel in the auxiliary hose is disregarded for determining the

return flow rate.
• Specified amount in 30 seconds: 90 ... 110 ml

If the specification is not attained, the fuel pressure regulating
valve - N276- is defective and must be renewed ⇒ page 364 .
Installing
– Installation is performed in the reverse sequence.
6.5 Removing and installing fuel pressure

sender - G247-

Amarok 2011 ➤
Fuel pressure sender - G247- is located in high-pressure accu‐

mulator. It measures the fuel pressure and sends a voltage signal
to the control unit for direct diesel injection system - J248- .
In the event of sender failure, pressure regulation is controlled
using a map from the engine control unit. In back-up function, the AG. Volkswagen AG d
maximum engine speed is limited to approx. 3000 rpm. olksw
agen oes
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Removing ris
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Caution s
ce
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nl
pt
du
an
itte
Read through the rules for cleanliness and the instructions for
y li
erm
ab
working on the fuel system ⇒ page 7 .
ility
ot p
wit
, is n
h re
ing on the fuel system.
hole
spec
es, in part or in w
t to the co
– Clean threaded area around the regulating valve with com‐
mercially available degreaser, for example, before removing
it. Under no circumstances may dirt enter the hole of the high-
rrectness of i
pressure accumulator (fuel rail).
l purpos
Note
nf
ercia
orm
Clean carefully; cleaning solvent must not enter the electrical
m
atio
m
connector.
o
n in
or c
thi
te
sd
– Dry fuel pressure sender - G247- .

iva
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rp
cu
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f
en
ng
t.
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Cop py
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Release connector -1- from fuel pressure sender - G247- -2-

and pull off.
– Unscrew fuel pressure sender - G247- .
– Use suction device to extract dirt from high-pressure accumu‐
lator bore (threads and sealing surface). Do not use any
mechanical tools to do this.
Note
Seal off high-pressure accumulator hole immediately with a suit‐

able plug to prevent dirt from entering.
Installing
Installation is carried outswinagthe
en Areverse
G. Volkswaorder;
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does
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Note utho eo
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♦ Check that sealing surfaces (deformable sealing lip) and

nl
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du
threads on fuel pressure sender - G247- are undamaged.
an
itte
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ab
♦ Check the sealing surface of the high-pressure accumulator
ility
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hole as well.
wit
, is n
h re
♦ Thread of fuel pressure sender - G247- is coated with an anti-
hole
spec
friction lacquer. The thread must therefore be free of oil and
es, in part or in w
grease. t to the co
– Tighten fuel pressure sender - G247- by hand.

rrectness of i
– Tightening sender.
l purpos
– Bleeding fuel system ⇒ page 316 .

– After mounting, leave engine running at moderate speed for a
nform
ercia
few minutes and then switch off again.

m
at

om
ion
c
in t
r

o
his
ate
do
riv
– Then test drive the vehicle, accelerating to full throttle at least

p
cum
or
once. Check high pressure part of fuel system again for leaks.
f
en
ng
t.
yi Co
– Read event memory again. t. Cop py
rig
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Specified torques p by
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♦ ⇒ “1.3 Assembly overview - fuel system”, page 311 Prote AG.

Amarok 2011 ➤
7 Air filter
⇒ “7.1 Assembly overview - air filter”, page 368
⇒ “7.2 Removing and installing air filter”, page 370
7.1 Assembly overview - air filter

AG. Volkswagen AG d
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1 - Air duct by Vo gu
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ed
❑ Check for secure en‐ horis nte
eo
gagement. s aut ra
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s
2 - Rubber bush
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un
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❑ Clipped into lower part

itte
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of air filter.
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3 - Air filter lower part
wit
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ole,
4 - Bolt
spec
❑ Rubber bush clipped in‐
t to the co
to lower part of air filter.
❑ 8.5 Nm
rrectne
5 - Water drainage pipe
⇒ page 370
s
❑ Clipped onto lower part
s o
of air filter.
cial p
f inform
❑ Make sure it is mounted
mer
in correct position on
atio
m
longitudinal member
o
n
c
i
or
n
❑ Clean if soiled
thi
te
sd
va
6 - Filter element
i
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pr
cum
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fo
❑ Renewng air filter: clean

en
ng
t.
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and replace filter ele‐
Co
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ment ⇒ Maintenance ;
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Booklet 11 p by
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❑ Renewing air filter: with
agen
Prote AG.
saturation indication in
dash panel insert
⇒ Maintenance ; Book‐
let 11
7 - Air filter upper part
8 - Bolt
❑ 2 Nm
9 - O-ring
10 - Intake manifold pressure sender - G71-
11 - Bolt
❑ 1.6 Nm
12 - Bracket
❑ For coolant hose mounting.
13 - O-ring
14 - Air mass meter - G70-

Amarok 2011 ➤
15 - Bolt
❑ 1.6 Nm agen
AG. Volkswagen AG d
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16 - Screw-type clip d by ara
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The screw-type clips on
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the charge air lines must
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always be tightened to
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5.5 Nm. If the torque is
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too low or too high, the
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charge air hose may slip
hole
spec
off the charge air pipe
es, in part or in w
during vehicle operation.
t to the co
❑ 5.5 Nm
rrectness of i
17 - Intake hose
l purpos
❑ It is essential that the marks on intake hose be in line with the webs on the turbocharger.
❑ Clean oil from ends of hoses before installing.
nf
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❑ Do not use lubricants containing oil.
rm
m
atio
❑ To turbocharger.
om
n in
c
❑ With heater element for crankcase breather - N79- and connection for crankcase breather/cylinder head
or
thi
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cover connecting pipe.

