Gas 4-Cylinder Injection Engine (2.0 L Direct Injection Engine, Turbocharger) PDF

Service
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
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Contents
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.1 General notes on the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.3 General notes on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3.3 Safety precautions during work on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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3.4 Releasing pressure in high-pressure area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3.5 Safety precautions when working on charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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4 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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4.1 Rules for cleanliness when working on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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4.2 Rules for cleanliness when working on charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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4.3 Instructions for hose connections with screw-type clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Securing engine on engine and gearbox support VAS 6095 . . . . . . . . . . . . . . . . . . . . . . 21
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.1 Removing and installing engine and gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2 Removing and installing tensioning device for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.4 Removing and installing ancillary bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.6 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.3 Renewing needle bearing in drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.4 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.2 Checking piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.3 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.4 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.2 Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.4 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.5 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.6 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Contents i
Amarok 2011 ➤
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 04.2013
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.3 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.4 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2 Cover for timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.1 Assembly overview - cover for timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.2 Removing and installing upper timing chain cover gen AG . . . . . . .n.A.G.d.oe. . . . . . . . . . . . . . . . . . . . .
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2.3 Removing and installing timing chain ycover V olk (bottom) . . . . . . . . . s.n.ot.g.u . . . . . . . . . . . . . . . 79
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3 Chain drive . . . . . . . . . . . . . . .o.ris. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .an.te.e. . . . . . . . . . . .
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3.1 Exploded view - camshaft timing au chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.a.c . . . . . . . . . 84
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3.2 Assembly overview - balancer shaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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3.3 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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3.4 Removing and installing balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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3.5 Renewing balancer shaft for inlet camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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3.6 Renewing balancer shaft for exhaust camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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3.7 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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4.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.2 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
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4.3 Renewing valve stem seals with cylinder head installed . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.4 Renewing valve stem seals with cylinder head removed . . . . . . . . . . . . . . . . . . . . . . . . . . 117
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4.5 Measuring axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

4.6 Removing and installing inlet camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . 121
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5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

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5.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
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5.2 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 do
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1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

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1.1 Assembly overview - sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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1.2 Removing and installing lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
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1.3 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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1.5 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

2 Crankcase breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.1 Removing and installing coarse oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.1 Assembly overview - oil filter housing, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.2 Removing and installing oil pressure switch F22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.3 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.1 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.1 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.3 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.4 Coolant hose schematic diagram for vehicles with 2nd heat exchanger . . . . . . . . . . . . . . 147
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2.1 Assembly overview - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
ii Contents
Amarok 2011 ➤
2.2 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

2.3 Removing and installing continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . 151
2.4 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 152
2.5 Removing and installing toothed belt for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.6 Renewing oil seal for coolant pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
2.7 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.8 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3.1 Assembly overview - radiator/ radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3.2 Assembly overview - radiator cowl and radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3.3 Removing and installing radiator cowl with radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . 162
3.4 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

1 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.1 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.2 Removing and installing fuel pump control unit J538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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2.2 Removing dand by ara 175
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2.3 Removing oris and installing filler neck . . . . . . . . . . . n.te.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
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3.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

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3.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

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4 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
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4.1 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

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4.2 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

ole,
spec
5 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

t to the co
5.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

5.2 Removing and installing accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
6 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
rrectne
6.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

6.2 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
ss o
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21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
nform
mer
1 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

atio
m
1.1 Assembly overview - charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

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1.2 Removing and installing pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

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1.3 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

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1.4 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

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1.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
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2 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
pyri
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197
2.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
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2.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Prote AG.
2.3 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2.1 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2.2 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.3 Renewing seals on injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.4 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Contents iii
Amarok 2011 ➤
3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

3.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
3.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3.3 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
4 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
4.1 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
4.2 Removing and installing fuel pressure sender -G247- . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
4.3 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
4.4 Checking double non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
5 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
5.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
ks
5.2 Removing and installing intake manifold . . . . . . . . . . . . . . s.w.a.ge.n.A.G.. V. o. l . .w.ag. e.n.A.G.d.oe. s. . . . . 229
lk n
5.3 Removing and installing throttle valve module J338 .d b. y.V. . . . . . . . . . . . . . . . . . . . . . . .ot.g.ua. 233
o
e ran
5.4 Cleaning throttle valve module J338 . . . . . . . . . h.o.ris. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 tee
t o
5.5 Checking intake manifold change-over . . . . . s.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 r ac
a u
6 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
ce
le
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6.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
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6.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
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6.3 Check fuel holding pressure upstream of high-pressure pump . . . . . . . . . . . . . . . . . . . . . . 240
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7 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
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7.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
es, in part or in w
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
1 Exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
rrectness of i
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
1.2 Removing and installing centre silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
l purpos
1.3 Removing and installing rear silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

1.4 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
nform
ercia
1.5 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

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a
1.6 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
com
tion in
2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
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2.1 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
s
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28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

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1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
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1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yri
253
p by
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by c lksw
1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . .Prote
cted AG.
agen
254
1.3 Removing and installing spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
1.4 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
1.6 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
iv Contents
Amarok 2011 ➤
00 – Technical data
1 Identification
(VRL005652; Edition 04.2013)
olkswagen AG
en AG. V
⇒ “1.1 Engine number, engine data”, page 1olkswag does
not
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1.1 Engine number, engine data tho
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New four digit engine codes have ss been introduced since model c
ce
e
year 2008. The first 3 digits refer to the mechanical configuration
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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‐
erm
ab
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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unit.
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The engine number (“engine code” and “serial number”) can be
es, in part or in w
found at the joint between engine and gearbox -arrow-.
t to the co
In addition, there is a sticker on the toothed belt guard with “engine
code” and “serial number”.
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The engine code is also included on the vehicle data sticker.
l purpos
The engine number consists of up to nine characters (alphanu‐

meric). The first part (maximum 4 characters) makes up the
nform
ercia
“engine code”, and the second part (6 characters), the “serial

number”. If more than 999,999 engines were produced with the
m
at
om
same code letters, the first of the six digits is replaced by a letter.
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ate
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Engine code CFPA
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Manufactured From - to 12.10 ▶
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Emissions fulfil EU2 ddk., EU4
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Capacity l 2.0
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Output kW at rpm 118 kW at 3800 to
5500 rpm
Torque Nm at rpm 300 Nm at 1600
to 3750 rpm
Capacity cm3 1984 cm3
Bore ∅ mm 82.5 mm
Stroke mm 92.8 mm
Valves per cylinder 4
Compression ratio 9.6:1
Fuel according to DIN EN 228
Firing order 1-3-4-2
Balancer shafts 2
Catalytic converter yes
Exhaust gas recirculation yes
Turbocharging/supercharging yes
Charge air cooler yes
Camshaft timing control yes
Secondary air injection no
1. Identification 1
Amarok 2011 ➤
1) If petrol with a RON rating of less than 95 is used, reduced power output and
torque must be expected.
AG. Volkswagen AG d
agen oes
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2 Rep. gr.00 - Technical data

Amarok 2011 ➤
2 General notes
⇒ “2.1 General notes on the lubrication system”, page 3
⇒ “2.2 General notes on ignition system”, page 3
⇒ “2.3 General notes on fuel system ”, page 4
2.1 General notes on the lubrication system
Note
The oil level must not be above the max. mark - danger of damage
to catalytic converter!
Caution
If large quantities of metal chips and abraded material are

found during engine repair, this may indicate that the crank‐
shaft bearings or conrod bearings are damaged. To avoid any
subsequent damage, the following work must be carried out
following the repair:
♦ Thoroughly clean oil passages,
♦ Renew oil spray jets,
♦ Renew engine oil cooler,
♦ Renew oil filter element.
2.2 General notes on ignition system

♦ The battery must be disconnected only with ignition switched
off. If a coded radio is installed, ascertainencode before
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necting battery. ag oes
olksw not
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♦ Observe required procedures ris after connecting battery ⇒ Elec‐
e nte
trical system; Rep. gr. 27 th;o Disconnecting and reconnecting eo
au ra
battery. ss c
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♦ For trouble-free operation of electrical components, a voltage

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of at least 11.5 V is necessary.

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♦ After completing work, read event memory of engine control

ot
unit and delete all event memory entries which may have been
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created during checks and repairs. The readiness code must

hole
be generated if the event memory has been cleared ⇒ Vehicle

spec
es, in part or in w
diagnosis tester .
t to the co
♦ If, after fault finding, repairs or component tests, the engine

starts, runs for a short period and then stops, then the fault
may be that the immobilizer is blocking the engine control unit.
rrectness of i
In this case, the control unit may have to be adapted ⇒ Vehicle

l purpos
diagnosis tester .
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com
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AG.
2. General notes
Amarok 2011 ➤
2.3 General notes on fuel system
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
AG. Volkswagen AG d
agen oes
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♦ When the engine is warm, the cooling system is under pres‐
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sure. If necessary, release pressure before beginning repair

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work.
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♦ Hoses are secured with spring-type clips. In case of repair, t to the co

only use spring-type clips.
♦ When installing or removing spring-type clips, we recommend
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using spring-type clip pliers - VAS 6340- or

♦ … hose clip pliers - VAS 6362- .
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♦ When installing coolant hoses, route stress-free so that they

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do not come into contact with other components (observe

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markings on coolant connection and hose).

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♦ The arrows on the coolant pipes and on the ends of the hoses
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must be aligned with each other.

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Amarok 2011 ➤
3 Safety instructions
⇒ “3.1 Safety precautions when working on cooling system”, page
5 en AG. V
olkswagen AG
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⇒ “3.2 Safety precautions when working on ignition bsystem”,
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⇒ “3.3 Safety precautions during work on sfuel
s a system”,
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page 6
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⇒ “3.4 Releasing pressure in high-pressure area”, page 7
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⇒ “3.5 Safety precautions when working on charge air system”,
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page 7
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3.1 Safety precautions when working on
hole
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cooling system
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WARNING
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Steam may escape when expansion tank is opened. Wear eye
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protection and protective clothing to avoid eye injuries and

scalding. Cover cap with cloth and open carefully.
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Caution
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vated charcoal filter system, coolant and refrigerant, brake cop Vo
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fluid and vacuum) and electrical wiring in their original po‐ cted agen
Prote AG.
sitions.
♦ To avoid damage to lines, ensure sufficient clearance from
all moving or hot components.
Note
♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ Spring-type clip pliers - VAS 6340- or hose clip pliers - VAS
6362- are recommended for installation of spring-type clips.
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
♦ The arrows on the coolant pipes and coolant hoses must be
aligned with each other.
♦ Only demineralised / distilled water to standard VDE-0510
may be used for mixing. Tap water does not have the required
quality to ensure the coolant's function.
3. Safety instructions 5
Amarok 2011 ➤
AG. Volkswagen AG d
agen
3.2 Safety precautions when working ksw on ig‐
oes
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nition system ed
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To prevent injuries to persons and/or damage
ss to the injection and c
ignition system, the following must be observed:
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♦ Do not touch or pull off ignition coils with output stage when
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engine is running or turning at starter speed.
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♦ Switch off ignition before connecting or disconnecting injection is n
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and ignition system wiring as well as test instrument cables.
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spec
♦ If the engine has to be turned over at starting speed without it
t to the co
starting (e.g. compression test), first unplug the connectors
from the ignition coils and the injectors. Read and delete event
memory after completion of work.
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♦ Always switch off ignition before cleaning engine.
♦ Disconnecting and connecting the battery must only be done
ss o
with the ignition switched off, otherwise the engine control unit
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could be damaged.
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Note the following if testers and measuring instruments have to
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be used during a road test:

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♦ Test and measuring instruments must always be secured to
te
sd
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the rear seat and operated by a second person from this lo‐
i
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cation.
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If test and measuring instruments are operated from front pas‐
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senger seat and the vehicle is involved in an accident, there is a
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possibility that the person sitting in this seat may receive serious p by
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injuries when the airbag is triggered.
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3.3 Safety precautions during work on fuel

system
Caution

tions:
sitions.
hot components.
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
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

Amarok 2011 ➤
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!
3.4 Releasing pressure in high-pressure

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

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

ducing fuel high pressure .
– Switch off ignition.
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The fuel lineshoare
ris pressurized! Wear eye protection andntpro‐
e
ee
tective clothing
aut to avoid eye injuries and skin contact. Before or
a
opening thess high-pressure section, wrap a cloth around the c
ce
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connection.
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– Now place a clean cloth around the connection and carefully

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open the connection to release the residual pressure of ap‐

is n
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prox. 6 bar. Catch the escaping fuel.

ole,
spec
– After completing work, read event memory of engine control

t to the co
unit and delete all event memory entries.

rrectne
Note
The readiness code must be generated if the event memory has

ss
been cleared ⇒ Vehicle diagnosis tester .

o
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mer
3.5 Safety precautions when working on

atio
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charge air system

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sitions.
hot components.
3. Safety instructions 7
Amarok 2011 ➤
Note the following if testers and measuring instruments have to

be used during a road test:
♦ 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.
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ss 4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 04.2013
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⇒ “4.1 Rules for cleanliness when working on fuel system”, page
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page 9
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⇒ “4.3 Instructions for hose connections with screw-type clips”,
page 10
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4.1 Rules for cleanliness when working on
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fuel system
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When working on the fuel supply and injection system, pay careful
attention to the following “6 rules” for cleanliness:
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♦ Thoroughly clean all unions and surrounding areas before dis‐
r
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connecting.
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♦ Carefully cover opened components or seal if repairs cannot
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be carried out immediately.
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♦ Install clean components only. Do not remove replacement
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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.
4.2 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:
♦ 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.
4. Repair instructions 9
Amarok 2011 ➤
4.3 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
• Do not loosen these screw-type clips and pull back over

the delivery hose. Risk of damage to the hose!
• If a clip has been removed, it must be renewed together
with the hose.
– Screw-type clips with “locking hooks” -arrows- may only be

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released. Loosen bolt of screw-type clips sufficiently
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Hose and clip are supplied together as sone part.
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– Do not use substances containing oil, silicone or grease when

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assembling. Only use clean water.

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Amarok 2011 ➤
10 – Removing and installing engine

olkswagen AG
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1 Removing and installing engine
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⇒ “1.1 Removing engine”, page 11 rise nte
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⇒ “1.2 Securing engine on engine and gearbox
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⇒ “1.3 Installing engine”, page 22
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1.1 Removing engine
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Special tools and workshop
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♦ Lifting tackle - 2024 A-
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♦ Support bracket - 10 - 222
A-
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♦ Hook - 10 - 222 A /10-
nf
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♦ Shackle - 10 - 222 A /12-
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♦ Adapter - 10 - 222 A /20-
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1. Removing and installing engine 11

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-
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12 Rep. gr.10 - Removing and installing engine

n AG. Volkswagen AG do
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4-cylinder injection engine (2.0 ledirect
d by injection engine, turbocharger) ua- Edition 04.2013
ran
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♦ Drip tray for workshop hoist ss
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- VAS 6208-
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♦ Step - VAS 6292/4-
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♦ Hose clip pliers - VAS
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♦ Hose clip pliers - VAS
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♦ Retainer - T10014-
♦ High-temperature grease -
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G 052 133 A2-
l purpos
♦ Cable ties
♦ Wooden block 10 x 30 x
nform
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10 cm
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Procedure
Note
♦ Before carrying out further work, remove the battery. Check

whether a coded radio is fitted. Obtain anti-theft coding be‐
forehand if necessary.
♦ The engine is removed upwards.
♦ The gearbox remains installed.
♦ All cable ties that are opened or cut through when the engine
is removed must be renewed/replaced in the same position
when the engine is installed.
♦ 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.

Amarok 2011 ➤
Caution

tions:
sitions.
♦ To avoid damage to lines, ensure sufficient clearance from
all moving or hot components.
♦ Cut through cable ties carefully and reinstall in the same
position.
– Remove bonnet ⇒ General body repairs, exterior; Rep. gr.

55 ; Bonnet .
– Remove underbody guard, if fitted ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody guard .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing starter .
– Drain coolant ⇒ page 141 .
– Detach coolant hose -2- with both brackets -1-.
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– Unscrew bolts -3-. olks not
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– Press retaining lever -1- down and pull connector off.

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Amarok 2011 ➤
– Detach clip -1- of charge air hose -3- from connector nozzle
-2- of turbocharger.
– Remove poly V-belt ⇒ page 30 .
WARNING
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system! en AG. V
olkswagen AG
wag does
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– Disconnect fuel lines -1 and 2-. au
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– Disconnect fuel lines -1- from bracket -2-.

Vehicles with air conditioner
nform
mercia
at
om
Note
ion
c
in t
or
his
e
To prevent damage to condenser or to refrigerant lines and ho‐

at
do
riv
ses, ensure that lines and hoses are not stretched, kinked or bent.
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To facilitate removing and installing engine without opening re‐
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frigerant circuit:
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– Secure air conditioner compressor to body so that the refrig‐ by c lksw
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erant lines and hoses are not under tension. Prote AG.
– Remove AC compressor with hoses connected and secure to

body ⇒ Heating, air conditioning system; Rep. gr. 87 ; Re‐
moving and installing air conditioner compressor .
Continuation for all vehicles
– Remove catalytic converter ⇒ page 251 .
– Remove cover from fuse box above battery.

Amarok 2011 ➤
– Unscrew nut -2- of battery positive cable -1-. agen

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– Unhook clips -1- and -3-.
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– Lay wiring harness -2- to one side.
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ion
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– Unscrew shear bolts -1- and remove bow -3-. t. C rig
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Note
AG.
Shear bolts must always be renewed.
– Release and pull off connector -2-.
– Unhook clips -2- and -3-.

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

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

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

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– Pull line -2- out of brake booster.

– Open clip -1- and remove coolant hose -3-.
nform
ercia
– Remove vane pump for power steering with hoses connected

m
at
om
and secure to body ⇒ Running gear, axles, steering; Rep. gr.

ion
c
48 ; Removing and installing vane pump .

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

-1- in order to access bolt.
– Remove air filter housing ⇒ page 218 .
– Unplug all necessary electrical connectors.
– Disconnect all necessary vacuum hoses.
– Remove bolts -1-.
– Detach retaining clips -3- with water hose -4- from radiator
cowl -2-.
– Release radiator cowl -2- at left and right. To do this, press

retaining lever -1- forwards using a screwdriver, and raise ra‐
diator cowl -2- slightly.
– Remove radiator cowl.
AG. Volkswagen AG d
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nl
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ility
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es, in part or in w
– Unscrew bolts -1- from left engine mounting -A-.

t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
do
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Cop py
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cop Vo
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Rep. gr.10 - Removing and installing engine Prote
cted AG.
agen
Amarok 2011 ➤
– Unscrew bolts -1- from right engine mounting -A-.
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– Install support bracket - 10 - 222 A- .
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– Secure hook - 10 - 222 A /10- and adapter - 10 - 222 A /20- to
wit
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support bracket - 10 - 222 A- .
h re
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– Connect adapter - 10 - 222 A /20- to gearbox transport eye.
spec
t to the co
– Remove bolts -2- and -3-.
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– Only unscrew bolt -1- beneath starter.
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Caution
Prote AG.
• Do not unscrew the two upper bolts -1-.
– Unscrew all connecting bolts for engine/gearbox at bottom and

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

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

1 -arrow A- and hole 7 -arrow B-.
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– Unscrew the two upper bolts -1-.
t to the co
– If necessary, disconnect all connecting, coolant, vacuum and
intake hoses that have to be disconnected from the engine in
rrectness of i
order to remove it.
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– Carefully pull engine from gearbox in longitudinal direction. Do

not damage needle bearing in the crankshaft whilst doing this. nform
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Caution
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♦ Only a few millimetres of space are available between

te o
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plenum chamber and radiator/lock carrier for removing

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and installing the engine. The engine must therefore be

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guided carefully when raising and lowering.

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♦ Raise and lower the engine slowly with the assistance of C py
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♦ The workshop hoist - VAS 6100- must also be guided cted agen
Prote AG.
carefully when raising and lowering the engine.
– When raising and lowering engine, make sure that neither

vacuum hose -1- nor connection -2- on vacuum pump are
damaged.
– Guide vacuum hose -1-, connection -2- and vacuum pump
past plenum chamber when raising and lowering.
– When raising and lowering engine, make sure that rollers of
belt drive and turbocharger do not damage radiator.
– When raising and lowering engine, pay attention to lines and
hoses to prevent these from being damaged.

Amarok 2011 ➤
– Check needle bearing -arrow- in crankshaft. If it is damaged

or has turned blue, it must be renewed ⇒ page 55 .
– 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.
1.2 Securing engine on engine and gearbox support - VAS 6095-

equipment required
♦ Lifting tackle - 2024 A-
♦ Workshop hoist - VAS
6100-
♦ Engine and gearbox sup‐
port - VAS 6095- olkswage es n
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Prerequisite
• Engine with gearbox removed and secured on engine bracket
- T10359- .

Amarok 2011 ➤
– Attach lifting tackle - 2024 A- as shown and lift from engine en AG. V
olkswagen AG
and gearbox jack - VAS 6100- using workshop crane - V.A.G olkswag does
not
1383 A- . ed byV gu
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Caution ss c
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Use securing pins arrows on hooks and locking pins to avoid
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damage to engine.
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– Secure engine to engine and gearbox support - VAS 6095- .
hole
spec
es, in part or in w
t to the co
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nform
ercia
1.3 Installing engine

m
a
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tion in
Special tools and workshop equipment required
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♦ Vehicle diagnosis tester
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Installing
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Installation is carried out in the reverse order; note the following: C py
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Caution cted agen
Prote AG.
♦ 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 ➤
– When raising and lowering engine, make sure that neither

vacuum hose -1- nor connection -2- on vacuum pump are
damaged.
– Guide vacuum hose -1-, connection -2- and vacuum pump
past plenum chamber when raising and lowering.
– When raising and lowering engine, make sure that rollers of
belt drive and turbocharger do not damage radiator.
– When raising and lowering engine, pay attention to lines and
hoses to prevent these from being damaged.
– Check whether dowel sleeves for centring engine/gearbox are
in cylinder block, install if necessary (gearbox removed).
– Check clutch release bearing for wear and, if necessary, re‐
place (gearbox removed). n AG. Volkswagen AG do
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Vol t gu
by
Caution ris
ed ara
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a
• Bring engine and gearbox together in longitudinal
ss direc‐ c
tion, not at an incline.
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e
nl
pt
du
an
itte
• When bringing engine and gearbox together, make sure
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that needle bearing -arrow- is not damaged.
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t to the co
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nform
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ion
c
in t
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do
priv
– First tighten the two upper bolts -1-. cum

for
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Cop py
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Prote AG.

