Service Workshop Manual Amarok 2011 > Edition 04.2013 Service Department. Technical InformationService List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups Repair Group 00 - Technical data 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling 20 - Fuel supply system 21 - Turbocharging/supercharging 23 - Mixture preparation - injection 26 - Exhaust system 28 - Glow plug system 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 D4Be0260554‘Amarok 2011 > A-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 Contents 00 - Technical data 1 1 Identification 1 4.1 Engine number, engine data 1 2 Safety instructions 3 24 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 25 Safety precautions during road tests in which testing and measuring equipment is used .. 6 7 7 7 8 8 9 3 Repair instructions 3.1. General notes on the lubrication system 3.2 General notes on fuel system 3.3. Rules for cleanliness when working on fuel supply systeminjection system 3.4 — Rules for cleanliness when working on charge air system 3.5 Instructions for working on fuel system 3.6 To avoid any risk of injuries to persons andlor 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 1“ 10 - Removing and installing engine ............ - 12 1. Removing and installing engine 12 1.4 Removing engine 12 1.2 Securing engine on engine and gearbox support VAS 6095 26 1.3 Installing engine 2 2 Assembly mountings .. : 31 24 Removing and installing assembly mountings 3 13 - Crankshaft group GUI PICs eter tenet eee eee . 33 1 Oytinder block (pulley end) 34 1.1. .cAssembly overview - cylinder block % 34 12° Assembly overview - sealing flange, belt pulley.end 36 43 Assembly overview poly V-belt drive .. sees 3? 44 Assembly overview poly V-belt drive, vehicles without AIC system .evssssessevecsss 38 1.5 Removing and installing poly V-belt... ep eee eee : cee 40 4.6 Removing and installing tensioner for poly V-belt ee 42 1.7 Removing and installing ancillary bracket > vets tee 43 1.8 Removing and installing vibration damper .......000jscecvveeeeseee vee 4d 18. Renewing crankshaft oil seal - belt pulley end . 46 1.10 Removing and installing sealing flange on pulley end 48 2 Ancillary drive 5 51 2.1 Assembly everview- ancillary drive 5 2.2 Retrofitting preparation for ancillary drive 8 51 3 ylinder block (gearbox end) 54 3.1 Assembly overview - cylinder block, gearbox end 5a 3.2 Removing and installing dusl-mass flywhee! 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 42 Checking piston and cylinder bore 68 4.3, Piston and cylinder dimepsions 69 4.4 © Measuring piston projectigy at TOC 70 45 Checking radial clearancktf conrods, a” contanis i@ 15 17 48 47 5 54 52 53 54 55 1 1.4. Assembly overview - cylinder head 1.2. Assembly overview - cylinder head cover 4.3. Removing and installing cylinder head 4.4 Removing and installing cylinder head cover 4.5 Removing and installing injector seals 1.6 Removing and installing vacuum pump 1.7 Checking compression. 2 Toothed belt drive. 24 Assembly overview - toothed belt drive | 2.2 Removing and installing toothed belt. 3 Fresh air supply system, belt drive 3.1 Assembly overview fresh air supply system 3.2. Removing and instaling blower for fresh air supaly system 3.3. Removing and installing ai filter housing for fresh air supply system 3.4 Removing and installing bracket for fresh air supply system 4 Valvegear . a 4.1 Assembly overview valve gear A 4.2 Measuring axial clearance of camstatt ... 4.3 Measuring radial clearance,of camshafts 4.4 — Removing and installing.