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18 - Screw-type clip
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The screw-type clips on cop Vo
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the charge air lines must
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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.
❑ 5.5 Nm
19 - Vacuum hose
20 - Bracket
❑ For wiring harness.
21 - Heat shield
22 - Bolt
❑ 2 Nm
23 - Mounting for air duct
❑ Secured to lock carrier.
❑ Check for secure engagement.
24 - Bolt
❑ 8.5 Nm
7. Air filter 369

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ris ee 04.2013
t or
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s
Water drainage pipe on lower part of air filter
ce
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nl
pt
du
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– Water drainage pipe -1- is clipped into lower part of air filter
itte
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7.2 Removing and installing air filter
nform
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Removing
– Pull vacuum hose -1- off upper part of air filter.
– Remove cowling -3- from lower part of air filter and unscrew
securing bolt -2- for bracket.

Amarok 2011 ➤
lks wage es n
– Pull off connector -1- for intake manifold pressure Vosender - ot g
by ua
G71- . rised ran
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– Unclip coolant hose -2- from bracket ons aupper
u part of air filter. ac
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– Pull off connector -3- for air mass meter - G70- .
un
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itte
– Loosen screw-type clip -4- and remove intake hose from air
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mass meter - G70- .
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– Open screwed-attached clip -2- and pull intake pipe -4- off the
is n
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air filter container.
ole,
spec
– Unclip wiring harness from brackets on air filter housing.
t to the co
– Unscrew securing bolt -2- ⇒ Item 4 (page 368) for air filter
rrectne
housing -1- in area of coolant expansion tank.
– Pull air filter out of mountings.
ss o
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Installing
inform
mer
atio
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Specified torques
n
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Cop py
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7. Air filter 371

Amarok 2011 ➤
8 Engine control unit

⇒ “8.1 Removing and installing engine control unit”, page 372
⇒ “8.2 Renewing engine control unit”, page 372
8.1 Removing and installing engine control

unit
Removing
– Switch off ignition.
AG. Volkswagen AG d
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 . agen oes
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– If fitted, remove shear-head bolts -1- using a suitablerise tool and
d
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remove retaining bar -4-. autho eo
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ss c
– Release and pull off connectors -2- and -3-.
ce
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nl
pt
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– Pull engine control unit out of its bracket.
itte
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Installing
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Note
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Use new shear-head bolts.
rrectness of i
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8.2 Renewing engine control unit
nf
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Note
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n in
c
The diesel direct injection system control unit is equipped with an

or
thi
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event memory. Read event memory before and after making re‐
t
sd
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pairs or adjustments ⇒ Vehicle diagnostic tester.

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• When the engine control unit is renewed, the “injector de‐ cted agen
Prote AG.
livery calibration values” must be written into the new
engine control unit ⇒ page 327 .
Removing
– Before removing engine control unit, read identification and
coding of present control unit ⇒ Vehicle diagnostic tester.
– Remove engine control unit ⇒ page 372 .

Amarok 2011 ➤
– Remove shear-head bolts -2- using a suitable tool and remove

bracket -1-.
Installing
wage e
Installation is carried
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Use new shear-head bolts.
an
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– Install engine control unit ⇒ page 372 .
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– Check previous coding and code new control unit ⇒ Vehicle
h re
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diagnostic tester.
spec
t to the co
rrectness o
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mer
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n
c
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8. Engine control unit 373

Amarok 2011 ➤
26 – Exhaust system
1 Exhaust pipes, silencers
⇒ “1.1 Assembly overview - silencers”, page 374
⇒ “1.2 Checking exhaust system for leaks”, page 375
⇒ “1.3 Aligning exhaust system free of stress”, page 375
1.1 Assembly overview - silencers
1 - Screw-type clip
tion.
❑ 35 Nm
2 - Rubber mounting
tion ⇒ page 375 .
3 - Front silencer
❑ Removing:
– Remove front propshaft.
– Remove gearbox sup‐ AG. Volkswagen AG d

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– Detach front/rear silenc‐ss a c
ers at separating point.
ce
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pt
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– Undo bolts holding

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hanger
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⇒ Item 6 (page 374) on

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gearbox cross member.

h re
hole
spec
– Detach front silencer

es, in part or in w
from rubber mounting

t to the co
⇒ Item 2 (page 374) and

completely remove front
silencer.
rrectness of i
4 - Rear silencer
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❑ Removing:
nform
ercia
– Detach front and rear si‐

lencers at separating
m
at
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point.
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– Detach rear silencer

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⇒ Item 2 (page 374) and completely remove rear silencer.

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❑ Installation of double clamp ⇒ page 375 Prote
cted AG.
agen
❑ 31 Nm
6 - Mounting
❑ Fasten mounting on gearbox cross member ⇒ page 375
374 Rep. gr.26 - Exhaust system

Amarok 2011 ➤
7 - Bolt
❑ 20 Nm
Fasten mounting on gearbox cross member

– Secure mounting -2- to gearbox cross member -1- with bolts
-3-.
Installation of double clamp

– Mark the distances 39 mm -a and b- at end of pipe of front
silencer -2- and beginning of pipe of rear silencer -1- - 4-.
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du
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tighten bolts -3- for double clamp.
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Installation location of rubber mounting
hole
spec
es, in part or in w
– Align rubber mounting -1- in such a way that the distance -a-
t to the co
is 8 mm.
rrectness of i
Note
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Check entire installation location of exhaust system.