Amarok 2011 ➤
– Tighten new bolts -1- for left engine mounting -A-.
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– Tighten new bolts -1- for right engine mounting d b-A-.
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– Install catalytic converter ⇒ page 251 . auth eo
ra
ss c
– Install air conditioner compressor ⇒ Heating, air conditioning;
ce
e
nl
pt
Rep. gr. 87 .
du
an
itte
y li
– Install vane pump for power steering ⇒ Running gear, axles,
erm
ab
ility
steering; Rep. gr. 48 ; Removing and installing vane pump .
ot p
wit
, is n
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Removing and
h re
hole
installing starter .
spec
es, in part or in w
– Install underbody guard, if fitted previously ⇒ General body
t to the co
repairs, exterior; Rep. gr. 66 ; Underbody guard .
– Install bonnet ⇒ General body repairs, exterior; Rep. gr. 55 ;
rrectness of i
Bonnet .
l purpos
– Fit new screw-type clips with “barb”, notes on screw-type clips

⇒ page 10 .
nform
ercia
To prevent the high-pressure pump from running while it is empty

and to ensure that the engine starts quickly after parts have been
m
at
om
renewed, it is important to observe the following:
ion
c
in t
or
♦ If components of fuel system between fuel tank and high-pres‐

his
ate
sure pump are unbolted, removed or renewed, Bleeding

do
priv
fuel system function must be carried out to bleed fuel system

um
for
en
g
using ⇒ Vehicle diagnostic tester.

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♦ This process takes 130 seconds. Fuel pumps are actuated a t. C rig
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yri
total of 3 times in this case. The process must not be termi‐ p by
co Vo
nated prematurely.
by lksw
cted agen
Prote AG.
– Check oil level ⇒ page 133 .
Note
♦ Only reuse drained coolant if neither cylinder head nor cylinder

block have been renewed.
♦ Soiled coolant must not be reused.
– Replenish coolant ⇒ page 141 .

– Carry out road test and read event memory ⇒ Vehicle diag‐
nostic tester.
Specified torques
♦ ⇒ “1.1 Assembly overview - silencers”, page 245
♦ ⇒ “2.1 Removing and installing engine and gearbox mount‐
ing”, page 25

Amarok 2011 ➤
2 Assembly mountings
⇒ “2.1 Removing and installing engine and gearbox mounting”,
page 25
2.1 Removing and installing engine and

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

AG. Volkswagen AG d
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• If nut -2- is loosened, engine mounting must subsequently
d by V gu
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be renewed. horise nte
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♦ Engine mounting connection to enginesssupport
a
may only c
be loosened if engine mounting is to be renewed.
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le
un
pt
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erm
ab
– Secure engine support -1- to crankcase with bolts -3-.
ility
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Specified torque
h re
ole,
spec
Component Specified torque
t to the co
Bolts -3- 50 Nm +180°
Right engine mounting to frame
rrectne
– Secure engine mounting -A- to frame with bolts -1-.
ss
Specified torque
o
cial p
f inform
mer
atio
m
Bolts -1- 50 Nm + 90°

o
n
c
i
or
n thi
te
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fo
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ng
t.
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Cop py
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Left engine mounting to frame cop Vo
by lksw
cted agen
Prote AG.
– Secure engine mounting -A- to frame with bolts -1-.
Specified torque
Bolts -1- 50 Nm + 90°
2. Assembly mountings 25
Amarok 2011 ➤
Left engine mounting to engine support

– Bolt new engine mounting -3- to engine support -1- with nut
-2-.
Specified torque
Nut -2- 90 Nm + 90°
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Right engine mounting to engine support s
ce
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nl
pt
du
– Bolt new engine mounting -3- to engine support -2- with nut
an
itte
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-1-.
erm
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ility
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Specified torque
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hole
spec
es, in part or in w
Nut -1- 90 Nm + 90°
t to the co
rrectness of i
l purpos
Gearbox mounting to gearbox
nf
ercia
– Secure gearbox mounting -A- to gearbox with bolts -1-.
orm
m
atio
m
Specified torque
o
n in
or c
thi
te
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o
r
Bolts -1- 50 Nm + 90°

rp
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
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cted agen
Prote AG.
Gearbox mounting to gearbox cross member

– Secure gearbox mounting -A- to gearbox cross member with
bolts -1-.
Specified torque
Bolts -1- 30 Nm + 90°

Amarok 2011 ➤
13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - poly V-belt drive”, page 27
⇒ “1.2 Removing and installing tensioning device for poly V-belt”,
page 29
⇒ “1.3 Removing and installing poly V-belt”, page 30
⇒ “1.4 Removing and installing ancillary bracket”, page 32
⇒ “1.5 Removing and installing vibration damper”, page 35
⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”,
page 36
1.1 Assembly overview - poly V-belt drive
1 - Poly V-belt
❑ Check for wear.
❑ Do not kink.
❑ Poly V-belt routing
⇒ page 29 .
AG. Volkswagen AG d
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Caution
d byV gu
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r
If a usedubelt
tho runs in the eo
ra
opposite
ss a direction when c
it is refitted, this can
ce
le
un
pt
cause breakage.
an
d
itte
Before
♦ removing, mark
y li
rm
ab
direction of rotation of
pe
ility
poly V-belt with chalk or

ot
wit
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felt-tipped pen for re-in‐

h re
stallation.
hole
spec
es, in part or in w
t to the co
❑ When installing, make

sure it is properly seated
on pulleys.
rrectness of i
❑ Removing and installing

⇒ page 30 .
l purpos
2 - Guide roller
nform
ercia
❑ 20 Nm
m
3 - Bolt
a
com
tion in
❑ Renew after removing

r
te o
thi
❑ Use counterhold -
s
iva
do
T10355- when loosen‐

r
rp
cum
ing and tightening

fo
en
ng
t.
yi Co
Cop py
.
Caution
ht rig
rig ht
py by
o Vo
Risk of damage to en‐ by c lksw
cted agen
gine.
Prote AG.
To
♦ avoid disturbing valve
timing, do not turn crank‐
shaft when bolt has been
removed.
❑ 150 Nm + 90°
1. Cylinder block (pulley end) 27

Amarok 2011 ➤
4 - O-ring
5 - Vibration damper
❑ With poly V-belt pulley.
Caution
Risk of damage to en‐
gine.
To
♦ avoid disturbing valve
timing, do not turn crank‐
shaft out of “TDC” posi‐
tion when vibration
damper is removed.
❑ Removing and installing ⇒ page 35 .

6 - Bolt
❑ 40 Nm
7 - Tensioning element for poly V-belt
❑ Swing with spanner to slacken poly V-belt.
❑ Lock with locking tool - T40098- .
8 - Bracket for ancillaries
❑ With oil filter and engine oil cooler
❑ Removing and installing ancillary bracket n⇒Apage
G. Volk32
swa.gen AG
swage does
❑ Removing and installing engine boily V cooler ⇒ page 139 .
olk not
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a d ran
ise
9 - Alternator ho
r tee
aut or
ac
❑ Removing and installingss ⇒ Rep. gr. 27 .
ce
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nl
pt
10 - Bolt
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❑ Specified torque ⇒ Rep. gr. 27

erm
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ility
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11 - Bolt
wit
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❑ Observe tightening sequence ⇒ page 29 .

h re
hole
spec
❑ 20 Nm + 90°
es, in part or in w
t to the co
12 - Bolt
rrectness of i
13 - Sleeve
l purpos
14 - Vane pump
❑ Removing and installing ⇒ Rep. gr. 48 .
nform
ercia
15 - Air conditioner compressor

m
at
❑ Do not unscrew or disconnect refrigerant hoses or pipes.

om
ion
c
❑ Removing and installing ⇒ Rep. gr. 87 .

in t
or
his
ate
16 - Bolt
do
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cum
or

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en
ng
t.
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17 - Dowel sleeve t. Cop py
rig
❑ For air conditioner compressor.
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by
18 - Bolt cted agen
Prote AG.
28 Rep. gr.13 - Crankshaft group

Amarok 2011 ➤
Bracket for ancillaries - tightening sequence

– Fit bracket for ancillaries (first tighten bolt -4-).
– Tighten bolts in the sequence -1 … 5-.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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aut ra
ss c
ce
le
Poly V-belt route with air conditioning system

un
pt
an
d
itte
1- Vibration damper
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rm
ab
pe
ility
2- Guide roller
ot
wit
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3- Poly V-belt tensioning element
h re
hole
spec
4- Alternator
es, in part or in w
t to the co
5- Vane pump
6- Air conditioner compressor
rrectness of i
l purpos
Poly V-belt route without air conditioner
nform
ercia
1- Vibration damper
m
a
com
tion in
2- Guide roller
r
te o
thi
3- Poly V-belt tensioning element s
iva
do
r
rp
cum
4- Alternator
fo
en
ng
t.
yi Co
5- Vane pump t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.2 Removing and installing tensioning de‐

vice for poly V-belt

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

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

-arrow-. agen
AG. Volkswagen AG d
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olks ot g
– Lock tensioning device with locking
db
y V tool - T40098- . ua
ran
e
ris tee
– Remove poly V-belt fromuttensioning
ho device. or
a ac
ss
– Remove bolt -1- and take off tensioning device for poly V-belt
ce
e
nl
from bracket for ancillaries.

pt
du
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itte
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Installing
erm
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ility
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Installation is carried out in the reverse order; note the following:

wit
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h re
– Install poly V-belt ⇒ page 30 .

hole
spec
Specified torques
es, in part or in w
t to the co
♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 27

rrectness of i
1.3 Removing and installing poly V-belt

l purpos

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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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
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
swage es n
Removing byV
olk ot g
ua
d ran
ir se tee
tho
or
Caution au ac
ss
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
-arrow-.
– Lock tensioning device with locking tool - T40098- .
rrectness of i
– Remove poly V-belt.
l purpos
Installing
nform
mercia
a
com
tio
Note
n in
r
te o
thi
s
iva
Alternator and air conditioner compressor must be firmly mounted
do
r
rp
c
before poly V-belt is installed.
um
fo
en
ng
t.
yi Co
op
– Fit poly V-belt as shown in figure.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
Vehicles with air conditioner Prote
cted AG.
agen
Vehicles with no air conditioner

Amarok 2011 ➤
– Turn tensioning device in -direction of arrow- and withdraw

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

et
♦ Drip tray for workshop hoist - VAS 6208-
AG. Volkswagen AG d
agen oes
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ara
ed
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ss c
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le

un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f in
Removing
form
mer
atio

om
n
c
i
or
n thi
e
Caution
t
sd
iva
o
pr
cum
r
fo

en
ng
t.
yi
Co
Cop py
ht. rig
rig ht
py by
o Vo
with chalk or felt-tipped pen for re-installation. by c lksw
cted agen
Prote AG.

-arrow-.

Amarok 2011 ➤

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

caping engine oil.
AG. Volkswagen AG d
agen oes
o lksw not
byV gu
ara
ed
– Detach connector -2- from oil pressure switch ho -
ris
F22- -1-. nte
eo
aut ra
– Unbolt water pipe ⇒ Item 19 (page 149) from
ss bracket for an‐ c
ce
e
cillaries.
nl
pt
du
an
itte
– Release clip -3- from pressure hose -4-.
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Release hose clip -arrow- from throttle valve module - J338- .
l purpos
– Unscrew bolt -1- from pressure pipe -2- and remove pressure
pipe -2-.
nf
ercia
or
– Remove alternator ⇒ Rep. gr. 27 .
m
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 ➤
– Disconnect electrical connector -1- for magnetic clutch on air

conditioner compressor.
WARNING
Risk of injury caused by refrigerant.AG. Volkswagen A

gen G do
swa es
♦ The air conditioner refrigerant
by
Vol
k
circuit must not be opened.
not
gu
ara
ed nte
oris e
th or
au ac
– Remove boltsss-arrows- for air conditioner compressor.
ce
e
nl
pt
du
an
itte
Caution
y li
erm
ab
ility
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Danger of damage to refrigerant lines and hoses.
wit
, is n
h re
♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
hole
spec
es, in part or in w
t to the co
– Tie up air conditioner compressor together with refrigerant ho‐
ses to longitudinal member (refrigerant hoses remain connec‐
ted).
rrectness of i
l purpos
nform
ercia
Note
m
at
om
Hydraulic lines and vane pump remain connected.

ion
c
in t
or
his
ate
do
riv
– Unscrew bolts -1- from front through belt pulley, unscrew bolt
p
cum
or
-2- from rear.

f
en
ng
t.
yi Co
Cop py
t. rig
gh
Note
ht
pyri by
Vo
co lksw
by
cted agen
The vane pump is shown without a belt pulley and without hy‐
Prote AG.
draulic lines in the figure.
– Place vane pump with attached hydraulic lines on longitudinal

member.
– Release oil filter -arrow- using oil filter tool - 3417- and remove
oil filter.
– Remove bolts from bracket of continued coolant circulation
pump - V51- .

Amarok 2011 ➤
– Remove bolt -arrow- for dipstick guide tube.

– Unscrew bolts -1 … 5- and detach bracket for ancillary units
from coolant pump housing.
Installing
Note
♦ Renew bolts that are tightened with specified further tightening

angle.
♦ Renew O-rings and seals.
– Coat O-rings -4- with coolant additive.

– Insert connection -2- into coolant pump housingag-3-.
en AG. V
olkswagen AG
doe w s no
olks t gu
– Push bracket for ancillaries -1- onto connection,
ed
by
V
start bolts and ara
tighten them. horis nte
eo
t
au ra
– Install vane pump ⇒ Rep. gr. 48
ss . c
ce
le
un
pt
– If present, fit air conditioner compressor ⇒ Rep. gr. 87 .
an
d
itte
y li
– Install alternator ⇒ Rep. gr. 27 .
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
Specified torques
t to the co
rrectness of i
1.5 Removing and installing vibration damp‐
l purpos
er
nform
ercia
♦ Locking pin - T10060 A-

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.

Amarok 2011 ➤
♦ Counterhold tool - T10355-
AG. Volkswagen AG d
agen oes
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byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
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le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Removing
t to the co
– Remove poly V-belt ⇒ page 30 .
rrectne
– Turn vibration damper to TDC position -arrow- using counter‐
ss
hold - T10355- .
o
cial p
f inform
• Notch on vibration damper must align with arrow marking on
mer
cover for timing chains (bottom).
atio
om
n
c
– Remove bolt for vibration damper using counterhold -
i
or
n thi
T10355- .
te
sd
iva
o
pr
cum
r
fo
Caution
en
ng
t.
yi Co
Cop py
.
Risk of damage to engine.
ht rig
rig ht
py by
co Vo
♦ To avoid disturbing valve timing, do not turn crankshaft out
by lksw
cted agen
Prote
of “TDC” position when vibration damper is removed.
AG.
Installing
Note
♦ Renew bolt for vibration damper.

♦ Renew O-ring -1-.
– Lubricate sealing lip of oil seal with gear oil.

– Fit vibration damper (pay attention to shape of tooth -arrow-).
Specified torques
1.6 Renewing crankshaft oil seal - belt pul‐

ley end

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
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
ercia
♦ Thrust piece - T10368-

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 ➤
♦ Puller hooks - T20143-
Removing
Caution


-arrow-.
– Remove poly V-belt from pulley on vibration damper.
Caution

AG. Volkswagen AG d
agen oes
♦ To avoid disturbing valve timing, doy Vnot
olks turn crankshaft out
w not
gu
of “TDC” position when vibration
ise
d bdamper is removed. ara
nte
r
ho eo
aut ra
ss c
ce
le
un
pt

an
d
itte
y li
rm
ab
pe

ility
ot
hold - T10355- .
wit
, is n
h re

hole
spec
cover for timing chains (bottom).

es, in part or in w
t to the co

T10355- .
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 ➤
– Remove vibration damper and screw on thrust piece - T10368-

in its place.
– Pull out oil seal using puller hooks - T20143/2- .
Installing
– Clean contact surface and sealing surface.
– Unscrew thrust piece - T10368- .
– Use thrust piece - T10354- and bolt for vibration damper to pull
in oil seal -arrow- onto stop.
Note
AG. Volkswagen AG d
agen oes
ksw
♦ Renew bolt for vibration damper. byV
ol not
gu
d ara
ise nte
♦ Renew O-ring. hor eo
aut ra
ss c
– Install vibration damper ⇒ page 35 .
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
Specified torques
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
2 Cylinder block (gearbox end)

AG. Volkswagen AG d
⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
ksw
agen oes
not
page 40 y Vol gu
db e
ara
ris nte
⇒ “2.2 Removing and installing drive plate”,
ut page 41
ho eo
ra
sa c
⇒ “2.3 Renewing needle bearing in drives plate”, page 43
ce
le
un
pt
⇒ “2.4 Removing and installing sealing flange on gearbox side”,
an
d
itte
y li
page 44 erm
ab
ility
ot p
2.1 Assembly overview - cylinder block, gearbox end
wit
is n
h re
ole,
spec
1 - Cylinder block
t to the co
2 - Sealing flange with oil seal
❑ Renew complete only.
rrectne
❑ Do not oil or grease oil
seal sealing lip.
ss
❑ Use support sleeve sup‐
o
cial p
f
plied when installing.
inform
❑ Before installing, re‐
mer
atio
move oil residue from
om
crankshaft journal using
n
c
i
or
n
a clean cloth.
thi
te
sd
va

i
o
pr
c
⇒ page 44 .
um
r
fo
en
ng
t.
yi
3 - Bolt
Co
Cop py
t. rig
❑ Observe tightening se‐
gh ht
yri by
quence ⇒ page 41 .
op Vo
by c lksw
cted agen
❑ 9 Nm
Prote AG.
4 - Drive plate
❑ To loosen securing
bolts, lock using coun‐
terhold - 3067-
⇒ page 41 .
5 - Bolt
❑ 60 Nm + 90°
6 - Needle bearing
needle bearing
⇒ page 43
7 - Intermediate plate
❑ Must seat on dowel
sleeves.
❑ Do not damage or bend when assembling.
❑ Is fitted onto sealing flange ⇒ page 41
8 - Dowel sleeve

Amarok 2011 ➤
Sealing flange at gearbox end - tightening sequence

– Tighten bolts -1 to 8- in the sequence shown.
Installing intermediate plate

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

♦ Counterhold tool - VW 558-
AG. Volkswagen AG d
agen oes
olksw not
V gu
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♦ Depth gauge
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♦ Hexagon bolt M8×40 and hexagon nut M8

– Remove gearbox ⇒ Rep. gr. 34 ; Removing and installing
rrectness of i
gearbox; Removing gearbox .

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2. Cylinder block (gearbox end) 41

Amarok 2011 ➤
Preparing counterhold tool - VW 558- :

– Tighten hexagon bolt M8x40 -A- with hexagon nut on clutch
counter-hold tool - VW 558- .
Loosening and tightening drive plate:
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– Insert counterhold - VW 558- in cylinder block and drive plate
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– Fit drive plate without washer -A- first.

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– Fit used securing bolts -3- and tighten to 30 Nm.
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– Check dimension between drive plate and cylinder block at

three points and calculate average.
Note
Measure through hole in drive plate to milled surface of cylinder

block. When measuring intermediate plate, plate thickness has to
be taken into account.
• Specification measured without intermediate plate: 19.5…

21.1 mm
• Specification measured with intermediate plate: 18.8…
20.4 mm
If the specification is not reached, replace all securing bolts and
tighten.

Amarok 2011 ➤
If specification is not attained:

– Remove drive plate again and fit shim -A-. Tighten bolts -3-
again to 30 Nm.
– Repeat measurement. If the specification is not reached, re‐
place all securing bolts and tighten.
Specified torques
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
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♦ Pipe section - VW 421-
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♦ Support - 40 - 103-
2. Cylinder block (gearbox end) 43

Amarok 2011 ➤
Procedure
• Gearbox removed.
– Remove drive plate ⇒ page 41 .
– Place support - 40 - 103- under drive plate when removing or
installing it.
– Remove needle bearing using pipe section - VW 421- and
workshop press.
• Thinner ∅ of pipe section -VW 421- to drive plate.
– Press in needle bearing using pipe section - VW 418 A- and

workshop press as far as stop.
• Installation position: closed side of needle bearing to engine.
– Install drive plate ⇒ page 41 .
2.4 Removing and installing sealing flange

on gearbox side
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♦ Sealant ⇒ Electronic Parts Catalogue (ETKA)
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♦ Guide sleeve - T20097-

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– Remove drive plate ⇒ page 41 .

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– Detach intermediate plate from sealing flange and dowel pins

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Amarok 2011 ➤
– Remove bolts -1 … 8-.

– Remove sealing flange at gearbox end.
Installing
Note
♦ Observe use-by date of silicone sealant.

♦ The sealing flange must be installed within 5 minutes of ap‐
plying the silicone sealant.
– Remove sealant residues from cylinder block with a flat scra‐

per.
WARNING
Risk of eye injury.