éamshafts 4.5 Removing and instalitig camshaft cil seal 4.6 Checking hydraulic'compensation element 4.7 Renewing valve stem seals 5 Inlet and exhaust valves: 5.1 Reworking valve seats 5.2 Checking valve guides 53 Valve dimensions Lubrication ..5 1 Sump, oil pump 1.1 Assembly everview - sump, el pump. 1.2 Removing and installing oil sump 1.3 Removing ahd installing oil pump 1.4 Removing and installing oil pump, vehicles with balancer shaft module 1.5 Checking engine oil level 1.6 Removing and installing oil level and oil temperature sender G266 1.7 Removing and installing dipstick tube 2 Oilfiter, oil pressure switch 2.1 Assembly overview “i fiter housing with engine oil cooler 2.2 — Removing and installing‘ol fiter housing with enginef@iycooler 2.3 Removing and installing oil‘pressure switch F1 2.4 — Checking cil pressure switch F1%.., 2 oi 2.5 Checking oil pressure 2.6 Measure oll consumption Amarok 2011 > 4-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 Bearing shells - installation position ‘Separating new conrod Crankshaft Assembly overview - crankshaft Crankshaft dimensions . Measuring axial clearance of crankshaft Measuring radial clearance of crankshaft . Renewing needle bearing in crankshaft Cylinder head, valve gear .......... : Cylinder head 1 72 73 73 74 74 75 76 78 78 78 81 85 93 99 - 102 103 - 105 - 105 107 116 116 117 217 118 119 119 121 122 123 129 131 - 132 135, 135 135 136 137 . 137 137 140 148 148 147 147 148 150 150 151 154 - 156 - 157 157 ContentsAmarok 2011 19 20 4-oylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 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 42 Removing balancer shaft module 163 4.3 Installing a new balancer shaft module 165 44 Installing a previously used balancer shaft module again 168 5 Oilcircuit =. 170 5.1 Removing and installing oil supply line to turbocharger, 120 kW and 132 kWengines .... 170 5.2 Removing and installing oil pressure line to turbocharger - 90 kW and 103 kW engine 172 Cooling oe 175 + Cooling system, coolant . 178 4.1 Coolant hose schematic ciagram 175 1.2. Assembly overview - coolant hoses 178 13. Checking cooling system for leaks 180 14 Draining and filing coolant 182 2 Coolant pump, regulation of cooling system 187 2.1 Assembly overview - coolant pumpiball 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 28 — Removing and installing continued coolant circulation pump V51 198 2.9 Removing and installing Y-iherméstat .. 199 2.10 Removing and installing récirculation pump V55 s+ 200 3 Radiator, radiator fart’... - 202 3.1 Assembly overviaw- raciator/ radiator fan V7 202 32 Assembly overview - radiator cow and radiator fan V7 2 204 33. Removing and installing radiator... 4, 204 3.4 Removingiand installing radiator cow with radiator fan V7 207 Fuel supply system : -210 + Procedure when filing with incorect uel 210 4.4 Procedure when filing with incorrect fuel 5 210 1.2. Enging isnot running . 210 13° Engine is running : an 2 Checking low-pressure fuel system. 213 2.1 Checking fuel low-pressure at high-pressure pump .. a... 213 22 Checking flow rate at high-pressure pump ........2eee0e - as 215 2.3. Checking fuel low-pressure ahead of fuel fiter 218 2.4 Checking flow rate ahead of fuel fiter g 222 3 Fuel tenk 226 3.4 Assembly overview - fuel tank 228 32 Assembly ovérview- fuel lines 228 3.3 Removing and installing fuel tank 229 3.4 Removing and installing filler neck + 232 4 Fuel delivery unit, fuel gauge sender » 236 4.4. Removing and installing fuel delivery unit 236 4.2 Removing and installing fuel gauge Sender G 237 5 Fuel fer we 238 5.1 Assembly overview - fuel fiter 238 consents Hii4-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 5.2 Removing and installing fuel fiter 230 5.3 Checking fuel fter 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) 6... eee eeee 245 7 Accslerator mechanism 248 7.4 Function .... vote tte ett teecteeees 2B 7.2 Assembly overview accelerator mechanism... ceseeeees » 249 21 - Turbocharging/supercharging «250 1 Charge air system covet eee eee sevees 250 11 Assembly overview - charge air