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1.2 Checking exhaust system for leaks

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– Start engine and run at idling speed.

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– Check (by listening) points of connection between exhaust
AG.
manifold and cylinder head, and between turbocharger and

front exhaust pipe to make sure there are no leaks.
– Rectify any leaks that are found.
1.3 Aligning exhaust system free of stress

1. Exhaust pipes, silencers 375

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♦ Torque wrench (5…50 Nm) - V.A.G 1331- ss
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• Exhaust system must be aligned when cold.
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Procedure
form
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– Loosen bolts of double clamp -3-.
om
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– Tighten bolts hand tight.
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– Align exhaust system until the marking- 4- is visible.

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– Align bolts of double clamp -3- horizontally.

– Align rubber mountings -1- for front silencer -2- and rear si‐
lencer -1- in such a way that dimension -a- is 8 mm.
– Tighten bolts for double clamp -3-.
Specified torques
♦ ⇒ “1.1 Assembly overview - silencers”, page 374

Amarok 2011 ➤
2 Cleansing exhaust emissions

⇒ “2.1 Assembly overview - emission control (diesel particulate
filter)”, page 377
⇒ “2.2 Assembly overview - emission control (catalytic convert‐
er)”, page 379
⇒ “2.3 Removing and installing particulate filter”, page 381
⇒ “2.4 Removing and installing catalytic converter”, page 387
2.1 Assembly overview - emission control (diesel particulate filter)

AG. Volkswagen AG d
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1 - Screw-type clip d b ara
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❑ Always renew aut after re‐
ho eo
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moving ss c
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❑ Fit screw-type clip by

un
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hand
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❑ When installing, first fit
pe
ility
screw-type clip on tur‐
ot
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bocharger for exhaust
h re
pipe.
hole
spec
❑ 8 Nm
es, in part or in w
t to the co
2 - Gasket
rrectness of i
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3 - Lambda probe - G39- nform

ercia
❑ Grease only thread. The

high-temperature paste
m
⇒ Electronic parts cata‐

com
tion in
logue (ETKA) must not

r
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get into the slots on the

thi
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probe body.
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❑ 50 Nm
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4 - Control line with union nut t. Cop py
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❑ 20 Nm
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sender 3 - G495-
using high-temperature
paste ⇒ Electronic
Parts Catalogue (ET‐
KA) .
❑ Connector (brown) at
coupling point of air filter
❑ 45 Nm
6 - Exhaust gas temperature sender 4 - G648-
❑ Grease thread of sender using high-temperature paste ⇒ Electronic Parts Catalogue (ETKA) .
❑ Connector (orange) at coupling point of air filter
❑ 45 Nm
2. Cleansing exhaust emissions 377

Amarok 2011 ➤
7 - Bracket with control lines

8 - Clip
9 - Control pipe
10 - Union nut
❑ 20 Nm
11 - Exhaust gas pressure sensor 1 - G450-
❑ Adaptation is necessary after this component has been renewed ⇒ Vehicle diagnostic tester.
12 - Bolt
❑ 5 Nm
13 - Front exhaust pipe
❑ Take into account the fact that there are different types ⇒ ETKA (electronic parts catalogue)
❑ Handle carefully to avoid damage.
• Transport shock-free.
• Do not kink flexible hose.
• Do not stretch flexible hose.
14 - Particulate filter
• Assembly sequence must be adhered to during installation to ensure stress-free installation.
♦ Position particulate filter with new gasket ⇒ Item 2 (page 377) and new screw-type clip
⇒ Item 1 (page 377) .
♦ Tighten screw-type clip ⇒ Item 1 (page 377) .
15 - Bracket
❑ Secured to gearbox on right n AG. Volkswagen AG do
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❑ Attaching bracket to gearbox
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16 - Bolt oris tee
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❑ 20 Nm au ac
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17 - Bracket
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❑ Fastened to engine support on right

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❑ Metal type
ility
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❑ Fasten to bracket on engine support ⇒ page 380

is n
h re
ole,
18 - Bolt
spec
❑ 20 Nm
t to the co
19 - Mounting
rrectness o
cial p
f inform
mer
atio
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n
c
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Cop py
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Prote AG.