♦ Wear safety goggles.
– Remove sealant residues from sealing flange, e.g. with rotat‐

ing plastic brush.
– Clean sealing surfaces. They must be oil and grease free.
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– Cut off nozzle on tube at front marking (∅tho of nozzle approx. tee
or
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Prote 2. Cylinder block (gearbox end)
AG.
Amarok 2011 ➤
– Apply silicone sealant onto clean sealing surface of cover, as

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

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

– Push sealing flange over guide sleeve - T20097- onto crank‐
shaft journal and tighten bolts immediately.
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After installing the sealing flange, wait aboututh30
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– Install drive plate ⇒ page 41 .
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Amarok 2011 ➤
3 Pistons and conrods

⇒ “3.1 Assembly overview - pistons and conrods”, page 47
⇒ “3.2 Checking piston and cylinder bore”, page 48
⇒ “3.3 Separating new conrod”, page 50
⇒ “3.4 Piston and cylinder dimensions”, page 50
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❑ To measure radial clear‐
ance, tighten to 30 Nm
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but not further.
❑ 45 Nm + 90°
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2 - Conrod bearing cap
❑ Note installation posi‐
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tion.
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❑ Separating new conrod

⇒ page 50 .
3 - Bearing shells
❑ Installation position
⇒ page 49 .
❑ Do not interchange
used bearing shells
(mark).
❑ Axial clearance new:
0.10…0.35 mm, wear
limit: 0.40 mm
❑ Measure radial clearance using Plastigage; new: 0.02…0.06 mm; wear limit: 0.09 mm. Do not rotate
crankshaft when checking radial clearance.
4 - Pressure relief valve
❑ 27 Nm
5 - Oil spray jet
❑ For piston cooling.
6 - Circlip
7 - Piston pin
❑ If difficult to move, heat piston to approx. 60 °C.
3. Pistons and conrods 47

Amarok 2011 ➤
❑ Remove and install using drift - VW 222 A- .
8 - Piston
❑ Checking ⇒ page 49 .
❑ Mark installation position and cylinder number.
❑ Arrow on piston crown points to belt pulley end.
❑ Install using piston ring clamp.
❑ Piston and cylinder dimensions ⇒ page 50 .
❑ Checking cylinder bores ⇒ page 49 .
9 - Compression rings
❑ Offset gaps by 120°.
❑ Use piston ring pliers to remove and install.
❑ “TOP” or “R” marking must face upwards towards piston crown.
❑ Checking ring gap ⇒ page 48 .
❑ Checking ring-to-groove clearance ⇒ page a48 gen.AG
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❑ Offset gaps of individual parts of oil scraper ring.
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11 - Conrod
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❑ Renew as set only.
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❑ Mark with cylinder number -A-.
❑ Installation position: Marking -B- faces towards pulley end.
rrectne
❑ Separating new conrod ⇒ page 50 .
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Oil scraper ring 0.25...0.50 0.80
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Checking ring-to-groove clearance

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

Amarok 2011 ➤
Checking piston
– Measure approx. 10 mm from lower edge, offset 90° from pis‐
ton pin axis.
♦ Difference between actual and nominal diameter max. 0.04
mm.
Checking cylinder bores

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♦ Inside caliper 50 … 100 mm.

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

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– Take measurements at 3 positions in both lateral direction

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

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

– Position bearing shells in centre of conrod and conrod bearing
cap when fitting.
Dimension -a- must be identical on both sides.
3. Pistons and conrods 49

Amarok 2011 ➤
3.3 Separating new conrod

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

♦ Conrod is clamped below dashed line.
– Unscrew both bolts -arrows- approx. 5 turns.

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– Using a plastic hammer,
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ing cap in -direction
ss
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3.4 Piston and cylinder dimensions

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

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thi
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Piston ∅ Cylinder bore ∅
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Basic dimension mm 82.465 1) 82.51
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• 1)
Dimensions without graphite coating (thickness 0.02
Prote AG.
mm). The graphite coating will wear down.

Amarok 2011 ➤
4 Crankshaft
⇒ “4.1 Assembly overview - crankshaft”, page 51
⇒ “4.2 Allocation of main bearing shells”, page 52
⇒ “4.3 Crankshaft dimensions”, page 53
⇒ “4.4 Measuring axial clearance of crankshaft”, page 54
⇒ “4.5 Measuring radial clearance of crankshaft”, page 54
⇒ “4.6 Renewing needle bearing in crankshaft”, page 55
4.1 Assembly overview - crankshaft
Note
Secure engine to repair stand using engine and gearbox support

- VAS 6095- when dismantling/assembling engine ⇒ page 21 .
1 - Cylinder block
2 - Bearing shell for cylinder
block
❑ With oil groove.
used bearing shells
(mark).
❑ Marking of crankshaft
bearing shells (classifi‐
cation) ⇒ page 52
3 - Crankshaft
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❑ Axial clearance
⇒ page 54
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❑ Radial clearance
⇒ page 54
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❑ Do not rotate crankshaft

when checking radial
s
clearance.
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inform
⇒ page 53 .
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4 - Bearing shell for bearing

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4. Crankshaft 51
Amarok 2011 ➤
5 - Bolt
❑ Tightening sequence ⇒ page 52 .
6 - Bearing cap
❑ Bearing cap 1: belt pulley end.
❑ Bearing shell retaining lugs in cylinder block and bearing caps must align.
7 - Bolt
❑ Always renew sender wheel if securing bolts have been unscrewed.
❑ 10 Nm + 90°
8 - Sender wheel
❑ For engine speed sender - G28-
❑ Can only be installed in one position, holes are offset.
❑ Always renew sender wheel if securing bolts have been unscrewed.
❑ Removing and installing ⇒ Item 7 (page 52) .
9 - Thrust washers
❑ For bearing 3.
10 - Bolt
Crankshaft tightening sequence

– Tighten crankshaft bolts in the sequence -1 …Vo5- as follows:
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4.2 Allocation of main bearing shells

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Bearing shells of the correct thickness are allocated to the cylin‐

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der block at the factory. Coloured dots are used to identify the
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Which bearing shell is to be inserted at each place in the cylinder

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agen
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cap 2, etc.

Amarok 2011 ➤
Marking on bearing shell for cylinder block:
Note
The marking on the cylinder block can be found engraved either

in the sump sealing surface or in the front end (gearbox side) of
the cylinder block.
Identification on cylinder block is allocated to upper bearing shell

(bearing shell for cylinder block).
– Note letters and identify colour code to be installed based on
table.
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Marking on bearing shell for bearing cap:
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– Note letters and identify colour code to be installed based on
table.
S = Black t to the co
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R = Red
G = Yellow
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B = Blue
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W = White
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4.3 Crankshaft dimensions
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(Dimensions in mm)
Prote AG.
Honing dimension Main journal ∅ Conrod journal ∅

1)
Basic dimension 58.00 47.80
4. Crankshaft 53
Amarok 2011 ➤
1)No provision has yet been made to recondition worn crank‐

shafts.
4.4 Measuring axial clearance of crankshaft AG. Volkswagen AG d

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♦ Universal dial gauge bracket - VW 387- hor eo
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♦ Dial gauge - VAS 6079-
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Procedure
– Screw dial gauge - VAS 6079- with universal dial gauge holder
- VW 387- onto cylinder block and set against crank web.
– Press crankshaft against dial gauge by hand and set gauge to
“0”.
– Push crankshaft away from dial gauge and read off value.
Axial clearance:
• New: 0.07 … 0.23 mm.
• Wear limit: 0.30 mm
4.5 Measuring radial clearance of crank‐

shaft
♦ Plastigage
Procedure
Note
♦ Do not interchange used bearings.

♦ Bearing shells worn down to nickel layer must be renewed.

Amarok 2011 ➤
– Remove main bearing caps and clean bearing caps and jour‐
nals.
– Place a length of Plastigage corresponding to the width of the
bearing on the bearing journal or in the bearing shells.
• Plastigage must rest in middle of bearing shell.
– Fit main bearing caps and tighten without twisting the crank‐
shaft.
– Remove main bearing cap again.
– Compare width of Plastigage with the measurement
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• New: 0.017 … 0.037 mm. au
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• Wear limit: 0.15 mm
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4.6 Renewing needle bearing in crankshaft

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♦ Internal puller - Kukko 21/2-
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and internal puller - Kukko
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rrectness of i
♦ Centring mandrel - 3176-
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♦ Drift - VW 207 C-
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Removing
• Gearbox is separated from engine.
4. Crankshaft 55
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Amarok 2011 ➤ d by ua
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4-cylinder injectionth engine (2.0 l direct injection engine, turbocharger)
o tee
or - Edition 04.2013
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– Pull needle bearing out using commercially available internal
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nl
pt
puller, e.g. KUKKO 21/2 and KUKKO 22/1, -A-.
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Installation depth dimension -a- = 1.5 to 1.8 mm.

Amarok 2011 ➤
15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 57
⇒ “1.2 Removing and installing cylinder head”, page 60
⇒ “1.3 Checking compression”, page 73
⇒ “1.4 Removing and installing vacuum pump”, page 75
1.1 Assembly overview - cylinder head
Note
♦ Renew cylinder head bolts.

♦ During fitting work, renew self-locking nuts, bolts which have
been tightened further as well as oil seals and gaskets.
♦ The plastic protectors fitted to protect the open valves must
only be removed immediately before fitting the cylinder head.
♦ When fitting a new cylinder head or cylinder head gasket, drain
off all the old coolant and refill with new coolant.
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1. Cylinder head 57
Amarok 2011 ➤
1 - Cylinder head gasket

❑ Observe installation po‐
sition: Part number to
cylinder head
2 - Bolt
❑ 25 Nm
3 - Transport lug
4 - Bolt
❑ Tighten in 2 stages:
❑ Initial tightening torque:
8 Nm
❑ Then, turn 90° further.
5 - Cylinder head
❑ Check for distortion
⇒ page 60 .
⇒ page 60 .
6 - Cylinder head bolt
❑ Note procedure when
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❑ Note procedure when
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❑ Lubricate with engine oil
8 - Plug
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❑ With ball head for engine cover panel
❑ 5 Nm
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❑ With seal.
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14 - Bolt
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❑ 20 Nm
15 - Bolt
❑ 20 Nm
58 Rep. gr.15 - Cylinder head, valve gear

Amarok 2011 ➤
16 - To intake manifold/turbocharger
17 - Breather pipe
18 - O-ring
❑ No replacement part available
19 - Seal
20 - Bolt
❑ Observe tightening sequence ⇒ page 59 .
❑ 11 Nm
21 - Crankcase breather
22 - Seal
23 - Seal
❑ Renew if damaged.
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26 - Connection
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28 - Bolt
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29 - O-ring
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❑ Moisten with coolant
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30 - Transport lug
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31 - Bolt
❑ 25 Nm
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32 - Bolt
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33 - Hall sender - G40-

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Note
♦ Bolts are self-tapping. When renewing cylinder head, only

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

-1 … 10-.
1. Cylinder head 59
Amarok 2011 ➤
Checking cylinder head for distortion

– Use straight edge and feeler gauge to measure cylinder head
for distortion at several points.
♦ Max. permissible distortion: 0.05 mm.
1.2 Removing and installing cylinder head

♦ Puller - T40039-
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♦ Removal tool - T10352- and removal tool - T10352/1- spec

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Amarok 2011 ➤
♦ Locking pin - T40011-
♦ Assembly pin - T40196-
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♦ Fit cable tie in same place when installing.
♦ Always seal open channels of intake and exhaust system with
suitable plugs, for example from engine bung set - VAS 6122- .
WARNING
Hot steam/hot coolant can escape - risk of scalding.

♦ The cooling system is under pressure when the engine is
hot.
♦ Cover filler cap on expansion tank with a cloth and open
carefully to dissipate pressure.
1. Cylinder head 61
Amarok 2011 ➤

– Release brake booster vacuum line.
– Remove rear coolant hoses from cylinder head.
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high-pressure pump -1-.

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– Disconnect electrical connectors -1 and 3- from air filter hous‐

ing.

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

pipe -2-.
– Unplug following electrical connectors.

2 - From knock sensor 1 - G61- and lay to one side.
3 - From variable intake manifold valve - N316- , fuel pressure
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6 - From intake air temperature sender - G42- .

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1. Cylinder head 63
Amarok 2011 ➤
– Unscrew bracket coolant line -arrow-.
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– Release connectors -arrows- and simultaneously detach all

connectors from ignition coils.

Amarok 2011 ➤
– Remove ignition coils using puller - T40039- .

– Unscrew spark plugs using spark plug socket and extension -
3122 B- .
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– Unscrew bolts -1 and 2- and lay oil supply line to one side.
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– Unscrew bolt -3- and lay coolant line to one side.
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– Detach connector -2- from oil pressure switch - F22- -1-.
1. Cylinder head 65
Amarok 2011 ➤

side.
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– Unscrew bolts -arrows- and remove by
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– Unscrew nuts -arrows- and remove catalytic converter
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⇒ page 251 .
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Amarok 2011 ➤
– Detach connector from inlet camshaft control valve 1 - N205-

-1-.
– Unscrew bolts -arrows- and remove inlet camshaft control
valve 1 - N205- .
– Unscrew bolts -1 to 5- and detach top cover for timing chain.

hold - T10355- .
bottom cover for timing chains.
• Markings -1- on camshafts must face upwards.
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Caution
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The timing valve has a left-hand thread.

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– Depending on model, remove regulating valve using removal

tool - T10352- or removal tool - T10352/1- in
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1. Cylinder head
Amarok 2011 ➤
– Remove bolts -arrows- and detach bearing saddle.

hold - T10355- .
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– Remove sealing plug -arrow-.

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Amarok 2011 ➤
– Insert scriber or suitable screwdriver in hole of chain tensioner

in direction of -arrow 1- and lift locking element for chain ten‐
sioner.
– Turn crankshaft in opposite direction to normal rotation
-arrow 2- and lock in place using locking pin - T40011- .
Note
Inlet camshaft will move in direction of engine rotation.
– Remove bolt -1- and guide tensioning rail -2- downwards.

– Use screwdriver to release catch and press off top guide rail
-3- forwards.
– Remove camshaft timing chain from camshaft sprockets.
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Avoid damage to valvestho and piston crowns. tee
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has been removed from the cylinder head.

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– Turn sealing plugs -arrows- 90° anti-clockwise -arrow- and re‐
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– Ball head -1 ... 2-. spec

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– Remove filler cap.
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1. Cylinder head 69
Amarok 2011 ➤
– Unscrew bolts -arrows-.

– Unscrew cylinder head bolts in the sequence -1 … 5- with
special wrench, long reach - T10070- apart from 2 bolts.
Note
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♦ Make sure all hoses/pipes and wiring are removed.tho eo
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♦ Ensure tensioning rail and guide rail are not damaged when
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lifting off cylinder head.
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– Remove cylinder head.
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Installing
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Avoid damage to sealing surfaces.

♦ Carefully remove sealant residue from cylinder head and
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cylinder block.
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♦ Ensure that no long scores or scratches are made on the
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Avoid damage to cylinder block.
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♦ No oil or coolant must be allowed to remain in the blind
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♦ Do not remove new cylinder head gasket from packaging
until it is ready to be fitted.
♦ Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
Avoid damage to open valves.
♦ 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 engine carefully at least 2 rotations to ensure that
none of the valves make contact when the starter is op‐
erated.

Amarok 2011 ➤
Note

angle.
♦ Renew gaskets, oil seals and self-locking nuts.
♦ Please note different sealants for sealing surfaces, bolts and
cylinder head.
♦ Secure all hose connections with the hose clips corresponding
to original equipment ⇒ Electronic Parts Catalogue (ETKA) .
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– Position cylinder head gasket.
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♦ Note centring pins in cylinder block -arrows-.

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♦ Check installation position of cylinder head gasket. The part
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When turning crankshaft, make sure that no components are
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– If crankshaft is turned in the meantime, position piston of No.

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– Fit cylinder head.

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To enable insertion of the cylinder head bolts, the inlet camshaft
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in total.
– Tighten bolts -arrows- in 2 stages in total.
Note
After repair work it is not necessary to retighten the cylinder head

bolts.
1. Cylinder head 71
Amarok 2011 ➤

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

markings on the chain sprockets.
– Fit camshaft timing chain: the drive chain/sprocket markings

must align -arrows-.
– Use spanner to turn inlet camshaft in direction of -arrow- and
fit timing chain.
– Attach bearing saddle and screw in bolts -arrows- hand-tight.

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– Remove locking pin
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Amarok 2011 ➤
– Insert bolts -1 … 2-.

– Tighten bolts for cylinder head in sequence -1 and 2- in 3
stages in total.
– Install timing chain cover (top) ⇒ page 78 .
– Fill cooling system with fresh coolant ⇒ page 141 .
– Install catalytic converter ⇒ page 251 .
WARNING
Never use battery charging equipment for boost starting. There

is the risk of damaging the vehicle's control units.
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 57
♦ ⇒ “2.1 Assembly overview - cover for timing chain”,
page 77
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1.3 Checking compression
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Special tools and workshop ut
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♦ Puller - T40039-
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1. Cylinder head 73
Amarok 2011 ➤
♦ Compression tester - V.A.G 1763-
Test procedure
Note
♦ Engine oil temperature min. 30 °C.

♦ Battery voltage at least 12.7 V

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Amarok 2011 ➤

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

crease.
Compression pressures:
New bar pressure Wear limit bar bar Difference between
pressure cylinders bar pres‐
sure
11.0 ... 14.0 7,0 max. 3.0
– Install ignition coils with output stages ⇒ page 254 .
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Amarok 2011 ➤
– Unscrew bolts -arrows- and remove vacuum pump.
Note
The vacuum pump must not be dismantled.
Installing
– Clean sealing surfaces.
– Place gasket on vacuum pump, insert 2 bolts and then fit on
cylinder head.
Specified torques
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⇒ page 78 .
9 - Seal
10 - O-ring
ling.
11 - Dowel pins
❑ For centring cover
12 - Lower timing chain cover
13 - Bolt
14 - Oil seal
❑ Renew. ⇒ page 36 .
2. Cover for timing chain 77

Amarok 2011 ➤
15 - Plug
Timing chain cover (top), tightening sequence

– Tighten bolts -1 to 5- in the sequence shown.
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Amarok 2011 ➤
– Unscrew bolts -1 to 5- and detach top cover for timing chain.

Installing
Note
Renew O-ring.
– Lubricate seal and O-ring with engine oil.

– Install upper timing chain cover. Observe tightening sequence
⇒ page 78 .
– Install inlet camshaft control valve 1 - N205- ⇒ page 121 .
Specified torques
♦ ⇒ “2.1 Assembly overview - cover for timing chain”, page 77
2.3 Removing and installing timing chain

cover (bottom)
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– Remove vibration damper.
Note
Always use thrust piece - T10368- when fitting bolt for vibration
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Amarok 2011 ➤
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Amarok 2011 ➤
– Lever off timing chain cover (bottom) (start at points

-1 and 2-).
Note
To prevent damaging the timing chain cover, apply tool only at

the bolt holes.
Installing
♦ Silicone sealant ⇒ Electronic Parts Catalogue (ETKA) .
Note

♦ The cover must be installed within 5 minutes after applying the
silicone sealant.
angle.
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then fill with engine oil.
– Install cover immediately and tighten bolts.

– Install tensioning device for poly V-belt ⇒ page 29 .
Specified torques

Amarok 2011 ➤
3 Chain drive
⇒ “3.1 Exploded view - camshaft timing chain”, page 84
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3.1 Exploded view - camshaft timing chain
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❑ 35 Nm
7 - Bolt
❑ 20 Nm + 90°
8 - Washer
9 - Bearing saddle
10 - Guide rail for camshaft tim‐
ing chain
11 - Camshaft housing
12 - Camshaft timing chain
❑ Before removing, mark running direction with paint.
13 - Guide rail for camshaft timing chain
14 - Guide pins
❑ 20 Nm

Amarok 2011 ➤
15 - Chain sprocket
❑ Crankshaft
❑ Installation position ⇒ page 85 .
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❑ 65 Nm
5 - Cylinder block
6 - Balancer shaft
❑ Inlet side
❑ Lubricate bearing with
engine oil
❑ Renewing ⇒ page 93 .
7 - O-ring
8 - Bearing mounting
⇒ page 86 .
9 - Intermediate shaft sprocket
❑ For balancer shaft.
❑ If bolt ⇒ Item 12 (page 86) has been loosened, intermediate shaft sprocket will need to be renewed.
3. Chain drive 85
Amarok 2011 ➤
10 - Bolt
❑ 9 Nm
11 - Washer
12 - Bolt
❑ If bolt has been loosened, intermediate shaft sprocket ⇒ Item 9 (page 85) will need to be renewed.
13 - Guide rail
14 - Guide pins
❑ 20 Nm
15 - Tensioning plate
16 - Guide pins
❑ 20 Nm
17 - Timing chain
❑ Removing ⇒ page 91
18 - Chain sprocket
19 - Guide rail
❑ For balancer shaft timing chain
20 - Guide pins
❑ 20 Nm
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olksw
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3. Chain drive 87
Amarok 2011 ➤
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– Remove camshaft timing chain from cylinder head.
Note
3. Chain drive 89
Amarok 2011 ➤
– Remove tensioning rail for timing chain -2-.

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– Remove timing chain.
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Amarok 2011 ➤

– Remove locking pin - T40011- .
– Tighten bolts -arrows- for bearing saddle.
– Install regulating valve ⇒ Item 6 (page 84) .
– Install timing chain cover (bottom) ⇒ page 79 .
Specified torques
♦ ⇒ “3.2 Assembly overview - balancer shaft timing chain”, page
85
♦ ⇒ “3.1 Exploded view - camshaft timing chain”, page 84
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3. Chain drive 91
Amarok 2011 ➤
– Remove chain tensioner for balancer shaft timing chain -1-.

– Remove tensioning rail -2-.
– Remove guide rail -3-.
– Remove guide rail -4-.
– Remove timing chain.
Installing
– Turn intermediate shaft sprocket/balancer shaft to markings

-arrows-.
Note
Timing chain links with coloured markings must be positioned at

markings on chain sprockets.
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– Fit guide rail for timing chain and tighten bolts -3-.
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Amarok 2011 ➤
– Check adjustment again.
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spec
For illustration purposes, the markings on intermediate shaft
sprocket/balancer shaft are shown with the chain removed.
t to the co
– Install camshaft timing chain ⇒ page 87 .
rrectne
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♦ ⇒ “3.1 Exploded view - camshaft timing chain”, page 84 cop Vo
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AG.
3.5 Renewing balancer shaft for inlet cam‐

shaft
♦ Puller - T10394-
3. Chain drive 93
Amarok 2011 ➤
♦ Puller - T10055- agen

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Removing
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Note
The balancer shaft for the inlet camshaft must always be renewed
nform
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after removing.
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– Remove toothed belt for coolant pump ⇒ page 154 .
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– Remove camshaft timing chain ⇒ page 87 . cted agen
Prote AG.
– Remove balancer shaft timing chain ⇒ page 91 .

– Remove intermediate shaft sprocket -1-.
– Unscrew bolt -2- for inlet camshaft balancer shaft.