system 250 1.2. Removing and installing charge air cooler 251 43 Removing and insaling intake air temperature sender G42 with charge air pressure sender 4.4 Removing and installing exhaist gas fap Valve N20 ree » 255 15. Checking charge alrsystem for leaks 00. geese ee eeeeceeeeeeeeees es 256 2 Turbochargers... cov vveeeeeceee 260 2.1 Assembly overview turbocharger, 120 KW and 132 KW engine, «os... sss es. s+ 280 2.2 Assembly overview - turbocharger, 90 kW and 103 kW engines, cece eee e es 264 2.3 Removing and installing turbocharger - 120 kW and 132 kW engines... . 267 2.4 — Reméving and installing turbocharger - 90 kW and 103 KW engines 272 2.5 Removing and installing charge pressure sender 2. G447 277 2.6 Removing and installing regulating flap potentiometer G584 and vacuum unit for turbocharger, 120 kW engine 278 2.7 Removing and installing regulating flap potentiometer G584 and vacuum unit for turbocharger, 132 kW engine 290 2.8 Removing and installing charge pressure control solenoid valve N75... 5............ 300 23 - Mixture preparation - injection ....... 2.6... 0e0eceeee eee wees 302 1 Injection system 302 1.1. Schematic overview - fuel system : 302 1.2 Fitting location overview - injection system 304 1.3. Assembly overview - fuel system att 14 Checking fuel system for leaks ........ 316 1.5 Filinglbleeding fuel system ........... a 316 2 Vacuurm'system . = 318 21 Schematiégiagram- vacuum system . $ 318 2.2 Testing vacuiam system for leaks... see gWOoveeeceereeteeeeeeee 321 3 Injectors and higf-pressure accumulator a6 327 34 Overview of injectors “., soso veces : 327 3.2 Injector delivery calibration voceeteees - 327 3.3. Removing and installing injectors (piezo injectors)... ss. coven 328 3.4 Removing and installing injectors (solenoid valves) 332 3.5 Removing and installing high-pressure lines . _ cece 338 3.6 Removing and installing high-pressure accumulator (ral) 340 3.7 Checking return flow rate of injectors with engine running 343 4 High-pressure pump vote eee cesteeteeeeesneseeees S47 4.1 Removing and instaling high-pressure pump... veveeeeees » 347 4.2 Checking high-pressure pump . : . : + 350 5 Intake manifold Seat eet e ec teteeteeectteeeeeentrceres O54 3.1 Assembly overview intake manifold... ..v.ssssvsessssssvseeierssseveevessss 384 5.2 Removing and installing intake manifold... » 354 5.3. Removing and installing throttle valve module J338 with throtle valve potentiometer G68 and intake manifold flap motor V157 357 IV contants26- 28 - Amarok 2011 cylinder diesel enginié (2.0 | engine, common rail) - Edition 04.2013 6° Senders and sensors 8.1 Removing and installing air mass meter G70 62 Removing and installing exhaust pressure sensor 1 G450 63 Removing and installing fuel pressure regulating valve N276 64 Checking fuel pressure regulating valve N276 65 Removing and installing fuel pressure sender G247 7 Airfiter 7.4 Assembly overview - air fiter Z 7.2, Removing and installing airfiter 8 Engine control unit : 8.1 Removing and installing engine control unit. 8.2 Renewing engine control unit .. Exhaust system a. 1 Exhaust pipes, silencers 14 Assembly overview silencers 12 Checking exhaust system for leaks 4.3. Aligning exhaust system free of stress 2°, Cleansing exhaust emiss 2.1 ©. Assembly overview - emibgidn control (diese! particulate fiter) 2.2 AsGembly overview - emifgtbn control (catalytic converter) 23 — Removifigrand installing particulate fter 24 — Removing and installing catalytic converter 3 Exhaust gas recirculation 3.1. Assembly overview - exhaust gas recirculation 32 Assembly overview - exhaust gas recirculation, 132 KW engine 3.3. Removing and installing exhaust gas recirculation cooler 34 Removing and installing exhaust gas recirculation cooler, 132 KWW engine 3.5 Removing and installing exhaust gas recirculation valve N18 , 132 kW engine 3.6 Removing and installing changeover valve for exhaust gas recirculation cooler N345 3.7. Checking exhaust gas recirculation cooler for leaks Glow plug system - : 1 Glow plug system 44 Checking glow plug system 1.2. Removing and installing glow plugs. 