Amarok 2011 ➤
4-cylinder
wag en AG.diesel
Volkswaengine
gen AG (2.0 l engine, common rail) - Edition 04.2013
doe
ks s no
Vol t gu
by ara
2.2 Assembly overview - emission control (catalytic converter)
ed
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nl
Note
pt
du
an
itte
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♦ After working on the exhaust system, ensure that the system is not under stress and that there is sufficient
ility
ot p
clearance to the bodywork. Loosen double clamp and clip if necessary. Align silencer and exhaust pipe so
wit
, is n
that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.
h re
hole
spec
es, in part or in w
t to the co
1 - Screw-type clip
rrectness of i
❑ Always renew after re‐
moving
l purpos
❑ Fit screw-type clip by

hand
nf
ercia
o
❑ When installing, first
rm
m
fasten the screw-type
atio
m
clip for the exhaust pipe

o
n in
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on turbocharger
thi
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❑ 8 Nm
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2 - Gasket
f
en
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t.
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❑ Renew after removing t. Cop py
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3 - Front exhaust pipe with cat‐
alytic converter
❑ Take into account the
fact that there are differ‐
ent types ⇒ ETKA (elec‐
tronic parts catalogue)
❑ Handle carefully to
avoid damage.
❑ When installing, first
fasten the top screw-
type clip for the exhaust
pipe on turbocharger
• Transport shock-free.
• Do not kink flexible hose.
• Do not stretch flexible hose.
⇒ page 387 .
4 - Bolt
❑ 20 Nm
5 - Bracket
❑ Secured to gearbox on right
❑ Attaching bracket to gearbox ⇒ page 380
6 - Bolt
❑ 20 Nm
7 - Bracket
❑ Fastened to engine support on right
❑ Metal type
❑ Attaching bracket to engine support ⇒ page 380

Amarok 2011 ➤
8 - Bolt
❑ 20 Nm
9 - Bolt
❑ 20 Nm
Fasten to bracket on gearbox

– Secure bracket -2- to gearbox -1- with bolts -3-.
Fasten bracket to engine support

– Secure bracket -2- to engine support -1- with bolts -3-.
AG. Volkswagen AG d
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Prote AG.

Amarok 2011 ➤
olkswagen AG
4-cylinder
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2.3 Removing and installing particulate filter
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♦ Torque wrench (5…50 Nm) pe
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Prote AG.

Amarok 2011 ➤
Removing
WARNING
Risk of burns.
Parts of the exhaust system may be hot.
Allow exhaust system to cool before removing.
tions:
sitions.
♦ Cut through cable ties carefully and install new ones in the
same position.
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Prote AG.

Amarok 2011 ➤

ing harness -2- from intake hose -3-.
– Open clips -1- and -4- and remove intake hose -3- together
with pipe -5-.
– Remove air filter ⇒ page 368 .
– Disconnect connectors -1, 2 and 3- for exhaust gas tempera‐

ture sender 1 - G235- (black connector), exhaust gas temper‐
ature sender 3 - G495- (brown connector) and exhaust gas
temperature sender 4 - G648- (orange connector) at coupling
point (in front of air filter).
– Loosen cable ties -3-, free lines -1 and 2- from fittings, and lay
them to one side.
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– Clamp off coolant hose -2- with hose clamps up to 25 mm -

t to the co
3094- .
– Open spring-type clip -1- for coolant hose -2- and pull coolant
rrectness of i
hose off.
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agen
Prote AG.
Amarok 2011 ➤
– Open spring-type clips -1- and pull hoses -2 and 3- off control
lines for particulate filter.
– Undo and remove bolt -2- for coolant pipe -1- at wheel housing
and tie on coolant hose somewhere at a slightly higher point.
Note
Do not bend coolant pipe.
– Undo screw -1- of screw-type clamp -2- between particulate

filter and turbocharger and remove clamp -2-.
– Undo and remove bolts -3- for particulate filter bracket -4-.
AG. Volkswagen AG d
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pt
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– Undo screw -1- of clamp -2-.

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– Undo and remove bolts -3- for exhaust pipe bracket -4-.
ot p
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Prote AG.

Amarok 2011 ➤
– When removing particulate filter, push -1- the coolant pipe

-2- a little to one side.
– Carefully remove particulate filter -1- upwards out of the en‐
gine compartment.
Installing
Caution
Ensure particulate filter is not stressed when installed.

The particulate filter could be damaged.
Follow installation sequence.
Use new clips and gaskets.
• Assembly sequence for installation of particulate filter must be

adhered to during installation to ensure stress-free installation.
AG. Volkswagen AG d
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Prote AG.

Amarok 2011 ➤
lkswage es n
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spec
♦ When installing particulate filter, push -1- the coolant pipe -2-
t to the co
a little to one side.
♦ Install particulate filter -1- carefully.
rrectne
♦ Screw in bolts -3- for particulate filter bracket -4- a few turns.
s
♦ Position particulate filter with new gasket
s o
⇒ Item 2 (page 377) and new screw-type clip
cial p
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⇒ Item 1 (page 377) .
form
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♦ Fit exhaust pipe bracket -4- and tighten bolts -3- hand-tight.
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♦ Tighten screw -1- for screw-type clip ⇒ Item 1 (page 377) -2-.
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♦ Tighten screw -1- for clamp -2-. cop Vo
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cted agen
Prote AG.
– Fasten lines -1 and 2- with new cable ties -3-.