Amarok 2011 ➤
– Insert shell half - T10394/1- from puller - T10394- and turns

upwards in direction of arrow.
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– Insert puller - sT10394-
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– Screw puller - T10055- into puller - T10394- and force out bal‐
ancer shaft in -direction of arrow-.
nform
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Installing
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Due to the small amount of play between the balancer shaft and
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cylinder block, the balancer shaft may need to be installed chilled.
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Check whether the balancer shaft can be fitted into the cylinder p by
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block without exerting force. If this is not the case, the balancer
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shaft must be chilled before installing.
AG.
– Place new balancer shaft in freezer compartment for 30 mi‐

nutes, if necessary, or spray with commercially available cool‐
ing spray.
– Lubricate balancer shaft bearing with engine oil.
– Install new balancer shaft for inlet camshaft and tighten bolt
-2-.
3. Chain drive 95
Amarok 2011 ➤
. Volkswagen AG
– Renew O-ring -1- and lubricate with gen AG oil.
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– Lubricate bearing mounting ise
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pin -arrow- for bearing umounting
thor
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The intermediate shaft sprocket must be replaced. Otherwise
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The new intermediate shaft sprocket is coated with a solid film
spec
lubricant that wears off after a short period and thus automat‐
es, in part or in w
t to the co
ically sets the tooth backlash.
rrectness of i
– Mark faces of gear teeth of intermediate shaft sprocket with
l purpos
paint -arrows-.
– Insert intermediate shaft sprocket; marking on balancer shaft
nf
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must be positioned between markings on faces of gear teeth.
orm
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– Tighten bolt -1- for intermediate shaft sprocket: tightening se‐ Prote AG.
– Check markings on intermediate shaft sprocket/balancer shaft
-arrow-.
– Install balancer shaft module ⇒ page 91 .
– Renew oil seal for coolant pump drive ⇒ page 155 .
– Fit toothed belt for coolant pump ⇒ page 154 .
Specified torques
85
♦ ⇒ “3.1 Exploded view - camshaft timing chain”, page 84
3.6 Renewing balancer shaft for exhaust

camshaft

Amarok 2011 ➤
♦ Puller - T10394-
♦ Puller - T10055-
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Removing
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Note
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The balancer shaft for the inlet camshaft must always be renewed
after removing.
nform
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– Remove camshaft timing chain ⇒ page 87 .

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– Remove balancer shaft timing chain ⇒ page 91 .
rig
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– Unscrew bolt -1- for exhaust camshaft balancer shaft.
by lksw
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3. Chain drive 97
Amarok 2011 ➤
– Insert shell half -T10394/1- from puller - T10394- .
– Insert puller - T10394- and push locking collar in

– Screw puller - T10055- into puller - T10394- and force out bal‐
ancer shaft.
Installing
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Due to the smallutamount
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cylinder block,ssthe balancer shaft may need to be installed chilled. ac
a
Check whether the balancer shaft can be fitted into the cylinder
ce
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un
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block without exerting force. If this is not the case, the balancer
an
d
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shaft must be chilled before installing.

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

h re
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spec
Lug -arrow- must engage in slot.

es, in part or in w
t to the co
– Place new balancer shaft in freezer compartment for 30 mi‐

nutes, if necessary, or spray with commercially available cool‐
ing spray.
rrectness of i
– Lubricate balancer shaft bearing with engine oil.

l purpos
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mercia
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Prote AG.

Amarok 2011 ➤
– Install balancer shaft for exhaust camshaft.

– Before tightening bolt -1-, check that balancer shaft rests flat
against crankcase.
Note
If the balancer shaft does not rest flat, the pipe for balancer shaft
must be inserted again.
– Install balancer shaft module ⇒ page 91 .

Specified torques
85
olkswagen AG
en AG. V
♦ ⇒ “3.1 Exploded view - camshaft timing chain”, pageolk84
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♦ ⇒ “2.1 Assembly overview - cover for timing chain”,
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♦ ⇒ “1.1 Assembly overview - poly V-belt drive”,
ss
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3.7 Checking valve timing
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Note
spec
es, in part or in w
t to the co
Use a ratchet spanner with a 24 mm socket to turn the vibration
damper. Always turn the vibration damper in the engine's direc‐
tion of rotation to the “TDC” position. Do not correct TDC position
by turning the damper in the other direction. rrectness of i
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bottom cover for timing chains (use a mirror).
nform
ercia
• Markings -1- on camshafts must face upwards.

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3. Chain drive 99
Amarok 2011 ➤ agen
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– Measure the distance from the outer edge ofaweb
ut
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-A- to mark‐ or
ac
ing -B- on the inlet camshaft. ss
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• Specification: 61…64 mm.
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– If the specified value is achieved, measure the distance be‐

tween the marking on the inlet camshaft -B- and the marking
on the exhaust camshaft -C-.
nform
ercia
• Specification: 124…126 mm
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Offset of one tooth means a deviation of approx. 6 mm from the
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Amarok 2011 ➤
4 Valve gear
⇒ “4.1 Assembly overview - valve gear”, page 101
⇒ “4.2 Removing and installing camshafts”, page 102
⇒ “4.3 Renewing valve stem seals with cylinder head installed”,
page 113
⇒ “4.4 Renewing valve stem seals with cylinder head removed”,
page 117 agen
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⇒ “4.5 Measuring axial
ed
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⇒ “4.6 Removingau
thoand installing inlet camshaft control valve 1 e or
ac
N205 ”, pages 121
s
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4.1 Assembly overview - valve gear
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1 - Exhaust valve
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❑ Do not rework. Only lap‐
hole
ping in is permitted.
spec
es, in part or in w
❑ Valve dimensions
t to the co
⇒ page 123
❑ Checking valve guides
rrectness of i
⇒ page 122 .
l purpos
2 - Cylinder head
3 - Valve guide
nform
ercia
❑ Checking ⇒ page 122 .

m
4 - Valve stem seal

com
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❑ Renewing with cylinder

r
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head installed
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⇒ page 117 .
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❑ Renewing with cylinder

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5 - Valve spring
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6 - Valve spring plate
7 - Valve cotters
8 - Hydraulic compensation el‐
ement
❑ Do not interchange.
❑ Oil contact surface.
9 - Exhaust camshaft
❑ Check radial clearance
with Plastigage (roller
rocker fingers re‐
moved).
❑ Radial clearance:
0.024 … 0.066 mm.
❑ Runout: max. 0.04 mm.
10 - Cylinder head cover
❑ With integrated camshaft bearings.
❑ Clean sealing surface; reworking not permitted.
❑ Remove sealant residue.
4. Valve gear 101

Amarok 2011 ➤
11 - Bolt
❑ Loosen ⇒ page 102
12 - O-ring
13 - Plug
14 - Inlet camshaft
❑ Check radial clearance with Plastigage (roller rocker fingers removed).
❑ Radial clearance: 0.024 … 0.066 mm.
❑ Runout: max. 0.04 mm.
15 - Cap
❑ Removing: With cylinder head cover installed, pierce one side of the cap with an awl and lever off cap.
16 - Inlet valve
❑ Do not rework. Only lapping in is permitted.
❑ Valve dimensions ⇒ page 123
❑ Checking valve guides ⇒ page 122 .
Cylinder head cover - release

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– Loosen cylinder head cover bolts in the sequence 1 … 6.Volkswa not
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Tightening sequence for cylinder head cover

– Renew bolts.
rrectness of i
1. Fit bolts in the sequence -1 … 6- and hand-tighten in several

l purpos
stages.
2. Tighten bolts in the sequence -1 … 6- to 8 Nm using torque
nform
ercia
wrench.
m
3. Turn 90° further in the sequence -1 … 6- using a fixed

com
tio
wrench.
n in
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Take care to keep cylinder head cover level. Cop py
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4.2 Removing and installing camshafts Prote AG.

Amarok 2011 ➤
♦ Puller - T40039-
♦ Removal tool - T10352/1-

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♦ Locking pin - T40011- t. Cop py
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4. Valve gear 103

Amarok 2011 ➤
AG. Volkswagen AG d
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♦ Assembly pin - T40196- ris ed
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♦ Spacers - T40191-
l purpos
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Cop py
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Prote AG.
Removing
Note
♦ Sealing surfaces at bottom of cylinder head cover and top of

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

ing.

Amarok 2011 ➤
– Release clip -4- and detach hose.

– Release air intake hose -3- from air filter housing -1-.
– Pull off vacuum hose -2-.

– Unscrew securing bolt for air filter housing in area of coolant
expansion tank.
– Withdraw air filter housing upwards.
AG. Volkswagen AG d
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ility
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wit
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es, in part or in w
t to the co
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on
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Cop py
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Prote AG.
4. Valve gear 105

Amarok 2011 ➤
– Disconnect crankcase breather hose -1-.

– Unscrew bolts -arrows-, remove crankcase breather system
and detach from hose -2- for crankcase breather system in
– Disconnect line -arrows-. agen

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– Detach and remove electrical yV
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-1-.
rrectness of i
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valve 1 - N205- . nf
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– Unscrew bolts -1 to 5- and detach top cover for timing chain. pyri
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Caution
AG.

Amarok 2011 ➤
– Remove regulating valve using removal tool - T10352/1- in di‐

rection of -arrow-.

– Turn vibration dampereto TDC

n AG. Volkposition
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hold - T10355- .olkswag does
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damper must align with arrow marking
ran
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cover afor
ut timing chains (bottom).
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Note
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Engine must be at “TDC” again.

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t to the co
– Use a waterproof pen to mark drive chain at marks on chain

sprockets -arrows-.
rrectness of i
l purpos
nform
mercia
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tion in
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Cop py
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Prote AG.
4. Valve gear 107

Amarok 2011 ➤
– Remove sealing plug -arrow-.

sioner.
– Turn crankshaft in opposite direction to normal rotation
-arrow 2- and lock in place using locking pin - T40011- .
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Note
ility
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es, in part or in w
– Remove bolt -1- and guide tensioning rail -2- downwards.
t to the co
– Use screwdriver to release catch and press off top guide rail
-3- forwards.
– Remove camshaft timing chain from camshaft sprockets. rrectness of i
l purpos
Caution
nf
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orm
Avoid damage to valves and piston crowns.

m
atio
om
♦ Do not turn the crankshaft after the camshaft timing chain

n in
or c
has been removed from the cylinder head.

thi
te
sd
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– Remove high-pressure pump ⇒ page 238 .

t.
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– Remove vacuum pump ⇒ page 75 .
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ho 4-cylinder injection engine (2.0 l direct injection eo
ra engine, turbocharger) - Edition 04.2013
s a c
s
– Undo and remove cylinder head cover bolts in the sequence
ce
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du
-1 … 6-.
an
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– Remove cylinder head cover.
ility
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– Detach camshafts.
, is n
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hole
spec
Caution
es, in part or in w
t to the co
Danger of soiling lubrication system and bearings.
♦ Cover open parts of engine.
rrectness of i
l purpos
Installing
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ercia

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♦ Sealing surfaces must be free of oil and grease.

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♦ Pistons must not be positioned at TDC.

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♦ Ensure that all roller rocker fingers are properly seated on
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Prote AG.
– Remove sealant remaining on cylinder head with flat scraper.
WARNING
Risk of eye injury.

– Remove sealant left in groove of cylinder head cover and on

sealing surfaces, e.g. using a rotating plastic brush.
– Clean sealing surfaces. They must be oil and grease free.
– Oil running surfaces of both camshafts.
4. Valve gear 109

Amarok 2011 ➤
WARNING
Risk of eye injury.

AG. Volkswagen AG d
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♦ Wear safety goggles. yV
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– Lock camshaft with spacers - T40191- assshown;
s a
if necessary, c
slide forked sleeves into correct position.
ce
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nl
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Note
ility
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If available, use 2nd set of spacers - T40191- or reuse -
h re
hole
T40191/1- .
spec
es, in part or in w
t to the co
– Insert camshafts in cylinder head; markings -arrows- must be
positioned as shown.
rrectness of i
l purpos
nf
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orm
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atio
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n in
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– Check alignment -arrows- of camshafts. . C rig
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Prote AG.
– Cut off nozzle of tube at front marking (∅ of nozzle approx.

2 mm).

Amarok 2011 ➤
– Apply silicone sealant onto clean sealing surface of cylinder

head cover, as illustrated -arrows-.
Note
♦ The cylinder head cover must be installed within 5 minutes

after applying the silicone sealant.
♦ Observe expiry date of sealing compound.
Sealant ⇒ Electronic Parts Catalogue (ETKA) .

– Fit cylinder head cover onto cylinder head.
– Renew bolts for cylinder head cover.
– Tighten bolts in several stages.
Note
AG. Volkswagen AG d
Take care to keep cylinder head cover level. lksw
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– Use thrust piece - T10174- to drive in asealing
ut
h cap -1- (do not ra
apply sealant). ss c
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- a -: 1 ... 2 mm
an
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hold - T10355- .
nform
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Note
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The timing chain links with markings must be positioned at the

fo
en
ng
markings on the chain sprockets.

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Valve gear 111

Amarok 2011 ➤
– Fit camshaft timing chain: the drive chain/sprocket markings AG. Volkswagen AG d
must align -arrows-. agen oes
olksw not
byV gu
ara
d
– Use spanner to turn inlet camshaft in direction of -arrow- andorise nte
fit timing chain. aut
h eo
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
– Remove locking pin - T40011- .
rrectness of i
– Tighten bolts -arrows- for bearing saddle.
l purpos
– Install regulating valve.
nform
ercia
– Turn crankshaft 4 times in direction of engine's rotation.

m
a
com
t
ion in
r
te o
– Install vacuum pump ⇒ page 75 .
thi
s
iva
do
– Installing high-pressure pump ⇒ page 238 .
r
rp
cum
fo
en
g
– Install air filter housing ⇒ page 218 .

n
t.
yi Co
Cop py
– Install underbody guard, if fitted previously ⇒ General body ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Specified torques
Prote AG.

♦ ⇒ “4.1 Assembly overview - valve gear”, page 101
♦ ⇒ “6.1 Assembly overview - high-pressure pump”, page 237
♦ ⇒ “3.1 Assembly overview - air filter housing”, page 216

Amarok 2011 ➤
4.3 Renewing valve stem seals with cylinder head installed

AG. Volkswagen AG d
agen oes
Special tools and workshop olksw not
yV gu
equipment required rised b ara
nte
ho eo
♦ Spark plug socket and ex‐ aut ra
s c
tension - 3122 B- s
ce
le
un
pt
♦ Valve stem seal puller -
an
d
itte
y li
3364-
rm
ab
pe
ility
♦ Valve stem seal fitting tool -
ot
wit
, is n
3365-
h re
hole
spec
♦ Adapter - T40012- es, in part or in w
t to the co
1331-
♦ Dismantling and assem‐
rrectness of i
bling device for valve cot‐
l purpos
ters - VAS 5161-

♦ Guide plate for 2.0 l and 3.0
nform
ercia
l FSI engine - VAS

5161/19B-
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.
Removing valve stem oil seals

– Remove camshafts ⇒ page 102 .
– Mark allocation of roller rocker fingers and hydraulic compen‐
sation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and place down on a clean surface.
3122 B- .
4. Valve gear 113

Amarok 2011 ➤
– Secure guide plate for 2.0 ltr. and 3.0 ltr. FSI engine - VAS
5161/19B- with knurled screws - VAS 5161/12- to cylinder
head as shown.
– Set piston of respective cylinder to “bottom dead centre”.
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
– Screw adapter - T40012- into spark plug thread.
is n
h re
ole,
– Connect compressed air with pressure rating of at least 6 bar.
spec
– Strike tight valve cotters with drift - VAS 5161/3- and a plastic
t to the co
hammer.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
For inlet side n thi

te
sd
va
– Screw retainer - VAS 5161/6- with guide fork - VAS 5161/5-

i
o
pr
cum
r
into centre thread of guide plate for 2.0 ltr. and 3.0 ltr. FSI
fo
en
ng
engine - VAS 5161/19B- .

t.
yi Co
Cop py
. rig
– Insert assembly cartridge - VAS 5161/8- into guide plate for
t
gh ht
yri by
2.0 ltr. and 3.0 ltr. FSI engine - VAS 5161/19B- . cop Vo
by lksw
cted agen
Prote
– Attach pressure fork - VAS 5161/2- to retainer - VAS 5161/6- .
AG.
For exhaust side

into outer threads of guide plate for 2.0 ltr. and 3.0 ltr. FSI
– Press installation cartridge - VAS 5161/8- down and turn
knurled screw of installation cartridge - VAS 5161/8- to right
until tips engage in valve cotters.
– Move knurled screw back and forth slightly to press apart valve
cotters and capture them in the assembly cartridge.
– Release pressure fork - VAS 5161/2- .
– Remove installation cartridge - VAS 5161/8- .

Amarok 2011 ➤
– Pull off valve stem seals using valve stem seal puller - 3364- .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– If valve stem seal puller - 3364- cannot be used on account of
rrectness of i
restricted space, knock out pin -arrow- with a punch and re‐
move the impact extractor attachment.
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
– Place lower part of valve stem seal puller - 3364- onto valve
rig ht
py by
stem seal.
co Vo
by lksw
cted agen
Prote AG.
– Insert punch -1- into bore in lower part of puller.
– Place installation lever on puller and pull out valve stem seal
-arrow-.
Installing valve stem seals
– To prevent damage to new valve stem seals -B-, attach plastic

sleeve -A- to valve stem.
– Lubricate sealing lip of valve stem seal -B-, place it in the valve
stem oil seal fitting tool - 3365- and push carefully onto valve
guide.
– Remove plastic sleeve -A-.
– Insert valve spring and valve spring plate.
– Install removal and installation device for valve cotters - VAS
5161- as shown.
4. Valve gear 115

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

cartridge, they must first be inserted into the insertion device
- VAS 5161/18- .
♦ Press assembly cartridge -VAS 5161/8- onto insertion device AG. Volkswagen AG d
from above and pick up valve cotters. agen oes
olksw not
y V gu
d b ara
rise nte
– Press installation cartridge - VAS 5161/8- down with utho pressure eo
ra
fork - VAS 5161/2- , and turn installation cartridge
ss a knurled c
screw back and forth whilst pulling upwards.
ce
le
un
pt
an
d
– Relieve pressure fork - VAS 5161/2- whilst pulling on knurled

itte
y li
screw.
erm
ab
ility
ot p
– Remove removal and installation device - VAS 5161- .

wit
is n
h re
ole,
Perform assembly analogously in reverse order of removal. When

spec
doing this, observe the following:

t to the co
– Install camshafts ⇒ page 102 .

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

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

AG. Volkswagen AG d
agen
Special tools and workshop Volksw
oes
not
gu
equipment required ed by ara
nte
ris
o eo
♦ Valve stem seal puller
aut -
h
ra
3364- ss c
ce
e
nl
pt
♦ Valve stem seal fitting tool -
du
an
itte
3365-
y li
erm
ab
ility
♦ Dismantling and assem‐
ot p
wit
bling device for valve cot‐
, is n
h re
ters - VAS 5161-
hole
spec
♦ Guide plate for 2.0 l and 3.0
es, in part or in w
t to the co
l FSI engine - VAS
5161/19B-
♦ Engine and gearbox sup‐
rrectness of i
port - VAS 6095-
l purpos
♦ Cylinder head tensioning

device - VAS 6419-
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.
Procedure
– Remove camshafts ⇒ page 102 .
– Mark allocation of roller rocker fingers and hydraulic compen‐
sation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and place down on a clean surface.
– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095- .
– Tension cylinder head on cylinder head tensioning device as
shown in illustration.
– Connect cylinder head tensioning device to compressed air.
4. Valve gear 117

Amarok 2011 ➤
– Use lever -arrow- to slide air cushion under combustion cham‐

ber from which valve stem seal is to be removed.
– Allow compressed air to flow into air cushion until it lies against
valve disc.
– Secure guide plate for 2.0 ltr. and 3.0 ltr. FSI engine - VAS
5161/19B- with knurled screws - VAS 5161/12- to cylinder
head as shown.
AG. Volkswagen AG d
– Set piston of respective cylinder to “bottom dead centre”.
olks
wage
n oes
not
byV gu
– Insert drift -VAS 5161/3- into guide plate rand
ised use a plastic ara
nte
hammer to knock loose the firmly seated ut valve cotters.
ho eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
For inlet side
t to the co
into centre thread of guide plate for 2.0 ltr. and 3.0 ltr. FSI
rrectne
– Insert assembly cartridge - VAS 5161/8- into guide plate for
2.0 ltr. and 3.0 ltr. FSI engine - VAS 5161/19B- .
ss o
– Attach pressure fork - VAS 5161/2- to retainer - VAS 5161/6- .
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
For exhaust side

p
cum
r
fo
en
ng

t.
yi Co
op
into outer threads of guide plate for 2.0 ltr. and 3.0 ltr. FSI C py
ht. rig
engine - VAS 5161/19B- . rig ht
py by
co Vo
by lksw
– Press installation cartridge - VAS 5161/8- down and turn cted agen
Prote AG.
knurled screw of installation cartridge - VAS 5161/8- to right
until tips engage in valve cotters.
– Move knurled screw back and forth slightly to press apart valve
cotters and capture them in the assembly cartridge.
– Release pressure fork - VAS 5161/2- .
– Remove installation cartridge - VAS 5161/8- .