1.3 Removing and instaling engine speed sender G28 1.4. Removing and installing Hall sender G40 359 359 360 362 364 365 368 368 370 372 372 372 374 374 374 375 375 377 377 379 381 387 390 390 301 302 308 400 401 402 404 404 404 405 406 407 Contents VAmarok 2011 > 4-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 Vi_ contons‘Amarok 2011 > A-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 wy) Technical data 1 Identification (VRLO05497; Edition 04.2013) = "“1.1 Engine number, engine.data”.page 1 1A Ehgine number, engine data New.f6ur digit engine codes have been introduced since model year 2008. The first 3 digits refer to the mechanical configuration of the engine. They are stamped onto the engine. The fourth digit denotes the power output of the engine and depends on the.en- gine control unit. The four digit engine code can be found on the identification plate, the vehicle data sticker and the engine control unit The engine number ("engine code" and “serial number’) can be found at the joint between engine and gearbox -arrow-. In addition, there is a sticker attached to the toothed belt guard showing the "engine code” and “serial number’ ‘The engine code is also included on the vehicle data sticker. ‘The engine number consists of up to nine characters (alphanu- meric). The first part (maximum 4 characters) makes up the “engine code", and the second part (B characters), the ‘serial number. If more than 999,989 engines were produced with the same code letters, the first of the six digits is replaced by a letter. eae TE Engine code DCA (DBA CNFA Manufactured from 01.10 to mating users” | cuasmeag | euocanaes U 4 standard EU 4 standard EU 4 standard EUS: sensors EUS standard EUS standard Capacity q 20 20 Output kW at sa014000 90/3750 90/3750 rpm| Torque Nm at} 400/ 340/ 3401 41500 - 2000 1750 - 2250 1600 - 2000 Cepecity 1968 1968 1988 Bore 81.0 81.0 81.0 stroke 95.5 95.5 955 ‘Valves per cylinder 4 4 4 Compression ratio 165 165 16.0 Fuel accord- DIN EN 590 DIN EN 590 DIN EN 590 ing to Firing order 1342 1342 1342 Balancer shaft module no no no, Catalytic converter yes yes yes Exhaust gas recirculation yes yes yes Turbocharging/supercherg- yes yes yes ing Charge air cooler yes yes yes Particulate fiter yes, in the case of EU 5 |yes, in the case of EU 5|yes. in the case of EU 5 \donfcation 1@ Amarok 2011 > 4-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 [Engine code ‘Cbca. (CDBA. ‘ONFA 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 reduction no. no no (SCR system) 1) Presentin the 6358 of engines compliant with EU 9 standard andiorn conjunction with dual clutch gerboxes. [Engine codes ‘CNEA CSHA NFB Manufactured from 01.10 Emissions fulfil EU 4 standard EU 4 standard EU 4 standard EU 5 standard EU 5 standard EUS standard Capacity I 20 20 2.0 JOutput kwat] 4132/4000 4132/4000 103/380 rpm| Torque Nm at 400/ 420/ 3401 rpm| 1500 - 2250 1750 1600 - 2250 (Capacity om] 1968 1968 1968 Bore Smm| 81.0 81.0 81.0 Stroke mm| 95.5 95.5 95.5 ‘Valves per cylinder 4 4 4 (Compression ratio 185 460 16.0 Fuel scvore ‘BiweN 590 ‘DIN EN 590 DIN EN 590 ing to| Firing order 1342 13-42 13-42 Balancer shaft module no yes no (Catalytic converter yes yes yes Exhaust gas recirculation yes yes yes ‘Turbocharging/super- yes yes yes charging Charge eir 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 cateyte reduc no no no {SCR system) 2) Present inthe case of engines compliant with EU 5 standard andlor in conjunction wth dual clutch gearboxes. 2 Rep. 07: 00- Technical data