Amarok 2011 ➤
– Connect connectors -1, 2 and 3- for exhaust gas temperature

sender 1 - G235- (black connector), exhaust gas temperature
sender 3 - G495- (brown connector) and exhaust gas temper‐
ature sender 4 - G648- (orange connector) at coupling point
(in front of air filter), and make sure they engage securely.
– Install air filter ⇒ page 368
Note
If a new particulate filter was installed, connect ⇒ Vehicle diag‐

nostic tester and carry out “Ash mass comparison”.
Specified torques
♦ ⇒ “2.1 Assembly overview - emission control
agen
AG.(diesel particu‐
Volkswagen AG
does
late filter)”, page 377 olksw not
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♦ ⇒ “7.1 Assembly overviewtho-risair filter”, page 368 e or
au ac
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2.4 Removing and installing catalytic con‐
ce
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iva
♦ Lambda probe open ring spanner set - 3337-

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Amarok 2011 ➤
Removing
lkswage es n
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nl
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itte
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ab
ility
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hole
with pipe -5-.
spec
es, in part or in w
– Remove air filter ⇒ page 368
t to the co
– Pull vacuum hose -2- off vacuum unit of exhaust gas recircu‐
lation cooler and vacuum hose -1- off regulating flap potenti‐
rrectness of i
ometer - G584- .
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi
– Loosen screw -2- for clamp -1- between exhaust pipe -4- and
Co
op py
turbocharger.
t. C rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Loosen clamp -3- on exhaust pipe -1- and pull exhaust pipe
-1- off a little.

Amarok 2011 ➤
– Undo and remove bolts -3- holding exhaust pipe -2- on gear‐
box bracket -1-.

pling point -2-. Then, free wiring nharness from
AG. Volksw agen fittings
AG do and lay
it to one side. olks
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– Carefully remove front
ris exhaust pipe upwards out of the engine
ed ran
tee
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or
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ss
Installing
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erm
ab
– Use new clips and gaskets.
ility
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– Install front exhaust pipe and first fasten the top screw-type
h re
clamp for the exhaust pipe on turbocharger
hole
spec
– Secure front exhaust pipe with all brackets, and fit screw-type
es, in part or in w
t to the co
clip ⇒ Item 1 (page 374) at bottom.
– Install air filter ⇒ page 368 rrectness of i
Specified torques
l purpos

nform
ercia

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at
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ion
c
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for
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Cop py
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pyri by
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Prote AG.

Amarok 2011 ➤
3 Exhaust gas recirculation

⇒ “3.1 Assembly overview - exhaust gas recirculation”,
page 390
⇒ “3.2 Assembly overview - exhaust gas recirculation, 132 kW
engine”, page 391
⇒ “3.3 Removing and installing exhaust gas recirculation cooler”,
page 392
⇒ “3.4 Removing and installing exhaust gas recirculation cooler,
132 kW engine”, page 398
⇒ “3.5 Removing and installing exhaust gas recirculation valve
N18 , 132 kW engine”, page 400
⇒ “3.6 Removing and installing changeover valve for exhaust gas
recirculation cooler N345 ”, page 401 en AG. V
olkswagen AG
ag does
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⇒ “3.7 Checking exhaust gas recirculation cooler Vol leaks”, page
yfor gu
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3.1 Assembly overview - exhaust gas recirculation ss c
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nl
pt
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valve - N18- with exhaust gas
ility
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recirculation potentiometer -
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G212-
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2 - Vacuum unit for exhaust
es, in part or in w
flap
t to the co
cooler
rrectness of i
⇒ page 392 .
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5 - Bolt
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For better accessibility and to en‐

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sure the correct torque for the bolts C py
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hexagon bolts with part number »N
cted agen
Prote AG.
107 188 01« can be used.
❑ First, fit bolts on turbo‐
charger side and screw
them in hand-tight.
❑ 8 Nm
6 - Gasket
7 - Bolt
❑ 20 Nm
8 - Lower pipe
9 - Gasket

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
10 - Bolt olksw not
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❑ 20 Nm rised
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11 - Bolt ss a ra
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12 - Upper pipe
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13 - Gasket
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14 - Bolt
t to the co
❑ 8 Nm
rrectne
3.2 Assembly overview - exhaust gas recirculation, 132 kW engine
ss o
cial p
f inform
mer
cooler
atio
om
n
c
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or
n
⇒ page 398 .
thi
te
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p
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❑ For exhaust gas recircu‐ yi

t.
Co
lation cooler. ht. Cop py
rig
rig ht
3 - Bolt py by
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Prote AG.
❑ 8 Nm
4 - Gasket
5 - Connecting pipe
❑ To exhaust gas recircu‐
lation valve - N18-
valve - N18-
⇒ page 400 .
7 - Connecting pipe
❑ From exhaust gas recir‐
culation cooler
8 - Bolt
❑ 20 Nm
3. Exhaust gas recirculation 391

Amarok 2011 ➤
3.3 Removing and installing exhaust gas recirculation cooler

equipment required
- V.A.G 1331-
Nm) - V.A.G 1332-
1410-
- VAS 6208-
6340- n AG. Volkswagen AG do
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♦ Hose clip pliers - VAS byV
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6362- ir se
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ility
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es, in part or in w
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rrectness of i
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mercia
at
om
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c
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ate
do
priv
cum
or

f
en
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t.
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op
♦ Hose clamps up to 25 mm - 3094- C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Small hand-held mirror

♦ Flexible magnet

Amarok 2011 ➤
Removing
Note
♦ Exhaust gas recirculation cooler is removed upwards. Conta‐

minated areas must be cleaned thoroughly after installing.
♦ To facilitate removal of the exhaust gas recirculation cooler,
remove the air filter housing and the exhaust pipe.
♦ For better accessibility and to ensure the correct torque for the
bolts of the exhaust gas recirculation cooler, hexagon bolts
with part number »N 107 188 01« can be used.
♦ Some connectors are difficult to see. A small hand-held mirror
is required to unscrew and insert the threaded connection.
♦ Note different bolt lengths for pipes.
♦ Renew gaskets and seals.
lkswage es n
o ot g
byV ua
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– Remove pipe -arrow- afrom
u th
cylinder head cover. or
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ab
ility
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mercia
at
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ion
c
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or
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ate
do
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Cop py
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Prote AG.