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

♦ Place plastic sleeve -A-, enclosed with new valve stem
seals -B-, onto valve stem.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
– Lightly oil sealing lip of valve stem seal.

itte
y li
erm
ab
– Push valve stem oil seal onto plastic sleeve.
ility
ot p
wit
is n
– Carefully press valve stem oil seal onto valve guide using
h re
valve stem seal fitting tool - 3365- .
ole,
spec
– Remove plastic sleeve.
t to the co
– Insert valve spring and valve spring plate.
– Remove removal and installation device for valve cotters -
rrectne
VAS 5161- as shown.
ss o
cial p
f in
Inlet side
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Exhaust side
4. Valve gear 119

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

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

fork - VAS 5161/2- , and turn installation
gen AGcartridge knurled
. Volkswagen AG
does
screw back and forth whilst pulling
lkswa
upwards. not
Vo g y ua
db ran
– Relieve pressure fork - VAS
ris
e
5161/2- whilst pulling on knurled tee
screw. utho or
a ac
ss
– Remove removal and installation device for valve cotters -
ce
le
un
pt
VAS 5161- .
an
d
itte
y li
erm
Further assembly is basically the reverse of the dismantling se‐
ab
ility
quence. In the process, note the following:
ot p
wit
is n
– Install camshafts ⇒ page 102 .
h re
ole,
spec
4.5 Measuring axial clearance of camshaft
t to the co
rrectne
♦ Universal dial gauge bracket - VW 387-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
♦ Dial gauge - VAS 6079- cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
aut
h
2011 ➤ Amarok
ra
s c
s
ce
le
un
pt
an
d
Test procedure
itte
y li
rm
ab
pe
– Take measurements with retaining frame removed.
ility
ot
wit
, is n
– Fit camshaft to be tested in retaining frame.
h re
hole
spec
– Attach dial gauge - VAS 6079- with universal dial gauge holder
es, in part or in w
- VW 387- to cylinder head.
t to the co
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
rrectness of i
– Press camshaft away from dial gauge and read off value:
l purpos
• Axial clearance: 0.05 … 0.17 mm.
nform
ercia
4.6 Removing and installing inlet camshaft

m
a
com
tio
control valve 1 - N205-
n in
r
te o
thi
s
Removing
iva
do
r
rp
cum
fo
en
ng
-1-.
t.
yi Co
Cop py
. rig
ht ht
rig by
py
valve 1 - N205- . co Vo
by lksw
cted agen
Prote
Installing
AG.
Note
Renew O-ring.
– Lubricate seal and O-ring with engine oil.

Specified torques
4. Valve gear 121

Amarok 2011 ➤
5 Inlet and exhaust valves

⇒ “5.1 Checking valve guides”, page 122
⇒ “5.2 Valve dimensions”, page 123
5.1 Checking valve guides

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge - VAS 6079-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
Test procedure ss c
ce
le
un
pt
– Insert valve in guide. Valve stem end must be flush with guide.
an
d
itte
On account of differing stem diameters, only use inlet valve in

y li
rm
ab
inlet guide and exhaust valve in exhaust guide.
pe
ility
ot
wit
, is n
– Determine rock. h re
hole
spec
Wear limit
es, in part or in w
t to the co
Inlet valve guide Exhaust valve guide

0.80 mm 0.80 mm
rrectness of i
l purpos
Note
nform
ercia
♦ If the wear limit is exceeded, repeat the measurement with

new valves. If the wear limit is exceeded again, renew the cyl‐
m
a
com
inder head.
ion in
r
te o
♦ If the valve is to be renewed as part of a repair, use a new

thi
s
iva
valve for the calculation.

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 ➤
5.2 Valve dimensions

Valve dimensions
Note
AG. Volkswagen AG d
agen oes
olksw not
Inlet and exhaust
ed by V valves must not be reworked. gu
Only
ara lapping-in
is permitted.
thoris nte
e or
au ac
ss
Dimension Inlet valve Exhaust valve
ce
e
nl
pt
du
an
itte
∅a mm 33.85 ± 0.10 28.0 ± 0.1
y li
erm
ab
∅b mm 5.98 ± 0.01 5.96 ± 0.01
ility
ot p
wit
c mm 104.0 ± 0.2 101.9 ± 0.2
, is n
h re
hole
α ∠° 45 45
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.
5. Inlet and exhaust valves 123

Amarok 2011 ➤
17 – Lubrication Volksw
agen
AG. Volkswagen AG d
oes
not
gu
d by ara
ise nte
r
1 Sump, oil pump ho eo
aut ra
ss c
⇒ “1.1 Assembly overview - sump, oil pump”, page 124
ce
le
un
pt
an
d
itte
⇒ “1.2 Removing and installing lower part of sump”, page 126
y li
erm
ab
ility
⇒ “1.3 Removing and installing upper part of sump”, page 129
ot p
wit
is n
⇒ “1.4 Removing and installing oil pump”, page 132
h re
ole,
spec
⇒ “1.5 Engine oil”, page 133
t to the co
1.1 Assembly overview - sump, oil pump
rrectne
1 - Bolt
ss o
❑ Tightening sequence
cial p
f in
⇒ page 125 .
form
mer
2 - Lower part of sump
atio
om
n
c
i
or
n thi
⇒ page 126 .
te
sd
iva
o
r
3 - Baffle plate
p
cum
r
fo
en
ng

t.
yi Co
Cop py
4 - Suction line
t. rig
gh ht
yri by
❑ Clean strainer if soiled.
op Vo
by c lksw
cted agen
Prote AG.
5 - Bolt
❑ 9 Nm
6 - O-ring
7 - Oil pump
⇒ page 132 .
8 - Centring sleeve
9 - O-ring
10 - Oil pressure control valve
- N428-
⇒ page 136 .
11 - Bolt
❑ 9 Nm
12 - Chain tensioner
13 - Drive chain for oil pump
❑ Mark direction of rotation before removing.
14 - Bolt
❑ 9 Nm
15 - Seal
124 Rep. gr.17 - Lubrication

Amarok 2011 ➤
16 - Coarse oil separator

❑ Removing and installing ⇒ page 135 . agen
AG. Volkswagen AG d
oes
olksw not
V
17 - Bolt e d by gu
ara
ris nte
❑ Observe tightening sequence ⇒ page u126
tho . eo
ra
a
❑ 9 Nm ss c
ce
e
nl
pt
18 - Upper part of sump
du
an
itte
y li
erm
ab
ility
ot p
19 - Bolt
wit
, is n
h re
❑ Renew after removing hole
spec
es, in part or in w
t to the co
20 - Bolt
rrectness of i
l purpos
21 - Bolt
❑ 20 Nm
nform
ercia
22 - Seal
m
at
23 - Bolt
om
ion
c
❑ 9 Nm
in t
or
his
ate
24 - Seal
do
priv
cum
or
25 - Non-return valve
f
en
ng
t.
yi Co
op
26 - Oil drain plug
C py
t. rig
gh ht
yri
❑ Renew after removing p by
o Vo
by c lksw
cted
❑ 30 Nm
agen
Prote AG.
Tightening sequence for sump (bottom section)

– Tighten bolts in sequence -1 to 19- in 2 stages as follows:
1. Tighten bolts to 8 Nm.
2. Turn bolts 45° further
Tightening sequence for sump (top section)

– 1) Tighten bolts to 15 Nm.
– 2) Turn bolts 90° further.
1. Sump, oil pump 125

Amarok 2011 ➤
Tightening sequence for coarse oil separator

– Tighten bolts in the sequence -1 … 9-.
AG. Volkswagen n AG do
wage es n
Volks ot g
by ua
ed ran
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
1.2 Removing and installing lower part of
t to the co
sump
rrectne
♦ Used oil collection and extraction unit - V.A.G 1782-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Support bracket - 10 - 222 A-
♦ Hand drill with plastic brush

♦ Eye protection
♦ Silicone sealant ⇒ Electronic Parts Catalogue (ETKA)
Removing
Note
♦ To remove the sump lower part the engine has to be supported

and raised by approx. 15 cm. This ensures the necessary
space to remove the sump lower part.
♦ Observe environmental regulations for disposal.
– Support engine with support bracket - 10 - 222 A- .

Amarok 2011 ➤
– Unscrew bolts for right and left engine mounting ⇒ page 25 .

– Raise engine by approx. 15 cm.
– Drain off engine oil.
– Unscrew bolts -1 … 20-.
– Remove sump; if necessary, loosen using light blows with a
rubber-headed hammer.
Installing
Note

♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
– Remove sealant residues from sump upper part with a flat

scraper.
WARNING
Risk of eye injury. agen

AG. Volkswagen AG d
oes
olksw not
V gu
♦ Wear safety goggles. sed by ara
nte
ri
ho eo
aut ra
ss c
ce
e
nl
– Remove sealant residue from bottom part of sump, e.g. with

pt
du
an
rotating plastic brush.

itte
y li
erm
ab
– Clean sealing surfaces until they are all oil- and grease-free.
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
3 mm).
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
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Apply the bead of silicone sealant to the clean sealing surface

of the sump (bottom section), as illustrated.
♦ Thickness of sealant bead: 2 … 3 mm.
Note
♦ The sump must be installed within 5 minutes of applying sili‐

cone sealing compound.
♦ Let sealing compound dry for approx. 30 minutes after instal‐
ling oil sump. Only then fill with engine oil.
– Fit lower part of sump immediately and tighten bolts in three

stages. wage
e ks s no
Vol t gu
– Top up engine oil, oil capacities
ed ⇒ page 133 .
by ara
ris nte
Specified torques utho eo
ra
a c
ss
♦ ⇒ “1.1 Assembly overview - sump, oil pump”, page 124
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
ir se
d ran
tee Amarok 2011 ➤
o
auth engine (2.0 l direct injection engine, turbocharger) or
ac - Edition 04.2013
ss
ce
e
1.3 Removing and installing upper part of sump
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
equipment required
, is n
h re
hole
♦ Assembly tool - T10118-
spec
es, in part or in w
♦ Brake lining wear gauge -
t to the co
VW 136-
rrectness of i
1331-
l purpos
♦ Silicone sealant ⇒ Elec‐

tronic Parts Catalogue (ET‐
KA)
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
– Remove gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Removing gearbox .
– Remove oil pump ⇒ page 132 .
– Remove sealing flange on gearbox side ⇒ page 44 .
– Unscrew bolts -arrows-.
DANGER!
Injury risk! When removing upper part of sump, spring of chain

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

Amarok 2011 ➤
– Remove bolts -1 to 14- and lever off upper part of sump.
Caution
Lever off upper part of sump on gearbox side first. When lev‐
ering off, exercise caution to ensure the timing chain cover is
not bent in the process.
Installing
Note

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

for oil pump drive in direction of guide rail -arrow-.
– Secure spring by inserting brake lining wear gauge - VW 136- ,
as shown in illustration, into hole of guide rail.
– Remove sealant residues from cylinder block with a flat scra‐
per.
WARNING
Risk of eye injury.

AG. Volkswagen AG d
♦ Wear safety goggles. lksw
agen oes
not
Vo gu
by ara
d
rise nte
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u ra
– Remove remaining sealant on upper part
ss a
of sump and lower c
timing chain cover e.g. using rotating plastic brush.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
Check timing chain cover for deformation. To do this, fit sump

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

es, in part or in w
t to the co
not be corrected. Renew cover once sump upper part has been
installed.
rrectness of i
– Clean sealing surfaces until they are all oil- and grease-free.
l purpos
– Check oil galleries in sump upper part and crankcase for soil‐
ing.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤

3 mm).
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
– Apply silicone sealant onto clean sealing surface of upper part
h re
of sump, as illustrated -arrow-.
hole
spec
es, in part or in w
• Thickness of sealant bead: 2…3 mm
t to the co
Note
rrectness of i
l purpos
♦ The sump upper part must be installed within 5 minutes of ap‐

plying silicone sealing compound.
nform
ercia

m
at
om
ion
c
in t
or
his
e
• Sump upper part and crankcase must be flush on gearbox

at
do
riv
side.
p
cum
for
en
ng
t.
yi
– Fit sump upper part immediately and tighten bolts -1 to 14- in
Co
op py
3 stages as follows:
t. C rig
gh ht
pyri by
Vo
o
1- Tighten bolts hand tight.
c by lksw
cted agen
Prote AG.
2- Tighten bolts to 15 Nm.
3- Turn bolts 90° further.
– Install bolts -arrows-.

Amarok 2011 ➤
. Volkswagen AG
– Pull brake lining wear gauge - VW 136- out of guide rail kswagen AG does
not
-arrow-. Spring now jumps back to installation position. Vol gu
by ara
ed nte
ris
Specified torques ut
ho eo
ra
sa c
♦ ⇒ “1.1 Assembly overview - sump, oil pump”,s page 124
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
1.4 Removing and installing oil pump
rrectne
s
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Remove sump (bottom section) ⇒ page 126 .
– Remove baffle plate -arrows-.
Note
The following procedure must be performed in one operation. A

2nd mechanic is required to assist.
– Unscrew bolts -arrows- and remove oil pump.

Amarok 2011 ➤
– Pull chain tensioner back using assembly tool - T10118- and

have oil pump removed by a second mechanic.
Installing
– Before installing oil pump, check strainer in oil suction pipe and
oil galleries in upper part of sump for soiling.
– Check that both centring sleeves for centring oil pump are
present.
– Renew baffle plate.
Note
. Volkswagen AG
gen AG d
Plastic ribs that are permanently
Vol
ksw
a
deformed during tightening
oes
not are
located on the baffleseplate.
db
y
The plastic rips ensure that the gu
abaffle
ran
plate rests withoutthoplay
ri and does not rattle. For this reason, the tee
or
baffle plate should
s au always be replaced. ac
s
ce
le
un
pt
Specified torques
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
1.5 Engine oil
h re
ole,
spec
Oil capacities:
t to the co
With oil filter change: 6.5 l
Without oil filter change: 6.1 l rrectne
Engine oil specifications:
s
⇒ Maintenance ; Booklet 11
s o
cial p
f in
Checking oil level:

form
mer
atio
om
Note
c
i
or
n thi
te
sd
va
The oil level must not be above the max. mark - risk of damage
i
o
pr
cum
to catalytic converter!
r
fo
en
ng
t.
yi Co
op py
Test prerequisites t. C rig
gh ht
pyri by
• Engine oil temperature at least 60 °C.
co Vo
by lksw
cted agen
Prote AG.
• Vehicle must be level (horizontal).
• Wait a few minutes after switching engine off to allow oil to flow
back into sump.
Test procedure
– Pull out dipstick, wipe off with a clean cloth and insert it again
to stop.
– Pull out dipstick again and read oil level.

olkswagen AG
wag en AG. V
Amarok 2011 ➤ olks
does
not
yV gu
sedengine, turbocharger) - Edition 04.2013
b ara
n ri tee
ho
ut or
Markings on dipstick: ss
a ac
ce
e
nl
a - Oil is not to be topped up.
pt
du
an
itte
y li
b - Oil can be topped up.
erm
ab
ility
ot p
c - Oil must be topped up.
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
The oil level must not be above the max. marking -arrow 1- nor
below the min. marking -arrow 2-.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
2 Crankcase breather
⇒ “2.1 Removing and installing coarse oil separator”, page 135
2.1 Removing and installing coarse oil sep‐

arator
♦ Support bracket - 10 - 222 A-
Removing
– Support engine.
pipe -2-.
– Remove left engine support ⇒ page 25 .
– Drain coolant ⇒ page 141 . olkswage es n
ot g
byV ua
– Release vacuum hoses ⇒ Item 17 (page 149) and ir se
d ran
tee
⇒ Item 13 (page 148) from coolant pump. autho
or
ac
ss
ce
e
nl
pt
du
– Remove coarse oil separator -1 ... 9-. an

itte
y li
erm
ab
Installing ility
ot p
wit
, is n

h re
hole
spec

es, in part or in w
t to the co
– Check oil level and top up, if necessary ⇒ page 133 .

Specified torques
rrectness of i

l purpos

ing”, page 25
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
135
cted agen
Prote AG.
2. Crankcase breather
Amarok 2011 ➤
3 Oil filter, oil pressure switch

⇒ “3.1 Assembly overview - oil filter housing, oil pressure switch”,
page 136
⇒ “3.2 Removing and installing oil pressure switch F22 ”,
page 137
AG. Volkswagen AG d
⇒ “3.3 Checking oil pressure”, page 137 agen oes
olksw not
y V gu
d b ara
3.1 Assembly overview - oil filter housing, oil pressure switch thorise nte
eo
au ra
ss c
ce
e
nl
1 - Bracket for ancillaries
pt
du
an
itte
y li
erm
ab
⇒ page 32 .
ility
ot p
wit
2 - Seal
, is n
h re
hole
spec
es, in part or in w
3 - O-ring
t to the co
❑ Not replacement part.
Include in items sup‐
plied with valve unit
rrectness of i
4 - O-ring
l purpos
❑ Not replacement part.

Include in items sup‐
nform
ercia
plied with valve unit

m
at
5 - Valve unit
om
ion
c
in t
❑ With O-rings
or
his
ate
do
riv
6 - Oil filter
p
cum
or
❑ Remove and install with

f
en
ng
t.
oil filter tool - 3417- .
yi Co
Cop py
❑ Removing and instal‐
t. rig
gh ht
yri
ling, Amarok ⇒ Mainte‐
p by
co Vo
by lksw
nance ; Booklet 11 . Prote
cted AG.
agen
7 - Seal
8 - Oil pressure switch - F22-
❑ Blue insulation
❑ Check ⇒ Vehicle diag‐
nostic tester.
⇒ page 137 .
❑ 20 Nm
9 - Bolt
❑ 23 Nm
10 - Connection
11 - Seal
❑ Moisten with coolant additive.
12 - Engine oil cooler
❑ Ensure clearance to adjacent components.
❑ See note ⇒ page 139 .

Amarok 2011 ➤
13 - Gasket
❑ Renew after removing agen
AG. Volkswagen AG d
oes
olksw not
V
14 - Bolt ed by gu
ara
ris nte
❑ Tightening sequence ⇒ page u27
t .
ho eo
ra
s a c
s
ce
le
un
pt
an
d
3.2 Removing and installing oil pressure
itte
y li
erm
ab
switch - F22-
ility
ot p
wit
is n
Removing
h re
ole,
spec
t to the co
Note
Place a cloth underneath bracket for ancillaries to catch any es‐
rrectne
caping engine oil.
s
– Detach connector -2- from oil pressure switch - F22- -1-.
s o
cial p
f i
– Unscrew oil pressure switch - F22- -2-.
nform
mer
Installing
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
Note
fo
en
ng
t.
yi Co
op
♦ Renew seal.
C py
t. rig
gh ht
yri by
♦ Insert new oil pressure switch - F22- immediately in bore to
op Vo
by c lksw
avoid loss of oil.
cted agen
Prote AG.
Specified torques
♦ ⇒ “3.1 Assembly overview - oil filter housing, oil pressure
switch”, page 136
3.3 Checking oil pressure

♦ Oil pressure tester - V.A.G 1342-
Test prerequisites
• Oil level OK.
• Engine oil temperature at least 80 °C (radiator fan must have
run once)
3. Oil filter, oil pressure switch 137

Amarok 2011 ➤
Test procedure
AG. Volkswagen AG d
agen oes
Note olksw not
y V gu
d b ara
rise nte
Place a cloth underneath bracket for ancillaries to catch any aes‐
ut
ho eo
ra
caping engine oil. ss c
ce
e
nl
pt
du
an
– Detach connector -2- from oil pressure switch - F22- -1-, un‐
itte
y li
screw oil pressure switch - F22- .
erm
ab
ility
ot p
– Screw oil pressure tester - V.A.G 1342- into oil filter bracket in
wit
, is n
place of oil pressure switch.
h re
hole
spec
– Start engine.
es, in part or in w
t to the co
• Oil pressure at idling speed:1.2 ... 2.1 bar.
• Oil pressure at 2000 rpm: 1.6 ... 2.1 bar.
rrectness of i
• Oil pressure at 3700 rpm: 3.0 ... 4.0 bar.
l purpos
Note
nf
ercia
orm
During the first 1000 km the oil pressure could be 3.0 to 4.0 bar
m
atio
m
at 2000 rpm.
o
n in
or c
thi
te
sd
a
Reassembly
iv
o
r
rp
cu
o
m
– Install oil pressure switch.
f
en
ng
t.
yi Co
op
Specified torques C py
t. rig
gh ht
yri
p by
co Vo
by lksw
switch”, page 136 Prote
cted AG.
agen

Amarok 2011 ➤
4 Engine oil cooler

⇒ “4.1 Removing and installing engine oil cooler”, page 139
4.1 Removing and installing engine oil cool‐

er
♦ Drip tray for workshop hoist - VAS 6208-
Removing AG. Volkswagen AG d

agen oes
olksw not
byV gu
WARNING rised ara
nte
ho eo
aut ra
Hot steam/hot coolant can escape - risk of scalding.
ss c
ce
le
un
pt
♦ The cooling system is under pressure when the engine is
an
d
itte
hot.
y li
rm
ab
pe
ility
♦ Cover filler cap on expansion tank with a cloth and open
ot
carefully to dissipate pressure.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove bracket for ancillaries ⇒ page 32 .
– Unscrew bolts -4 and 5- and remove engine oil cooler -3- to‐
rrectness of i
gether with seal -2-.
l purpos
Installing
nform
mercia
a
com
tio
Note
n in
r
te o
thi
s
iva
♦ Renew gaskets and seals.

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. Engine oil cooler 139

Amarok 2011 ➤
– Install engine oil cooler -3- with new seal -2-.

– Install bracket for ancillaries ⇒ page 32 .
Specified torques
switch”, page 136
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
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
19 – Cooling
1 Cooling system, coolant
⇒ “1.1 Draining and filling coolant”, page 141
⇒ “1.2 Checking cooling system for leaks”, page 144
⇒ “1.3 Coolant hose schematic diagram”, page 146
⇒ “1.4 Coolant hose schematic diagram for vehicles with 2nd heat
exchanger”, page 147
1.1 Draining and filling coolant

equipment required
♦ Refractometer - T10007 A-
♦ Drip tray for workshop hoist
AG. Volkswagen AG d
- VAS 6208- ksw
agen oes
not
ol
yV gu
♦ Hose clip pliers - VAS ised b ara
nte
6340- ut
hor eo
a ra
s c
♦ Cooling system charge unit s
ce
e
- VAS 6096-
nl
pt
du
an
itte
y li
♦ Adapter for cooling system
erm
ab
tester - V.A.G 1274/8-
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.
1. Cooling system, coolant 141

Amarok 2011 ➤
Draining
WARNING
Steam may escape when expansion tank is opened. Wear eye

protection and protective clothing to avoid eye injuries and
scalding. Cover cap with cloth and open carefully.
– Open filler cap -2- on expansion tank -1-.