Amarok 2011 ➤

with pipe -5-.
– Remove air filter ⇒ page 368
AG. Volkswagen AG d
agen oes
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– Pull vacuumaut hose off vacuum unit of exhaust gas recirculation ra
s c
cooler -1-
s and vacuum hose from regulating flap potentiometer
ce
le
- G584- -2-.
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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spec
t to the co
rrectne
– Detach connectors -1- from exhaust gas recirculation valve -

ss
N18- -2- and regulating flap for potentiometer - G584- -3-.

o
cial p
f inform
Vehicles with particulate filter

mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
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ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Undo and remove bolt -2- for coolant pipe -1- at wheel housing
and tie on coolant hose somewhere at a slightly higher point.
– Remove particulate filter ⇒ page 381 .
Vehicles with engines compliant with EU 4 and EU 3 standards

AG. Volkswagen AG d
agen oes Amarok 2011 ➤
olksw not
V
d by 4-cylinder diesel guengine (2.0 l engine,
ara common rail) - Edition 04.2013
rise nte
tho eo
– Loosen
ss au
bolt -2- in screw-type clip -1- for front exhaust r a pipe
c
ce
le
un
pt
an
– Unscrew and remove bolts -3- in bracket for front exhaust pipe
d
itte
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-4-.
rm
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pe
ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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com
tion in
r
te o
thi
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iva
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Cop py
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cted agen
Prote AG.
-1-.

it to one side.
compartment.

Amarok 2011 ➤

3094- .
– Loosen spring-type clip -3- and remove coolant hose -2- at
exhaust gas recirculation cooler -1-.
– Undo and remove bolts -2- for pipe -1- and remove pipe from
exhaust gas recirculation cooler.
Note
The bolts -3- for the pipe -4- are not undone.

3094- .
– Open spring-type clip -1- for coolant hose -2- and pull coolant
hose off.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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aut ra
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un
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– Undo and remove bolts -2- and -3- for pipe -1- and remove
itte
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pipe.
rm
ab
pe
ility
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Note
hole
spec
es, in part or in w
Bear in mind the differences between the types of bolt!

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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396
AG.
Rep. gr.26 - Exhaust system
Amarok 2011 ➤
– Undo and remove bolts -2- at exhaust gas recirculation cooler

-1-.
– Undo and remove bolts -2- at exhaust gas recirculation cooler

-1-.
– Carefully remove exhaust gas recirculation cooler upwards.
– Clean contaminated areas thoroughly.
Installing
AG. Volkswagen A
Installation is carriedlkout
swa in the reverse order;
gen G do
enote
s no the following:
o t gu
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– Renew gaskets ed b and seals. ara
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
Note
wit
is n
h re
ole,
For better accessibility and to ensure the correct torque for the
spec
bolts -2- of the exhaust gas recirculation cooler on the turbo‐

charger side, hexagon bolts with part number N 107 188 01 can
t to the co
be used.
rrectne
– Replace both bolts -2- at exhaust gas recirculation cooler on

right with hexagon bolts (part number »N 107 188 01«), and
tighten hexagon bolts.
ss o
cial p
f inform
Note
mer
atio
om
♦ Note different bolt lengths for pipes.

c
i
or
n thi
te
♦ Only screw pipe bolts in loosely at first, then tighten.

sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
– Replace screw-type clamp -1- for front exhaust pipe -4-.

Specified torques
♦ ⇒ “3.1 Assembly overview - exhaust gas recirculation”,
page 390
3.4 Removing and installing exhaust gas re‐

circulation cooler, 132 kW engine
Special tools and workshop equipment required AG. Volkswagen AG d
agen oes
lksw not
♦ Hose clamps up to 25 mm - 3094- by
Vo gu
ara
ed
ris nte
ho eo
aut ra
s s c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Drip tray for workshop hoist - VAS 6208-
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
agen
Prote AG.

Amarok 2011 ➤
Note
♦ The exhaust gas recirculation cooler is removed upwards.

Contaminated areas must be cleaned thoroughly after instal‐
ling.
♦ Renew gaskets and seals.
Removing
– Clamp off coolant hose -2- leading to input to exhaust gas re‐
circulation cooler -1- with hose clams up to 25 mm - 3094- .
– Loosen clamp -3- and pull coolant hose -2- off exhaust gas
recirculation cooler -1-.
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
– Clamp off coolant hose -1- coming from output of exhaust gas
wit
, is n
recirculation cooler -3- with hose clams up to 25 mm - 3094- . h re

hole
spec
– Loosen clamp -2- and pull coolant hose -1- off output of ex‐
es, in part or in w
haust gas recirculation cooler -3-.

t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
– Undo and remove bolts -1 and 4- and remove connecting pipe

or
his
e
-5-.
at
do
priv

um
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 ➤
– Unscrew bolts -arrows- and remove bracket -1- of exhaust gas

agen
AG. Volkswagen AG d
oes
recirculation cooler. Volksw not
g by ua
ed ran
– Carefully remove exhaust gas recirculationhcooler
or
is upwards. tee
t or
au ac
Installing ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
First, screw in all pipe bolts loosely and then tighten them to
hole
spec
specified torque.
es, in part or in w
t to the co
Specified torques
♦ ⇒ “3.2 Assembly overview - exhaust gas recirculation, 132 kW
rrectness of i
engine”, page 391
l purpos
3.5 Removing and installing exhaust gas re‐
nf
ercia
circulation valve - N18- , 132 kW engine
orm
m
atio
m
Removing
o
n in
or c
thi
– Loosen clip -2- and pull pressure hose off throttle valve control
te
sd
iva
module - J338- .
o
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f
– Remove bolt -1- for dipstick guide tube.
en
ng
t.
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op
– Detach connector -3- from throttle valve control module -
C py
t. rig
gh
J338- .
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Undo and remove bolts -2 and 3- and remove pressure pipe

-1-.

Amarok 2011 ➤
– Release oil dipstick again. To this, force expanding clip -2- off,
using removal lever - 80 - 200- .
– Remove throttle valve module - J338- ⇒ page 357 .
– Undo and remove bolts -1 and 3- from connecting pipe -2-.
– Remove connecting pipe -2-.
AG. Volkswagen AG d
agen oes
ksw
– Undo and remove bolts -arrows- and remove exhaust by V gas re‐
ol not
gu
ara
circulation valve - N18- -1- from intake manifold.rised
nte
ho eo
ut
Installing ss a ra
c ce
e

nl
pt
du
an
itte
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Specified torques
erm
ab
ility
ot p
♦ ⇒ “3.2 Assembly overview - exhaust gas recirculation, 132 kW

wit
, is n
engine”, page 391

h re
hole

spec
es, in part or in w
t to the co
3.6 Removing and installing changeover

rrectness of i
valve for exhaust gas recirculation cool‐

l purpos
er - N345-
nform
ercia

m
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
Removing
un
pt
an
d
itte
– Pull connector -3- and vacuum lines and pull off changeover
y li
erm
ab

ility
ot p
wit
– Unclip locking lug for changeover valve for exhaust gas recir‐
is n
h re
culation cooler - N345- -1- and remove changeover valve for

ole,
spec
exhaust gas recirculation cooler - N345- .

t to the co
Installing
rrectne
Caution
ss o
cial p
f in

form
mer
atio

om
connection piece.
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
3.7 Checking exhaust gas recirculation

en
ng
t.
yi Co
op
cooler for leaks
C py
t. rig
gh ht
pyri by
Vo
• Exhaust gas recirculation cooler is removed ⇒ page 398 .
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
– The cooler connection which will be immersed in the water

must be sealed watertight.
– Using a clamp, secure a hose to the cooler connection at which

compressed air is supplied.
swage es n
The exhaust gas recirculation cooler by Vis now ready to be immersed t gua
olk o
in the water. ir se
d ran
tee
tho or
au ac
ss
Note
ce
le
un
pt
an
d
itte
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♦ Supply compressed air at connection where coolant is sup‐

erm
ab
plied.
ility
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wit
is n
♦ The cooler should remain immersed in the water for at least

h re
ole,
30 minutes in order to obtain a significant result.

spec
♦ Using a commercially available immersion heater , heat water

t to the co
to approx. 60-80 °C.

♦ Perform the pressure test with the cooler in vertical position.
rrectne
♦ The pressure must not exceed 3 bar.

ss o
cial p
– Immerse cooler in water as shown in illustration. Hose

inform
-arrow- must protrude from water in order to perform pressure

mer
test.
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
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fo
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ng
t.
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

agen AG olksw
Amarok 2011 ➤ wage
n AG. V does
olks not
d by (2.0 l engine, common rail) - Edition
V gu
a 04.2013
e ran
ris tee
utho or
28 – Glow plug system

a ac
ss
ce
e
nl
pt
du
an
itte
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1 Glow plug system
erm
ab
ility
ot p
wit
⇒ “1.1 Checking glow plug system”, page 404
, is n
h re
hole
⇒ “1.2 Removing and installing glow plugs”, page 405
spec
es, in part or in w
⇒ “1.3 Removing and installing engine speed sender G28 ”, page
t to the co
406
⇒ “1.4 Removing and installing Hall sender G40 ”, page 407
rrectness of i
1.1 Checking glow plug system
l purpos
Procedure
nf
ercia
o
Automatic glow period control unit - J179- -A- is located in front
rm
m
left of engine compartment -arrow- beneath headlight.
atio
om
n in
c
Glow plug system is activated via automatic glow period control

or
thi
e
unit - J179- . The automatic glow period control unit - J179- is

t
sd
iva
capable of self-diagnosis.
o
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rp
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f
A fault entry is stored in the engine control unit if a fault occurs in
en
ng
t.
yi Co
the glow plug system. t. Cop py
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For faster starting, the vehicle is equipped with electronically con‐
trolled glow plugs and a separate glow period control unit.
Each glow plug is activated and diagnosed separately.
404 Rep. gr.28 - Glow plug system

Amarok 2011 ➤
1.2 Removing and installing glow plugs

equipment required
♦ Jointed wrench 10 mm -
3220-
♦ Pliers - 3314-
1410-
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– Switch off ignition.