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
– Remove spring-type clip -2 and detach bottom coolant hose
wit
, is n
h re
-1- from radiator -3-.
hole
spec
es, in part or in w
t to the co
Note
Observe environmental regulations for disposal.
rrectness of i
l purpos
Filling
nf
ercia
o
Note
rm
m
atio
om
The amount of water used in the coolant mixture has a great in‐
n in
or c
fluence on its effectiveness. Because the water quality differs

thi
te
sd
from country to country and even region to region, Volkswagen

iva
o
r
has decided to define the quality of the water to be used in the

rp
cu
o
coolant system. Distilled water fulfils all requirements. It is there‐

f
en
ng
t.
yi
fore recommended that the coolant be mixed with distilled water
Co
op py
whenever the coolant is replenished or replaced, even for older
t. C rig
gh ht
yri
models. p by
o Vo
by c lksw
cted agen
Prote AG.
Caution
Only distilled water may be used for mixing with coolant addi‐
tives. The use of distilled water ensures optimum protection
against corrosion.
142 Rep. gr.19 - Cooling

Amarok 2011 ➤
Note
Volkswa
♦ Use only coolant additivesswwhich
agen conform with
AG. gen AG
the
does⇒ Elec‐
tronic parts catalogue by (ETKA) . Other coolant additivesgumay
Volk not
reduce corrosionriprotection
sed substantially. The resulting dam‐
ara
nte
age could leaduthto loss of coolant and subsequent severe e or
o
damage to thess engine.
a ac
ce
e
nl
♦ The correct coolant solution ratio helps prevent damage due
pt
du
an
to freezing and corrosion as well as scaling. Moreover, the
itte
y li
erm
boiling temperature is raised. Therefore, the cooling system
ab
ility
must be filled all year round with coolant additive.
ot p
wit
, is n
♦ Because of its higher boiling point, the coolant improves en‐
h re
hole
gine reliability under heavy loads, particularly in countries with
spec
tropical climates.
es, in part or in w
t to the co
♦ Frost protection must be guaranteed down to about -25 °C (in
countries with Arctic climates, down to about -36 °C).
rrectness of i
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The
l purpos
coolant additive concentration must be at least 40%.

♦ If a stronger anti-freeze mixture is necessary due to harsher
nform
ercia
weather conditions, the coolant additive content can be in‐

m
creased. But only to 60 %, or the antifreeze protection will be
at
om
io
reduced again and the cooling effect will be impaired.
n
c
in t
or
his
♦ ONLY refractometer - T10007 A- may be used for determining
ate
do
riv
current anti-freeze density.

p
cum
for
♦ Read anti-freeze figures from respective scale for type of anti-

en
ng
t.
yi
freeze added.
Co
Cop py
ht. rig
ht
♦ Do not reuse old coolant.
rig by
copy Vo
by lksw
cted agen
Prote AG.
Recommended mixture ratios:
Frost protection Coolant additive Coolant ad‐ Distilled wa‐
to portion ditive 2) ter2)
-25 °C 40 % 5.0 l 7.5 l
-36 °C 50 % 6.25 l 6.25 l
2) The quantity of coolant can vary depending upon vehicle equipment.
Procedure
– Unscrew filler cap -2- from expansion tank -1-.

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

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
e
nl
pt
du
1.2 Checking cooling system for leaks
an
itte
y li
erm
ab
ility
ot p
wit
, is n
♦ Cooling system tester - V.A.G 1274 B-
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
♦ Adapter for cooling system tester - V.A.G 1274/8-

a
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.
♦ Adapter for cooling system tester - V.A.G 1274/9-
Test prerequisite
• Engine at normal operating temperature

Amarok 2011 ➤
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- .
– Join connection piece - V.A.G 1274 wageB/1- to cooling system
e
tester - V.A.G 1274 B- usingy Vconnecting
olks hose supplied. s not gu
b ara
ed
– Using hand pump on ttester,
ho
ris build up a pressure of approx. 1.0 nte
e or
bar. s au ac
s
ce
e
nl
pt
du
DANGER!
an
itte
y li
erm
ab
Risk of scalding! Before the cooling system tester - V.A.G 1274
ility
ot p
B- is disconnected from the connecting hose or the connector
wit
, is n
h re
- V.A.G 1274 B/1- it is essential that the pressure is first re‐
hole
lieved. To do this, press pressure relief valve on cooling system
spec
tester - V.A.G 1274 B- until pressure gauge displays value of
es, in part or in w
t to the co
»0«.
rrectness of i
If pressure drops:
l purpos
– Find leaks and rectify.

Checking pressure relief valve in filler cap:
nform
ercia
– Screw cap into adapter for cooling system tester - V.A.G

m
at
1274/9- .
om
ion
c
in t
r
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling

o
his
te
system tester - V.A.G 1274/9- .

a
do
priv
cum
for
en
– Join connection piece - V.A.G 1274 B/1- to cooling system

ng
t.
yi Co
tester - V.A.G 1274 B- using connecting hose supplied. t. Cop py
rig
gh ht
– Operate hand pump. pyri by
Vo
o
by c lksw
cted agen
• The pressure relief valve should open at a pressure of 1.4 … Prote AG.
1.6 bar.

Amarok 2011 ➤
1.3 Coolant hose schematic diagram
1 - Heat exchanger for heater

unit
2 - Cylinder head connection
3 - Circulating pump V 55 (only
for Climatronic)
4 - Auxiliary heater
♦ Depending on equipment.
5 - Circulating pump V 51
6 - Radiator wage
es n
lks ot g
Vo
♦ Renew coolant after replac‐
ed
by ua
ran
ing. horis tee
ut or
a ac
♦ Removing andssinstalling
⇒ page 160 .
ce
e
nl
pt
du
an
itte
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erm
ab
ility
8 - Turbocharger
ot p
wit
, is n
9 - Cylinder head
h re
hole
spec
10 - Thermostat
es, in part or in w
t to the co
11 - Coolant pump
12 - Expansion tank
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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

heat exchanger
2 - Heat exchanger for heater
unit
3 - Shut-off valve
4 - Circulating pump V 55 (only
for Climatronic)
5 - Auxiliary heater
♦ Depending on equipment.
6 - Radiator
♦ Renew coolant after replac‐
ing.
♦ Removing and installing
⇒ page 160 .
7 - Circulating pump V 51
AG. Volkswagen AG d
agen oes
9 - Turbocharger olksw not
y V gu
d b ara
10 - Cylinder head rise nte
tho eo
au ra
11 - Thermostat ss c
ce
e
nl
pt
12 - Coolant pump
du
an
itte
y li
13 - Cylinder head connection
erm
ab
ility
ot p
14 - Expansion tank
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - coolant hoses”, page 148
⇒ “2.2 Assembly overview - coolant pump, thermostat”,
page 150
⇒ “2.3 Removing and installing continued coolant circulation
pump V51 ”, page 151
⇒ “2.4 Removing and installing coolant temperature sender G62
”, page 152
⇒ “2.5 Removing and installing toothed belt for coolant pump”,
page 154
⇒ “2.6 Renewing oil seal for coolant pump drive”, page 155
⇒ “2.7 Removing and installing coolant pump”, page 157
⇒ “2.8 Removing and installing thermostat”, page 158
2.1 Assembly overview - coolant hoses

Volkswa AG. gen AG
agen does
olksw not
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1 - Coolant hose rise
db ara
nte
❑ To expansion tank. tho eo
au ra
c
ss
2 - Coolant hose
ce
le
un
pt
an
❑ To heat exchanger
d
itte
y li
rm
ab
❑ Return line
pe
ility
ot
3 - Coolant hose
wit
, is n
h re
❑ To heat exchanger
hole
spec
❑ Supply
es, in part or in w
t to the co
4 - Coolant pipe
5 - Coolant hose
rrectness of i
❑ From coolant pipe to

l purpos
supplementary water
pump
nform
ercia
6 - O-ring
m
7 - Coolant hose
a
com
tion in
8 - Continued coolant circula‐

r
te o
thi
tion pump - V51-

s
iva
do
r

rp
cum
fo
⇒ page 151 .
en
ng
t.
yi Co
op
9 - Coolant hose C py
ht. rig
rig ht
❑ To water connection py by
co Vo
by lksw
cted agen
10 - Coolant pipe with coolant Prote AG.
hose
11 - Coolant hose
❑ To supplementary water
pump
12 - Retainer
13 - Coolant pipe with coolant
hose
❑ To coolant pump.

Amarok 2011 ➤
14 - Coolant hose
15 - Coolant hose
❑ Radiator top
AG. Volkswagen AG d
agen oes
16 - Coolant hose olksw not
V gu
d by ara
❑ To radiator orise nte
h eo
❑ Top left aut ra
ss c
ce
e
17 - Coolant hose
nl
pt
du
an
❑ From radiator to coolant pump
itte
y li
erm
ab
18 - Retainer
ility
ot p
wit
, is n
19 - Coolant pipe
h re
hole
spec
20 - Bracket for continued coolant circulation pump - V51- .
es, in part or in w
t to the co
21 - Coolant pipe
❑ Return line
rrectness of i
22 - Seal
l purpos
23 - Coolant pipe
❑ Supply
nf
ercia
o
24 - Coolant hose
rm
m
atio
m
25 - Coolant hose
o
n in
or c
❑ To expansion tank
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. Coolant pump, regulation of cooling system 149

Amarok 2011 ➤
4-cylinder injection engine (2.0 ol lkdirect
sw
injection engine, turbocharger) - Edition 04.2013
AG. V agen AG
agen does
lksw not
2.2 Assembly overview - coolant pump, thermostat
o
yV gu
db ara
rise nte
tho eo
s au ra
c
1 - Bolt s
ce
le
un
pt
an
d
itte
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rm
ab
pe
❑ 9 Nm
ility
ot
wit
, is n
2 - O-rings
h re
hole
spec
es, in part or in w
3 - Connection
t to the co
4 - Retaining clip
❑ Only for inserted ver‐
rrectness of i
sion.
l purpos
❑ Check for secure seat‐

ing.
nform
ercia
5 - Coolant temperature send‐

m
er - G62-
a
com
tio
n in
r
te o
⇒ page 152 .
thi
s
iva
do
6 - O-ring
r
rp
cum
fo

en
ng
t.
yi Co
op py
7 - Coolant pump t. C rig
gh ht
yri by
❑ New coolant pump: re‐ op Vo
by c lksw
move protective cap cted agen
Prote AG.
⇒ page 157 .
8 - Gasket
9 - Centralising pin
10 - Toothed belt
❑ For coolant pump.
⇒ page 154 .
11 - Toothed belt guard
12 - Bolt
❑ 9 Nm
13 - Bolt
❑ Left-hand thread.
❑ 10 Nm + 90°
14 - Toothed belt drive sprocket
❑ Note installation position.
15 - Oil seal
❑ Renewing ⇒ page 155 .
16 - Balancer shaft
17 - Thermostat

Amarok 2011 ➤
18 - Centralising pin
19 - O-ring
20 - Connection
21 - Bolt
❑ 9 Nm
Coolant pump - tightening sequence

– Tighten bolts for coolant pump in the sequence -1 … 5-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut ra
2.3 Removing and installing continued cool‐ ss a c
ce
le
ant circulation pump - V51-

un
pt
an
d
itte
y li
erm
ab
ility
ot p
♦ Hose clamps up to 25 mm - 3094-
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
♦ Hose clip pliers - V.A.G 1921-

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

– Clamp off coolant hoses -arrows- using hose clamps to 25 mm
- 3094- and remove.
– Disconnect electrical connector -2-.
– Remove bolt -1- and detach continued coolant circulation
pump - V51- .
Installing
Note
♦ Hose unions and air intake pipes/hoses must be free of oil and
grease when installing.
n AG. gen AG Volkswa
♦ Secure all hose connections with the hose
olks clips corresponding
wage does
not
to original equipment ⇒ Electronic
ed
bParts
yV Catalogue (ETKA) . gu
ara
ris nte
♦ In order to be able to attach the
uthoair ducts on their connections, eo
ra
the screws of the used hose ss clips have to be sprayed with
a c
penetrating spray before installing.
ce
e
nl
pt
du
an
itte
y li
– Check coolant level ⇒ page 141 .

erm
ab
ility
ot p
wit
, is n
2.4 Removing and installing coolant temper‐

h re
hole
ature sender - G62-

spec
es, in part or in w
t to the co
Removing
• Engine cold
rrectness of i

l purpos

nform
ercia
pipe -2-.
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 ➤
– Disconnect electrical connector -1- at throttle valve module -

J338- .
– Remove bolts -arrows- and detach throttle valve module -
J338- .
– Remove support for intake manifold (remove nut -2- and bolt
-1-).
– Disconnect electrical connector -1- at coolant temperature
sender - G62- .
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.

lkswage es n
o ot g
byV ua
d ran
ir se
Amarok 2011 th ➤
o tee
or
u
4-cylinder
ss injection engine (2.0 l direct injection engine, turbocharger)
a ac
- Edition 04.2013
ce
le
un
pt
– Detach retaining clip (press release tabs -arrows-).
an
d
itte
y li
rm
ab
pe
ility
ot
Note
wit
, is n
h re
hole
Place a cloth underneath to absorb escaping coolant.
spec
es, in part or in w
t to the co
– Remove coolant temperature sender - G62- -2-.
Installing
rrectness of i
l purpos
Note
nform
mercia
a
♦ Renew O-rings.
com
tion in
r
♦ Insert new coolant temperature sender - G62- immediately in‐

te o
thi
to connection to avoid loss of coolant.
s
iva
do
r
rp
cum
♦ Hose unions and air intake pipes/hoses must be free of oil and
fo
en
g
grease when installing.

n
t.
yi Co
Cop py
t. rig
gh ht
yri
p by
co Vo
by lksw
cted agen
♦ In order to be able to securely attach the air ducts on their
Prote AG.
connections, the screws of the used hose clips have to be

sprayed with penetrating spray before installing.
– Install intake manifold support ⇒ page 229 .

– Install throttle valve module - J338- ⇒ page 233 .
Specified torques
♦ ⇒ “2.2 Assembly overview - coolant pump, thermostat”,
page 150
2.5 Removing and installing toothed belt for

coolant pump
♦ Socket - T10360-
Removing
– Remove short coolant pipe ⇒ page 148 .
– Release long coolant pipe and lay aside ⇒ page 148 .

Amarok 2011 ➤
– Disconnect coolant hoses -1 and 2- and move clear to one

side.
– Unscrew bolts -arrows- and remove toothed belt guard.
Caution
Risk of damage to thread.

♦ The drive sprocket bolt has a left-hand thread.
– Use torque wrench - V.A.G 1331- and socket - T10360- to re‐

move bolt on coolant pump drive sprocket -1- (counterhold at
vibration damper.
– Detach drive sprocket -1- and toothed belt -2-.
Installing n AG. Volkswagen AG do
wage e n
Installation is carried o out in the reverse order. sWhen
lks ot g installing,
byV ua
note the following:
ir se
d ran
tee
tho
u or
a ac
ss
Note
ce
le
un
pt
an
d
itte
y li
♦ Replace bolt for drive sprocket.

erm
ab
ility
ot p
♦ Renew seals and O-rings.

wit
is n
h re
♦ Note installation position of V-belt pulley ⇒ page 150 .

ole,
spec
t to the co
– Install short coolant pipe ⇒ page 148 .

rrectne
Specified torques
ss
page 150
o
cial p
f inform
mer
2.6 Renewing oil seal for coolant pump drive

atio
om

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 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Procedure
hole
spec
– Remove short coolant pipe ⇒ page 148 .
es, in part or in w
t to the co
– Release long coolant pipe and lay aside ⇒ page 148 .
rrectness of i
– Press screwdriver -1- firmly onto section -2- of oil seal
l purpos
-arrow B-.
– Lever out oil seal -arrow A-.
nf
ercia
orm
– Clean contact surface and sealing surface.
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
– Lubricate sealing surface of balance shaft -2- with gear oil.
AG.
– Fit oil seal -1- onto balance shaft.

• The marking “Luftseite” (“Outside”) -arrow- should be legible
from the outside.
Caution
Risk of damage to thread.

♦ The drive sprocket bolt has a left-hand thread.
– Apply thrust piece - T10353- to oil seal -1- and press into cyl‐
inder block as far as stop using bolt -2- (take care not to tilt oil
seal).

Amarok 2011 ➤
2.7 Removing and installing coolant pump AG. Volkswagen AG d

agen oes
ksw
Removing by
Vol not
gu
ara
ed
is nte
– Remove short coolant pipe ⇒ page 148 . hor eo
aut ra
c
– Release long coolant pipe and lay aside ⇒ page 148 . ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Disconnect electrical connector -1- at throttle valve module -
ility
ot p
J338- .
wit
, is n
h re
– Remove bolts -arrows- and detach throttle valve module -
hole
J338- .
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
– Disconnect electrical connector -1- at coolant temperature
om
n in
sender - G62- .
or c
thi
te
sd
iva
o
r
rp
cu
Note
o
m
f
en
ng
t.
yi Co
op
Disregard -item 2 and arrows-. C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Disconnect coolant hoses. To do so, raise retaining clips -1-

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

Amarok 2011 ➤
– Remove bolts -1 … 5-.

– Detach coolant pump from centring pin and pull off engine oil
cooler.
Note
Ignore -arrow-.
Installing
Note
Renew seals and O-rings.
– Moisten O-rings -4- with coolant.

– Check whether the two centring pins are fitted in the cylinder
block; install if necessary.
– Fit connecting piece -2- into engine oil cooler -1-.
– Push coolant pump -3- onto connecting piece and centring pin
into cylinder block.
– Tighten bolts for coolant pump.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Note rised
nte
ho eo
aut ra
Remove protective cap -arrow- if a new coolant pump has been ss c
ce
fitted.
le
un
pt
an
d
itte
y li
rm

ab
pe
ility
ot
– Install throttle valve module - J338- ⇒ page 233 .

wit
, is n
h re

hole
spec
es, in part or in w

t to the co
Specified torques
rrectness of i
page 150
l purpos
♦ ⇒ “5.1 Assembly overview - intake manifold”, page 228

nform
ercia
2.8 Removing and installing thermostat

m
a
com
tio
Removing
n in
r
te o
thi

s
iva
do

r
rp
cum
fo

en
ng
t.
yi Co
op py
– Disconnect coolant hose ⇒ Item 17 (page 149) arrow from en‐
. C rig
ht ht
rig
gine mounting. py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Remove engine mounting (left-side) ⇒ page 25 .

– Unscrew continued coolant circulation pump - V51- with brack‐
et.
– Remove coarse oil separator ⇒ page 135 .
– Unscrew bolts -arrows- and remove connection.
– Detach thermostat.
Installing
Note
Renew seals and O-rings.
– Clean sealing surface for O-ring.

– Moisten O-ring with coolant.
– Insert thermostat -4- in coolant pump housing -5- and swivel

forwards slightly -arrow-.
. Volkswagen AG
gen AG does
– Fit connection -3- carefully (insert centralising pin -2-olin
kswguide
a
not
-1-). byV gu
ara
ed nte
ris
– Install coarse oil separator ⇒ page 135 . ho eo
aut ra
ss c
– Install left engine mounting ⇒ page 25 .
ce
le
un
pt
an
d

itte
y li
rm
ab
Specified torques
pe
ility
ot
wit
, is n
h re
page 150
hole
spec
es, in part or in w
t to the co
ing”, page 25
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
3 Radiator, radiator
en AG. V
ofan
lkswagen AG
ag does
ol ksw n
⇒ “3.1 Assembly overview
y V - radiator/ radiator fan V7 ”, t gua
o
db
page 160 rise ran
te
ho eo
ut
⇒ “3.2 Assembly
ss
a overview - radiator cowl and radiator fan V7 ”, r ac
page 162
ce
e
nl
pt
du
an
⇒ “3.3 Removing and installing radiator cowl with radiator fan V7
itte
y li
”, page 162
erm
ab
ility
ot p
⇒ “3.4 Removing and installing radiator”, page 164
wit
, is n
h re
3.1 Assembly overview - radiator/ radiator fan - V7-
hole
spec
es, in part or in w
t to the co
1 - Radiator upper mounting
2 - Radiator
rrectness of i
❑ Renew coolant after re‐
l purpos
placing.
nform
ercia
⇒ page 164 .
m
3 - Charge air cooler
at
om
ion
c
4 - Upper cowling
in t
or
his
ate
5 - Condenser (only for vehi‐

do
priv
cles with air conditioning sys‐

um
for
tem)
en
ng
t.
yi Co
op py
6 - Cap t. C rig
gh ht
yri by
❑ Check using cooling cop Vo
by lksw
system tester - V.A.G cted agen
Prote AG.
1274- and adapter for
cooling system tester -
V.A.G 1274/9- .
❑ Test pressure 1.4…1.6
bar
7 - Connector
8 - Bolt
❑ 5 Nm
9 - Expansion tank
❑ With coolant tempera‐
ture display sender -
G32- .
❑ Leakage test
⇒ page 144 .
10 - Bolt
❑ 5 Nm
11 - Radiator cowl with radiator
fan - V7-
12 - Bolt
❑ 4 Nm
13 - Breather line
❑ Secured to radiator at top.
❑ Coolant hose schematic diagram ⇒ page 146 .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
thor eo Amarok 2011 ➤
u ra
ss a engine (2.0 l direct injection engine, turbocharger) c - Edition 04.2013
ce
e
nl
pt
du
14 - Spring-type clip
an
itte
y li
erm
ab
15 - Bolt
ility
ot p
❑ 1.2 Nm
wit
, is n
h re
16 - Retainer
hole
spec
❑ For continued coolant circulation pump - V51-
es, in part or in w
t to the co
17 - Bolt
❑ 4.5 Nm
rrectness of i
18 - Continued coolant circulation pump - V51-
l purpos
19 - Coolant hose
nform
ercia
20 - Retainer
m
at
om
io
21 - Radiator outlet coolant temperature sender - G83-
n
c
in t
or
his
ate
do
riv
22 - Retainer
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
24 - Radiator lower mounting opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.
3. Radiator, radiator fan 161

Amarok 2011 ➤
3.2 Assembly overview - radiator cowl and radiator fan - V7-
1 - Radiator
2 - Radiator fan - V7-
3 - Bolt
❑ 5 Nm
4 - Bolt
❑ 5 Nm
5 - Locking lug
❑ Must be engaged in ra‐
diator.
6 - Radiator cowl
⇒ page 162 .
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
3.3 Removing and installing radiator cowl

with radiator fan - V7-
rrectness of i
Removing
l purpos

nform
ercia
– Unclip coolant hose -1- from brackets -2-.

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– Unscrew securing bolts -3- for radiator cowl -4-.

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Amarok 2011 ➤
– Disconnect connector -1- from radiator cowl -2-.
– Remove bolts -1-.