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Make sure that no wiring connections are damaged when dis‐

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ness will need to be renewed. Do not compress the pliers -
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3314- to firmly to separate the connectors, otherwise the

support sleeve may be damaged.
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1. Glow plug system 405

Amarok 2011 ➤
– Position pliers - 3314- with groove -arrow A- on support sleeve

shoulder -arrow B-.
– Carefully pull connector off glow pin plug

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– Clean glow pin plug opening in cylinder head. It must be as‐
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♦ Cleaning procedure:
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♦ Use a vacuum cleaner to remove coarse dirt.

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plug opening, let it work in briefly, and blow out with com‐
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♦ Then use an oil-soaked cloth to clean the glow pin plug open‐
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– To loosen glow plugs, use special tool U/J extension and

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– To tighten the glow plugs use special tool U/J extension and
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socket, 10 mm - 3220- with a suitable torque wrench.
– Tighten glow plugs.
– Fit glow plug connectors to the respective glow plugs and en‐
sure they are firmly seated.
– Delete event memory of engine control unit.
Specified torques
1.3 Removing and installing engine speed

sender - G28-

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– Pull the connector -2- off the engine speed sender - G28- be‐
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low the oil filter holder -1-.

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press connector on engine speed sender - G28- in with a screw‐
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driver and at the same time raise release tab with a thin wire hook.
– Loosen securing bolt -arrow- with socket AF 4 mm - T10370-

and remove speed sender.
Installing
Specified torques
♦ ⇒ “3.1 Assembly overview - cylinder block, gearbox end”, page
54
1.4 Removing and installing Hall sender -

G40-
Removing

Amarok 2011 ➤
– Unscrew bolt -3- for bracket -1-.
– Detach connector -1- for Hall sender - G40- .

– Remove vibration damper ⇒ page 44 . n AG. Volkswagen AG do
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– Turn engine to TDC and lock crankshaft toothed belt pulley in

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position with crankshaft stop - T10050- . To do this, push the

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crankshaft stop into the teeth of the toothed belt pulley from
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the latter's face side. The toothed segment of the camshaft

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Amarok 2011 ➤
Arrow on camshaft pulley must be at almost »12 o'clock«.

– Mark direction of rotation of toothed belt.
– Lock the camshaft hub with locking pin - 3359- . To do this,

in cylinder head.
– Loosen bolts -arrows- approx. 90° for camshaft toothed belt
pulley.
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– Remove bolts of toothed belt pulley of high-pressure pump
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– Turn eccentric of tensioning roller anti-clockwise -arrow- using

socket - T10264- , until the tensioning roller can be locked with
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Amarok 2011 ➤
– Now turn tensioning roller eccentric clockwise -arrow- onto

stop and tighten securing nut -1- hand-tight.
– Remove toothed belt from idler roller and high-pressure pump.
– Screw off Hall sender - G40- -arrow-.
– Remove guide roller -1- ⇒ Item 18 (page 106) .

– Using a screwdriver, remove webs -arrows- and detach wiring
harness
– Remove cover -2- of repair aperture -arrows-.
– Unscrew Hall sender - G40- from cylinder head.
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– Pull wiring harness -1- out of retainer -2- and separate.

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– Seal repair aperture in toothed belt guard with rubber plugs as

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Amarok 2011 ➤
– Install guide roller -1- ⇒ Item 18 (page 106) .

– Fit toothed belt and adjust the valve timing ⇒ page 107 .
– Install upper toothed belt guard -3- and secure with clips
-arrows-.
– Clip vacuum hose -2- into toothed belt guard -1-.
– Tighten bolt -3- for coolant pipe bracket -1-.

Specified torques
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♦ ⇒ “2.1 Assembly overview - toothed belt drive”, pageby
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Amarok 2.0 Biturbo

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Service

4-cylinder diesel engine (2.0 l engine, common rail)

Service Department. Technical Information

20 - Fuel supply system

23 - Mixture preparation - injection

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Copyright © 2013 Volkswagen AG, Wolfsburg D4B80260554

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.5 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

1.6 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1.7 Removing and installing ancillary bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1.8 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1.9 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.10 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.1 Assembly overview - ancillary drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3.2 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

3.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

4.2 Checking piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

4.6 Bearing shells - installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4.6 Checking hydraulic compensation element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

4.7 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

5.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

5.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

5.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

1.1 Assembly overview - sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

1.7 Removing and installing dipstick tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

2 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

2.6 Measure oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

3 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

3.2 Assembly overview - radiator cowl and radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . 204

3.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

1 Procedure when filling with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

1.1 Procedure when filling with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

1.2 Engine is not running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

2 Checking low-pressure fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

2.1 Checking fuel low-pressure at high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

2.3 Checking fuel low-pressure ahead of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

2.4 Checking flow rate ahead of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

3 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

3.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

3.2 Assembly overview - fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

3.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

5 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

5.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

2.2 Assembly overview - turbocharger, 90 kW and 103 kW engines . . . . . . . . . . . . . . . . . . . . 264

2.5 Removing and installing charge pressure sender 2 G447 . . . . . . . . . . . . . . . . . . . . . . . . 277

turbocharger, 120 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

1.2 Fitting location overview - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

1.3 Assembly overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

1.4 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

1.5 Filling/bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

2.1 Schematic diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318