– Detach retaining clips -3- with water hose -4- from radiator
cowl -2-.
– Release radiator cowl -2- at left and right. To do this, press

retaining lever -1- forwards using a screwdriver, and raise ra‐
diator cowl -2- slightly.
– Remove radiator cowl. AG. Volkswagen A
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– Unscrew bolts -arrows- and remove radiator fan - V7- -1-.

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Specified torques
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♦ ⇒ “3.2 Assembly overview - radiator cowl and radiator fan V7

te
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”, page 162
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Amarok 2011 ➤
3.4 Removing and installing radiator

♦ Socket set 1/4", 22-piece - VAS 5528-
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Removing
– Undo and remove bolts -2- that fasten radiator to lock carrier
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Only for vehicles with air conditioning

– Remove lock carrier ⇒ General body repairs, exterior; Rep.
nform
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gr. 50 ; Lock carrier .

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– Remove coolant hose -1- at radiator -3- and remove connect‐

ing hose -2-.
– Remove right connecting hose leading to turbocharger from
charge air cooler and place to one side.
– Remove air duct mounting ⇒ page 162 .

Amarok 2011 ➤
– Unclip left radiator fastening -2- at condenser -3-.

– Unclip right radiator fastening as well and pull condenser
agen
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– Support condenser, e.g. with cable ties.
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– Do not bend or stretch the refrigerant lines excessively.
hole
spec
– Carefully remove radiator upwards together with charge air
es, in part or in w
t to the co
cooler. When doing so, take the radiator -2- past the refrigerant
lines.
rrectness of i
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Note
♦ If the radiator -1- is to be replaced, undo bolts of charge air
nf
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cooler and remove it from radiator.
rm
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♦ Undo and remove bolt -2- on right and left (not shown in illus‐
o
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c
tration) at radiator.
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Note
Before installing radiator, check that radiator mountings -1- are

correctly seated on front part of car -2- and, if necessary, reposi‐
tion:

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".
– Insert top radiator mountings -1- on right and left into the
mounting on radiator -2- appropriately.
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– When installing the radiator, make sure that the catches -1- of
spec
the radiator mounting on the left and right at the top have en‐
es, in part or in w
t to the co
gaged completely in the lock carrier.
Observe instructions for hose connections with screw-type clips
⇒ page 10 .
rrectness of i
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Amarok 2011 ➤
– Fit condenser -3- on radiator -1- on left and right so that it en‐
gages securely in the catches -2-.
– Install radiator cowl ⇒ page 162 .
For vehicles with air conditioning
– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
50 ; Lock carrier .
Specified torques
♦ ⇒ “3.1 Assembly overview - radiator/ radiator fan V7 ”,
page 160
♦ ⇒ “3.2 Assembly overview - radiator cowl and radiator fan V7
”, page 162
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Amarok 2011 ➤
4-cylinder injection engine (2.0 l direct injection engine,
gen AG
turbocharger)
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20 – Fuel supply system
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⇒ “1.1 Checking fuel pump”, page 168
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⇒ “1.1.1 Checking voltage supply of fuel pump”, page 169
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⇒ “1.1.2 Checking fuel pressure”, page 170 ole,
spec
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⇒ “1.1.3 Checking holding pressure”, page 171
⇒ “1.1.4 Checking fuel delivery rate ”, page 172
rrectne
⇒ “1.2 Removing and installing fuel pump control unit J538 ”, page
172
ss
1.1 Checking fuel pump
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Note
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When replacing fuel delivery unit, check fuel tank for heavy soiling
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and clean if necessary.

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equipment required
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♦ Pressure gauge - VAS
Prote AG.
6550-
♦ Remote control - V.A.G
1348/3A-
♦ Test instrument adapter/
DSO (5-pin) - VAS 5565-
♦ Multimeter - V.A.G 1715-
♦ Special wrench - T10202-
♦ Measuring container, ca‐
pacity 3 litres
168 Rep. gr.20 - Fuel supply system

Amarok 2011 ➤
Checking function and voltage supply ⇒ page 169

Check fuel pressure ⇒ page 170 .
Checking holding pressure ⇒ page 171 . agen
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• Fuel pump control unit - J538- OK.
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Function of fuel pump is checked using final control diagnosis.
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– Connect ⇒ Vehicle diagnostic tester as follows:
ss
– Connect diagnosis cable connector to diagnostic connection
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inform
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– Switch ignition on.
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– Perform final control diagnosis using ⇒ Vehicle diagnostic
n
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tester.
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The fuel pump must now run slowly up to maximum speed.

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The fuel pump runs very quietly.
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If fuel pump does not run:
– Lower fuel tank until connectors on fuel delivery unit are ac‐
cessible.
1. Fuel pump 169

Amarok 2011 ➤
– First ensure that 5-pin wiring connection -1- is secure by pull‐

ing the connector without pressing the catch. If connector was
not inserted correctly, repeat functional gcheck ofolkfuel
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– Pull off connector -1-. byV gu
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– Check contacts on plug and
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– Check voltage supply against current flow diagram with mul‐
ce
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timeter - V.A.G 1715- .

un
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• Specification: approx. battery voltage.
erm
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WARNING
h re
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spec
Fuel supply lines are under pressure! Wear eye protection and
protective clothing to avoid eye injuries and skin contact. Be‐
t to the co
fore loosening hose connections, wrap a cloth around the
connection. Then release pressure by carefully pulling hose off
connection.
rrectness
Voltage supply not OK:
o
cial p
f inform
– Locate and eliminate open circuit referring to current flow di‐
mer
agram ⇒ Current flow diagrams, Electrical fault finding and
atio
m
Fitting locations.
o
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Voltage supply OK:
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– Remove fuel delivery unit ⇒ page 184 .

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– Check that electrical wires between flange and fuel pump are
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– Fuel pump is defective, renew fuel delivery unit ⇒ page 184 .
AG.
1.1.2 Checking fuel pressure

Test prerequisites
• Function of fuel pump has been checked ⇒ page 169 .
Test procedure
Note
Check fuel pressure using final control diagnosis.
WARNING
Fuel supply lines are under pressure! Wear eye protection and
protective clothing to avoid eye injuries and skin contact. Be‐
fore loosening hose connections, wrap a cloth around the
connection. Then release pressure by carefully pulling hose off
connection.

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

adapter - VAS 6550/1- and -VAS 6550/2- .
– Make sure that drain tap is closed and cut-off taps are open.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– Read off fuel pressure on pressure gauge.
• Specification: 4.0 … 7.0 bar
Fuel pressure OK, check holding pressure ⇒ page 171 .
If the specification is exceeded:
n AG. Volkswagen AG
– Pressure limiting valve in fuelodelivery
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age unit is defective.
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The pressure limiting valve is integrated in the fuel delivery unit

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If the specification is not attained:

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– Fuel pump is defective, renew fuel delivery unit ⇒ page 184 .

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1.1.3 Checking holding pressure

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

l purpos
Check fuel pressure ⇒ page 170 .

Test sequence:
nform
ercia

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pressure.
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tion in
– Read off fuel pressure on pressure gauge.

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• Specification: 4.0 … 7.0 bar

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– End self-diagnosis and switch ignition off.

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– Observe pressure drop on pressure gauge. After 10 minutes,
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pressure must not drop below 3.0 bar. rig ht
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Prote AG.

pressure.
1. Fuel pump 171

Amarok 2011 ➤
– After pressure has built up, cut-off tap -B- of pressure tester
immediately. Lever is then at right angle to direction of flow.
If the pressure does not drop now:
Note
Leak must be sought on engine side. Repeat holding pressure

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

If no fault is found:
– Renew high-pressure pump ⇒ page 238 .
If the pressure drops again:
Leak must be sought on fuel tank side; proceed as follows:
AG. Volkswagen AG d
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– Check fuel line leading to flange for leaks. olksw
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If no fault is found: orise nte
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– Open fuel delivery unit flange -1- ⇒ page 184
ss a . c
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– Check that all hose connections are connected.
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If no fault is found:
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– Renew fuel delivery unit.
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1.1.4 Checking fuel delivery rate
mer
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– Checking fuel delivery rate ⇒ Vehicle diagnostic tester.

o
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1.2 Removing and installing fuel pump con‐

t
sd
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trol unit - J538-

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

– Detach connector from fuel pump control unit - J538- .
– Loosen securing nuts.
Installing
Specified torques
♦ ⇒ “2.1 Assembly overview - fuel tank”, page 173

Amarok 2011 ➤
2 Fuel tank
⇒ “2.1 Assembly overview - fuel tank”, page 173
⇒ “2.2 Removing and installing fuel tank”, page 175
⇒ “2.3 Removing and installing filler neck”, page 178
2.1 Assembly overview - fuel tank

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Caution
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The fuel
au pump must not be allowed to run when the fuel
th or
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ss
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The fuel tank must contain at least 5 litres of fuel.
an
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1 - Union nut
ole,
spec
❑ Remove and install us‐
ing union nut tool -
t to the co
3217- .
❑ 110 Nm
rrectne
2 - Seal
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❑ Moisten with fuel when

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installing
form
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3 - Fuel delivery unit

atio
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c
i
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tion on fuel tank

thi
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⇒ page 174 .
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⇒ page 184 .
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❑ Removing and installing t. C rig
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fuel gauge sender pyri by
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⇒ page 185 .
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4 - Connecting hose
6 - Spring nut
7 - Filler neck
8 - Weld bolt with cap nut
❑ 5 Nm
9 - Filler cap with retaining
strap
10 - Seal
11 - Slotted pan head screw
12 - Fuel pump control unit -
J538-
13 - Fuel tank
❑ Drain fuel tank using fuel extractor - VAS 5190-
2. Fuel tank 173

Amarok 2011 ➤
14 - Breather line
❑ Check for secure seating.
15 - Quick-release coupling
❑ Must audibly engage
16 - Activated charcoal filter
17 - Slotted pan head screw
18 - Rear securing strap
19 - Hexagon bolt
❑ 30 Nm
20 - Protective cover
❑ For bottom of fuel tank.
❑ Depending on equipment.
21 - Securing nuts
❑ 20 Nm
22 - Double flange bolt
23 - Centre securing strap
24 - Heat shield for fuel filter
25 - Fuel filter with pressure regulator
❑ Removing and installing ⇒ page 182 . n AG. Volkswagen AG do
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26 - Return line byV
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❑ To pull off flange, press release button on connecting piece.
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27 - Supply line
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❑ Clipped onto fuel tank.
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spec
❑ Black
es, in part or in w
t to the co
❑ To pull off flange, press release button on connecting piece.
❑ To fuel filter ⇒ page 173 .
rrectness of i
28 - Breather line
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29 - Breather line
nf
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orm
Installation position of fuel gauge sender

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

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line are marked with arrows on fuel gauge sender flange.

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Note
p by
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Prote AG.
After installing fuel gauge sender, check whether fuel supply and
return lines are still clipped onto fuel tank.

Amarok 2011 ➤
2.2 Removing and installing fuel tank
Caution
The fuel pump must not be allowed to run when the fuel tank

equipment required
♦ Union nut tool - 3217-
1331-
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Fuel extractor - VAS 5190-
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Removing
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Note
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Fuel tank must be drained. Use the fuel extractor - VAS 5190- to C py
t. rig
do this.
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– Note safety precautions before starting installation work
AG.
⇒ page 6 .
– Observe rules for cleanliness ⇒ page 6 .
2. Fuel tank 175

Amarok 2011 ➤
– Thoroughly clean area around filler

agen
neck
AG. V-1- on
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do -4-. w es n
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– Loosen clamp -2- for connecting
edb
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t gu
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tank -4- and pull connecting
ho
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– Extract fuel with the
ss fuel extractor - VAS 5190- via the opening.
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Vehicles with lower protective cover
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– Unbolt protective cover from bottom of fuel tank .
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Continuation for all vehicles:
wit
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– Support fuel tank with engine and gearbox jack - V.A.G 1383
hole
spec
A- .
es, in part or in w
t to the co
– Disconnect supply line -3- and return line -2-. Press in buttons
on hose couplings to do this.
rrectness of i
– Unscrew bolt -arrow- for securing fuel tank -1- on left cross
l purpos
member.
– Loosen securing straps in succession:
nf
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orm
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or c
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– Unscrew bolt -arrow- for front securing strap -2- for fuel tank t. C rig
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Prote AG.
– Unscrew bolt -arrow- for rear securing strap -2- for fuel tank
-1-.

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aut 4-cylinder injection engine (2.0 l direct injection ra engine, turbocharger) - Edition 04.2013
ss c
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– Unscrew bolts -arrows- for securing straps -2- for fuel tank
an
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– Only lower fuel tank with engine and gearbox jack - V.A.G
ot p
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1383 A- until filler neck and breather line can be removed.
is n
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ole,
spec
t to the co
rrectness o
cial p
f in
– Loosen clamp -2- for connecting hose -1- of filler neck on fuel
form
mer
tank -4- and pull connecting hose off.
atio
m
– Unclip breather line -3- on fuel tank -4-.

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Note
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t.
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Immediately seal all openings on fuel tank with clean cloths.
ht. Cop py
rig
rig ht
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Prote AG.
– 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-.
– Release fuel lines by pressing in circlip.
– Unclip fuel lines -2 and 3- from fuel delivery unit -1-.

– Carefully lower fuel tank.
Installing
Caution
The fuel pump must not be allowed to run when the fuel tank
2. Fuel tank 177

Amarok 2011 ➤
Push hose -1- of filler neck onto connection on fuel tank -3-.
Position clamp -2- at assembly markings -arrows- using hose clip
pliers - VAS 6362- .
– Push on breather line -3- and engage securely.

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

♦ Hose clip pliers - VAS 6362-
AG. Volkswagen AG d
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♦ Torque wrench - V.A.G 1410-

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Amarok 2011 ➤
Removing
AG. Volkswagen AG d
– Remove fuel tank ⇒ page 175 . agen oes
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– Unscrew bolt -2- for filler neck -1- onorisunderbody.
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– Open tank flap and clean insidess tank flap unit thoroughly.
a c
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– Unscrew cap.
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– Unscrew bolt -2- from tank flap unit.
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– Unclip tank flap unit and remove completely.
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– Unscrew nuts -2- from filler neck -1- at top of tank flap unit cut-
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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-.
2. Fuel tank 179

Amarok 2011 ➤
– Tighten bolt -2-.

– Install fuel tank.
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– Push hose -1- of filler neck onto connection on fuel tank -3-.
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– Position clamp -2- at assembly markings -arrows- using hose
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– Push on breather line -3- and engage securely.
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♦ Connections for breather and fuel lines must engage audibly

m
when joined.
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♦ Clip fuel lines onto fuel tank.
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♦ Push connector onto fuel pump flange and clip wire onto fuel
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♦ Ensure that fuel hose connections are tight.
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♦ ⇒ “2.1 Assembly overview - fuel tank”, page 173 cted agen
Prote AG.

Bolt for tank flap unit 2 Nm

Amarok 2011 ➤
AG. Volkswagen AG d
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3 Fuel filter by gu
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⇒ “3.1 Assembly overview - fuel filter”, page
ss a 181 ra
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3.1 Assembly overview - fuel filter
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1 - Fuel filter
hole
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❑ Direction of flow is
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marked with arrows.
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❑ Do not interchange con‐
nections.
rrectness of i
❑ Installation position: pin
on filter housing must
l purpos
engage in notch of guide

in filter bracket
nform
ercia
⇒ page 182 .
m
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⇒ page 182 .
ion
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❑ Black
AG.
❑ From fuel tank.

❑ To pull off, press release
button on connection.
4 - Fuel return line
❑ Blue
❑ To fuel tank.
❑ To pull off, press release
button on connection.
5 - Fuel pressure regulator
❑ 4 bar
6 - Gasket
7 - O-ring
8 - Fuel supply line
❑ Black
❑ To engine.
❑ To pull off, press release button on connection.
9 - Bolt
❑ 3 Nm
10 - Retainer
❑ For fuel filter.
❑ Secured to fuel tank.
3. Fuel filter 181

Amarok 2011 ➤
3.2 Removing and installing fuel filter

AG. Volkswagen AG d
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♦ Container rise nte
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⇒ page 6 .
hole
spec
♦ Observe rules for cleanliness ⇒ page 9 .
es, in part or in w
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– Place container under fuel filter. rrectness of i
WARNING
l purpos
Fuel system is under pressure! Wear eye protection and pro‐

tective clothing to avoid eye injuries and skin contact. Before
nform
ercia
loosening hose connections, wrap a cloth around the connec‐

m
at
tion. Then release pressure by carefully pulling hose off con‐

om
io
nection.
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– Pull off fuel lines -1-, -2- and -3- by pressing release button.
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– Remove bolt -4-.
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– Remove fuel filter.
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Installing cted agen
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Note
Direction of flow is indicated with an arrow on filter housing.
– Bleeding fuel system

Amarok 2011 ➤
Installation position
Pin -2- on filter housing must engage in notch of guide -1- in filter
bracket.
Specified torques
♦ ⇒ “3.1 Assembly overview - fuel filter”, page 181
AG. Volkswagen AG d
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3. Fuel filter 183

Amarok 2011 ➤
4 Fuel delivery unit, fuel gauge sender

⇒ “4.1 Removing and installing fuel delivery unit”, page 184
⇒ “4.2 Removing and installing fuel gauge sender G ”,
page 185
4.1 Removing and installing fuel delivery

unit
♦ Union nut tool - 3217-
Removing
– Remove fuel tank ⇒ page 175 .
– Unclip fuel lines -2 and 3- from fuel delivery unit -1-.
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– Unscrew union nut with union nut tool - 3217- .

hole
spec
es, in part or in w
– Take fuel delivery unit out of the fuel tank.

t to the co
Installing
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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 tank ⇒ page 175 .
– Remove fuel delivery unit ⇒ page 184 .
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– Free lines -2- and unclipVol
kfuel
swa gauge sender - G- to
oes
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– Remove fuel gauge sender - G- -1- in -direction of arrow-.

rrectness of i
– Release connectors on fuel gauge sender - G- .

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Installing
nform
ercia
– Insert fuel gauge sender - G- into guides on fuel pump and

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press downwards until it engages.

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4. Fuel delivery unit, fuel gauge sender 185

Amarok 2011 ➤
5 Accelerator mechanism
⇒ “5.1 Assembly overview - accelerator module”, page 186
Volkswagen AG
⇒ “5.2 Removing and installing accelerator module”, page
swa
ge186
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❑ 10 Nm
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3 - Accelerator with electronic
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❑ The accelerator position
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t to the co
sender passes the posi‐
tion of the accelerator
on to the engine control
unit.
rrectness of i
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5.2 Removing and installing accelerator

module
Removing
– Disconnect connector -1-.
– Unscrew nuts -2-.
– Remove accelerator module -3- towards the front.

Amarok 2011 ➤
AG. Volkswagen AG d
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Installing
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Specified torques
atio
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n
♦ ⇒ “5.1 Assembly overview - accelerator module”, page 186
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5. Accelerator mechanism 187

Amarok 2011 ➤
6 Activated charcoal filter system

⇒ “6.1 Assembly overview - activated charcoal filter system”, page
188
⇒ “6.2 Checking fuel tank breather”, page 188
6.1 Assembly overview - activated charcoal filter system
1 - Breather line
ing.
2 - Activated charcoal filter
❑ Location: on fuel tank,
left.
❑ Remove with fuel tank
removed.
3 - Breather line
ing.
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4 - Quick-release couplingksw
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6 - Clip
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7 - Activated charcoal filter sol‐

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enoid valve 1 - N80-

spec
es, in part or in w
❑ Valve closed with igni‐

t to the co
tion switched off.

❑ When engine is warm,
valve will be activated
rrectness of i
(pulsed) by engine con‐

l purpos
trol unit.
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6.2 Checking fuel tank breather
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Special tools and workshop equipment required pyri by
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Prote AG.

Amarok 2011 ➤
♦ Hand vacuum pump - VAS 6213-

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♦ Adapter set - V.A.G 1318/17-
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• Ignition must be switched off. op Vo
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• Fuel tank must be lowered.
AG.
Test procedure
– Detach bleeder line ⇒ Item 1 (page 188) .
Note
To do this, press release button.
– Connect hand vacuum pump - VAS 6213- with adapter set -

V.A.G 1318/17- to breather line.
– Operate hand vacuum pump - VAS 6213- several times. Vac‐
uum must not build up.
If vacuum builds up:
– Check breather line ⇒ Item 1 (page 188) on activated charcoal
filter for soiling and clean if necessary.
If vacuum does not build up:
– Hold breather line ⇒ Item 1 (page 188) shut and operate vac‐
uum pump again several times. Vacuum must build up.
– Renew activated charcoal filter.
6. Activated charcoal filter system 189

Amarok 2011 ➤
21 – Turbocharging/supercharging
1 Charge air system
⇒ “1.1 Assembly overview - charge air cooling”, page 190
⇒ “1.2 Removing and installing pressure pipe”, page 191
⇒ “1.3 Removing and installing charge pressure sender G31 ”,
page 191
⇒ “1.4 Removing and installing charge air cooler”, page 191
⇒ “1.5 Checking charge air system for leaks”, page 194
1.1 Assembly overview - charge air cooling

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1 - Charge air cooler ir se
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Charge air cooler must be renewed
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⇒ page 191 .
h re
ole,
spec
2 - Seal
t to the co
3 - Hose clip
❑ Reinforced.
rrectne
❑ 5.5 Nm
4 - Pressure hose
ss
❑ To turbocharger.
o
cial p
f in
❑ Must be free of oil and
form
mer
grease before installing.
atio
om
5 - Hose clip n
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❑ Reinforced.
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❑ 5.5 Nm
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6 - Hose clip
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7 - Pressure hose
AG.
❑ To throttle valve
❑ Must be free of oil and
grease before installing.
8 - Hose clip
❑ Reinforced.
❑ 5.5 Nm
9 - Bolt
10 - Charge air pressure sender - G31-
11 - Bolt
12 - Rubber grommet
13 - Pressure pipe
❑ Must be free of oil and grease before installing.
190 Rep. gr.21 - Turbocharging/supercharging

Amarok 2011 ➤
14 - Hose clip
❑ Reinforced.
❑ 5.5 Nm
15 - Pressure hose
❑ Must be free of oil and grease before installing.
16 - Hose clip
❑ Reinforced.
❑ 5.5 Nm
1.2 Removing and installing pressure pipe

Removing
– Detach connector from charge pressure sender - G31- .
– Release clip -3- from charge air hose -4-.
– Loosen bolt -1- of pressure pipe -2-.
– Unclip water hose from pressure pipe.
– Release lower clip ⇒ Item 8 (page 190) from socket to throttle
valve module - J338- .
– Remove pressure pipe.
Installing
Specified torques
♦ ⇒ “1.1 Assembly overview - charge air cooling”, page 190
1.3 Removing and installing charge pres‐

sure sender - G31- o lkswage es n
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Removing ir se nte
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– Disconnect electrical connector -4- from charge
ss
apressure ra
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sender - G31- . ce
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nl
pt
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– Unscrew bolts -2- and pull charge pressure sender - G31- /
itte
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-3- out of air duct -1-.
erm
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Installing
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hole
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es, in part or in w
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Note
Renew O-ring.
rrectness of i
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Specified torques
nform
mercia
at
1.4 Removing and installing charge air cool‐

om
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Prote AG.
1. Charge air system 191

Amarok 2011 ➤
♦ Socket set 1/4", 22-piece - VAS 5528-
Removing
– Undo and remove bolts -2- that fasten radiator to lock carrier
-1-.
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Vehicles with air conditionerVolkswa not
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– Remove lock carrieroris⇒
e General body repairs, exterior; Rep.ran
tee
gr. 50 ; Lock carrier
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– Remove radiator cowl ⇒ page 162 .

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⇒ page 10 .
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spec
es, in part or in w
– Remove coolant hose -1- and pressure hose -2-.

t to the co
– Remove right pressure hose leading to turbocharger from

charge air cooler and place to one side.
rrectness of i
– Remove air duct mounting ⇒ page 162 .

l purpos

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tion in
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192
cted agen
Prote AG.
Rep. gr.21 - Turbocharging/supercharging
Amarok 2011 ➤
– Squeeze left and right catches -2- together and detach con‐
denser -3- from radiator -1-.
Caution
• Do not bend or stretch the refrigerant lines 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.
wage
Installing olks es n
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Installation is carried out in the reverse order; hornote the following:
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Note
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Before installing radiator, check that radiator mountings -1- are
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correctly seated on front part of car -2- and, if necessary, reposi‐
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tion:
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Amarok 2011 ➤
AG . Volkswagen AG
– Insert radiator mounting into lock carrier -2- at bottom -1-, do‐
ksw
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atio
– When installing the radiator, make sure that the catches -1- of
om
the radiator mounting on the left and right at the top have en‐
n
c
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gaged completely in the lock carrier.
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– Insert top radiator mountings -1- on right and left into the
mounting on radiator -2- appropriately.
⇒ page 10 .
– Install radiator cowl ⇒ page 162 .
Only for vehicles with air conditioning
– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
50 ; Lock carrier .
Specified torques
♦ ⇒ “3.1 Assembly overview - radiator/ radiator fan V7 ”,
page 160
1.5 Checking charge air system for leaks


Amarok 2011 ➤
4-cylinder injection engine
AG . Volk(2.0
swa gledirect
nA injection engine, turbocharger) - Edition 04.2013
n G do
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Volks ot g
♦ Charge air systemedtester
by - V.A.G 1687- ua
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– Release hose clip -1- and detach pressure hose -3- from tur‐
bocharger -2-.
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– Depending on hose diameter, insert adapter - 1687/10- , cted agen
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-1687/11- or -1687/12- in air duct -1- and secure with hose clip.
– Connect charge air system tester - V.A.G 1687- as shown in
figure.
Prepare charge air system tester - V.A.G 1687- as follows:

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

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

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

♦ The pressure must not exceed 0.5 bar!
olkswagen AG
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– Check charge air system for leaks by hearing, touching, with
ce
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commercially available leak detector spray or using ultrasonic
pt
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tester - V.A.G 1842- .
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Note
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♦ A small amount of air escapes through the valves and enters
es, in part or in w
the engine. Therefore a holding pressure test is not possible.
t to the co
♦ How to use the ultrasonic tester - V.A.G 1842- ⇒ operating
instructions
rrectness of i
♦ Before removing the adapters, depressurise the test circuit by
l purpos
detaching coupling.
♦ Hose unions and air pipes/hoses must be free of oil and grease
nf
ercia
when installing.
orm
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♦ In order to be able to securely attach the air ducts on their

sd
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connections, the screws of the used hose clips have to be

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sprayed with penetrating spray before installing.

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Amarok 2011 ➤
2 Turbocharger
⇒ “2.1 Assembly overview - turbocharger”, page 197
⇒ “2.2 Removing and installing turbocharger”, page 202
⇒ “2.3 Checking vacuum unit for turbocharger”, page 205
2.1 Assembly overview - turbocharger
Note
♦ Secure all hose connections with hose clips comparable to

production standard
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. The oil seal and seal‐
ing surface must be oiled lightly only for plug-in connector.
♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ Fill turbocharger with engine oil at oil supply line connection.
♦ After installing turbocharger, run engine for about 1 minute at
idling and do not rev up immediately, this ensures that the tur‐
bocharger is fully primed with oil
♦ Observe rules for cleanliness ⇒ page 9 .
Part I . Volkswagen AG
gen AG does
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Part II ⇒ page 198 y Volk not
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Part III ⇒ page
hor 200 eo
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Part IV s⇒ page 201
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es, in part or in w
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2. Turbocharger 197
Amarok 2011 ➤ n AG. Volkswagen AG do
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1 - Turbocharger tho
or
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❑ Can only be renewed to‐ ss
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gether with exhaust
nl
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manifold and vacuum
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unit as one unit
erm
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ility
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⇒ page 202 .
, is n
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hole
2 - Hose
spec
es, in part or in w
3 - Vacuum unit for turbocharg‐
t to the co
er
❑ Can only be renewed to‐
rrectness of i
gether with turbocharg‐
er. l purpos
4 - Hose clip
nform
ercia
5 - Hose
m
at
6 - Hose
om
ion
c
in t
7 - Bolt
or
his
ate
❑ 3 Nm
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8 - Charge pressure control

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9 - Hose
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10 - Turbocharger air recircu‐ Prote
cted AG.
agen
lation valve - N249-
tion ⇒ page 198 .
11 - Bolt
❑ 7 Nm
12 - O-ring
13 - O-ring
14 - Connection
15 - Bolt
❑ 9 Nm
Installation location of turbocharger air recirculation valve - N249-

– Note installation position -arrows-.
Part II
Part I ⇒ page 197
Part III ⇒ page 200

Amarok 2011 ➤
Part IV ⇒ page 201
1 - Turbocharger
gether with exhaust
manifold and vacuum
unit as one unit
⇒ page 202 .
2 - Bolt
❑ 9 Nm
3 - Crankcase breather line
4 - Seal
5 - Seal
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6 - Bolt olks not
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7 - Oil supply
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8 - Bolt
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❑ 9 Nm
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9 - Bolt
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❑ 9 Nm
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10 - O-ring
spec
es, in part or in w

t to the co
11 - Seal
rrectness of i
12 - Bolt
l purpos
❑ 35 Nm
nf
ercia
13 - Bolt
orm
❑ 9 Nm
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atio
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14 - Bolt
or c
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❑ 35 Nm
t
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15 - Seal
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16 - Coolant supply line
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17 - Bolt Prote
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agen
❑ 9 Nm
18 - Bolt
❑ 9 Nm
19 - Gasket
20 - Oil return line
21 - Seal
2. Turbocharger 199
Amarok 2011 ➤
Part III
Part I ⇒ page 197
Part II ⇒ page 198 lkswage es n
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Part IV ⇒ page 201 ir se
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1 - Seal
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2 - Nut
ility
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❑ Coat exhaust manifold
hole
spec
studs with high-temper‐
es, in part or in w
ature paste ⇒ Electronic
t to the co
Parts Catalogue .
❑ Tightening sequence
⇒ page 201 .
rrectness of i
3 - Bolt
l purpos
❑ 35 Nm
nform
ercia
4 - Seal
m
at
om
ion
c
5 - Coolant return line
in t
or
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ate
6 - Bolt
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❑ 9 Nm
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manifold and vacuum Prote AG.
unit as one unit
⇒ page 202 .
8 - Bolt
❑ 30 Nm
9 - Retainer
10 - Support
11 - Bolt
❑ 30 Nm
12 - Bolt
❑ Coat bolt with high-temperature paste ⇒ Electronic Parts Catalogue .
❑ 30 Nm
13 - Nut
❑ Do not unscrew to remove turbocharger
❑ Coat exhaust manifold studs with high-temperature paste ⇒ Electronic Parts Catalogue .
❑ 30 Nm
14 - Clamping rail

Amarok 2011 ➤
Tightening sequence - turbocharger

Part IV
Part I ⇒ page 197
Part II ⇒ page 198 AG. Volkswagen AG d
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Part III ⇒ page 200 by Vol
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1 - Turbocharger ss a c
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nl
pt
du
gether with exhaust
an
itte
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manifold and vacuum
erm
ab
unit as one unit
ility
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wit
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⇒ page 202 .
hole
spec
2 - Vacuum unit for turbocharg‐
es, in part or in w
t to the co
er
❑ Check ⇒ page 205 .
rrectness of i
⇒ page 205 .
l purpos
3 - Bolt
❑ 10 Nm
nform
ercia
4 - Nut
m
at
om
❑ Secure with sealing ion

c
in t
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paint ⇒ Electronic Parts

o
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Catalogue .
at
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❑ 9 Nm
um
for
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5 - Locking plate
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6 - Knurled nut
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Further specified torques

Right air duct to sump 10 Nm
2. Turbocharger 201
Amarok 2011 ➤

Air duct to bracket 10 Nm
2.2 Removing and installing turbocharger


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Removing t to the co
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– Release clip -3-, unclip vacuum line -5- from guide -2-.
l purpos
– Unclip line -1- for air mass meter - G70- .

nform
ercia
– Detach intake hose -4- from turbocharger.

m
– Remove air filter housing ⇒ page 218 .

a
com
tion in

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te o
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– Disconnect coolant hose from turbocharger.

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Amarok 2011 ➤
– Remove heat shield -arrows-.
– Unscrew crankcase breather system -arrow- from turbocharg‐

er.
– Pull off hose -1- from turbocharger.
– Unscrew bolts -1 and 2- and lay oil supply line to one side.
– Unscrew bolt -3- and lay coolant line to one side.
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– Release hose clip -1- and detach pressure hose -3- from tur‐
wit
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bocharger -2-.
h re
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es, in part or in w
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rrectness of i
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2. Turbocharger 203
Amarok 2011 ➤

side.
– Unscrew bolts -arrows- and remove support for turbocharger.
AG. Volkswagen AG d
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– Unscrew bolts -arrows- on oil return line.
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l purpos
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Prote AG.

Amarok 2011 ➤
– Remove nuts -arrows-.

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

gen AG
. Volkswagen nuts.
AG d a oes
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♦ Fill turbocharger with engine
db
y V oil at oil supply line connection.
o ot g
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e ran
ris tee
♦ Hose connectionsuthand
o hoses for charge air system must be or
free of oil and grease
ss
a before assembly. ac
ce
e

nl
pt
du
an
itte
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erm
ab
ility
ot p
– Install catalytic converter ⇒ page 251 .
wit
, is n
h re
– Aligning exhaust system free of stress ⇒ page 248 .
hole
spec
es, in part or in w
t to the co
– Check oil level ⇒ Maintenance ; Booklet 11 .
rrectness of i
Note
l purpos
After installing turbocharger, run engine for about 1 minute at

idling and do not rev up immediately, this ensures that the turbo‐
nf
ercia
o
charger is fully primed with oil
rm
m
atio
om
n in
Specified torques
or c
thi
te
♦ ⇒ “2.1 Assembly overview - turbocharger”, page 197

sd
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2.3 Checking vacuum unit for turbocharger
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Special tools and workshop equipment required Prote
cted AG.
agen
Test prerequisite:
♦ Hose from turbocharger via charge pressure control solenoid
valve - N75- to vacuum unit must have through-flow (not be
blocked).
♦ Charge pressure control solenoid valve - N75- OK.
2. Turbocharger 205
Amarok 2011 ➤
Procedure:
– Connect hand vacuum pump - VAS 6213- to vacuum unit
-arrow-.
AG. Volkswagen AG d
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ility
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– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐
spec
sition -B- for “pressure”.
t to the co
Caution
rrectne
The pressure must not exceed 750 mbar! If the pressure is
exceeded, the vacuum unit can be damaged.
ss o
cial p
f inform
mer
– Operate hand vacuum pump - VAS 6213- repeatedly, observ‐

atio
ing linkage.
om
n
c
The linkage -A- should start to move at a pressure of approx.

or
n thi
e
300 mbar and be at its limit stop at a pressure of approx.

t
sd
iva
700 mbar.
pr
cum
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The stroke of the linkage is approx. 10 mm.
Co
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Note cted agen
Prote AG.
If no pressure can be built up using the hand vacuum pump - VAS

6213- or the pressure drops immediately again, check the hand
vacuum pump - VAS 6213- and connecting hoses for leaks. If no
fault is found: renew vacuum unit ⇒ page 205 .

Amarok 2011 ➤
24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Overview of fitting locations - injection system”,
page 207
1.1 Overview of fitting locations - injection system
1 - Intake manifold pressure

sender - G71-
2 - Air mass meter - G70-
⇒ page 221 .
3 - Lambda probe - G39- and
Lambda probe heater - Z19-
Volkswagen AG
4 - Vacuum pump agen
AG. does
olksw not
ed
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V gu
ara
⇒ page 75 . horis nte
eo
t
au ra
5 - High-pressure
ss pump c
ce
e

nl
pt
du
⇒ page 238 . an
itte
y li
erm
6 - Engine speed sender - ab

ility
ot p
G28- wit
, is n
h re
hole
⇒ page 257 .
spec
es, in part or in w
t to the co

8 - Activated charcoal filter sol‐
enoid valve 1 - N80-
rrectness of i
9 - Intake air temperature

l purpos
sender - G42-
10 - Throttle valve module -
nf
ercia
J338-
rm
m
atio
❑ Throttle valve drive an‐

om
gle sender - G187- and

n in
or c
throttle valve drive angle

thi
te
sd
a
sender 2 - G188-
iv
o
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rp
cu

o
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f
en
ng
⇒ page 233 .
t.
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Cop py
11 - Wiring harness to engine
t. rig
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control unit
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12 - Charge air pressure sender - G31-
Prote AG.

13 - Coolant temperature sender - G62-
14 - Fuel pressure sender - G247-
1. Injection system 207

Amarok 2011 ➤
15 - Oil pressure switch - F22-

16 - Knock sensor 1 - G61-
17 - Intake manifold flap potentiometer - G336-
18 - Ignition coils with final output stage
wage
❑ Removing and installing Volks ⇒ page 254 . es n
ot g
by ua
ed ran
19 - Inlet camshaft control
ris valve 1 - N205- tee
utho or
❑ Removingssanda installing ⇒ page 121 . ac
ce
e
20 - Turbocharger air recirculation valve - N249-

nl
pt
du
an
itte
y li
erm
ab
ility
21 - Charge pressure control solenoid valve - N75-
ot p
wit
, is n
h re
hole
spec
22 - Lambda probe after catalytic converter - G130- and Lambda probe heater 1, after catalytic converter - Z29-
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
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cum
for
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Cop py
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by
cted agen
Prote AG.
208 Rep. gr.24 - Mixture preparation - injection

Amarok 2011 ➤
2 Injectors
⇒ “2.1 Assembly overview - fuel rail with injectors”, page 209
⇒ “2.2 Removing and installing injectors”, page 210
⇒ “2.3 Renewing seals on injectors”, page 212
⇒ “2.4 Cleaning injectors”, page 214
2.1 Assembly overview - fuel rail with injectors
1 - Injector
❑ With combustion cham‐
ber ring seal (Teflon ring
seal), always renew
❑ Renew O-rings after re‐
moval.
❑ Check installation loca‐
tion is correct
⇒ page 210 .
2 - Support ring
3 - Fuel rail
❑ Removing and installing AG. Volkswagen AG d
⇒ page 229 . agen oes
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4 - High-pressure pump orise nte
th eo
❑ With fuel pressure regu‐ s au ra
c
lating valve - N276- . s
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e
nl
pt
❑ Fuel tank contains elec‐
du
an
itte
tric fuel pump which
y li
erm
ab
pumps fuel to mechani‐
ility
ot p
cal high-pressure pump.
wit
, is n
❑ When installing the
h re
hole
high-pressure pump, it
spec
is essential to ensure
es, in part or in w
t to the co
that no dirt enters the
fuel system.
❑ The fuel system must
rrectness of i
not be under pressure

when installing the high-
l purpos
pressure pump; proce‐

dure for reducing fuel
nf
ercia
pressure ⇒ page 7 .
orm
❑ Install fuel lines free of

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2. Injectors 209
Amarok 2011 ➤
stress.
⇒ page 238 .
5 - Roller tappet
6 - Fuel pressure regulating valve - N276-
7 - Bolts
❑ 20 Nm
8 - Connection for fuel pressurisation line to fuel rail
❑ 40 Nm
9 - Union nut of fuel pressurisation line
❑ 27 Nm
10 - Air flow control flaps (intake manifold flaps)
11 - Seal
12 - Intake manifold
gen AG⇒. Vpage
olkswa229
gen A.G
d wa oes
olks no
13 - Vacuum unit dfor
by air flow control flaps (duct partition)
V t gu
ar
e an
ris te
14 - Throttleutvalve
ho module - J338- , throttle valve drive for electric
eo
ra throttle operation - G186-
a c
❑ Throttle
ss
valve drive angle sender 1 for electric throttle - G187- and throttle valve drive angle sender 2 for
ce
le
electric throttle - G188-

un
pt
an
d
itte
❑ After removing, installing or renewing throttle valve module - J338- it must be re-adapted to engine control
y li
erm
ab
unit - J623- using ⇒ Vehicle diagnostic tester.

ility
ot p
❑ 7 Nm
wit
is n
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15 - Bolts
ole,
spec
❑ 9 Nm
t to the co
16 - Intake manifold flap potentiometer - G336-

❑ Each time after intake manifold flap potentiometer - G336- or intake manifold has been removed or
rrectne
installed, intake manifold flap potentiometer - G336- must be adapted to engine control unit - J623- using
⇒ Vehicle diagnostic tester.
s
17 - Fuel pressure sender - G247-

s o
cial p
❑ Lubricate thread with clean engine oil

inform
mer
❑ Always renew connection and tighten to 25 Nm

atio
m
❑ 27 Nm
o
n
c
i
or
n thi
te
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2.2 Removing and installing injectors

um
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t.
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Special tools and workshop equipment required Cop py
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Prote AG.

Amarok 2011 ➤
♦ Tool case with puller - T10133-
Note
Puller tool T10133/2 has been modified and is now designated

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

– File out a semicircle as illustrated. The recess allows the tool
to be pushed further onto the injector so the contact surface is
increased.
– For identification purposes, mark the modified tool with the
letter “A” after the tool number.
AG. Volkswagen AG d
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Special tools and workshop equipment requiredss a ra
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♦ Round file approx. 6 mm

nl
pt
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itte
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Removing
erm
ab
ility
ot p
– Remove intake manifold and fuel rail ⇒ page 229 .

wit
, is n
h re
Remove injectors if these are still in fuel rail.

hole
spec
Carefully withdraw injectors from fuel rail.

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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atio
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Prote AG.
Amarok 2011 ➤
Remove injectors if these are still in cylinder head.

Injector (old version)
1 - Combustion chamber ring seal (Teflon ring seal), renew; when
fitting, do not grease ring or use any other lubricant.
2 - The support ring must be replaced with an intermediate ring.
See next figure ⇒ page 212
3 - Injector
4 - Spacer (renew if damaged)
5 - O-ring (renew; to install, lightly lubricate with clean engine oil).
6 - Support ring (via this support ring, the fuel rail exerts force
which secures injector in cylinder head)
Injector (new version)

1 - Replace intermediate ring
2 - Support
3 - Combustion chamber ring seal (Teflon ring seal), renew; when
fitting, do not grease ring or use any other lubricant.
4 - Injector
5 - Spacer (renew if damaged)
6 - O-ring (renew; to install, lightly lubricate with clean engine oil).
7 - Support ring (via this support ring, the fuel rail exerts force
which secures injector in cylinder head)
– Cover open intake ports with a clean cloth.
AG. Volkswagen AG d
agen oes
– Detach electrical connector from injector
Vol that is to be removed.
ksw not
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y
db ara
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– Insert puller -T10133/2A- into
au
thogroove in injector. eo
ra
ss c
– Then position removal tool -T10133/16- and pull injector out
ce
le
un
by turning bolt -1-.

pt
an
d
itte
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rm
ab
pe
ility
Note
ot
wit
, is n
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The combustion chamber seal must always be renewed prior to

hole
spec
reinstallation of the injector ⇒ page 212 .

es, in part or in w
t to the co
Specified torques
♦ ⇒ “2.1 Assembly overview - fuel rail with injectors”, page 209
rrectness of i
l purpos
2.3 Renewing seals on injectors

nform
ercia
Note
m
a
com
tion in
r
♦ The combustion chamber seal must always be renewed prior

te o
thi
to reinstallation of the injector

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iva
do
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rp
cum
♦ Injector must be renewed if groove is damaged.

fo
en
ng
t.
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– Carefully remove old Teflon ring using a suitable tool (e.g. cut
t. C rig
gh ht
yri
open ring using razor blade, or prise open ring with small p by
co Vo
screwdriver and then pull off forwards). It is essential to ensure
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that groove and continuous ridge in groove surface are not
AG.
damaged.

Amarok 2011 ➤
– Before fitting new Teflon ring, combustion residues must be

cleaned off seal groove and injector shaft using clean cloth.
Note
The figure shows an injector with an “angled connector”. This can

be ignored in the subsequent procedure since it is not important
when renewing the combustion chamber ring seal.
– Place assembly cone -T10133/5- with a new Teflon ring -1- on

injector -2-.
– Push Teflon ring with assembly sleeve -T10133/6- further on

to assembly cone -T10133/5- until Teflon ring engages in seal
ring. No lubricants whatsoever may be used.
Note
AG. Volkswagen AG d
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Pushing Teflon ring onto injector stretches Teflon ring.d by V For this
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reason, the Teflon ring has to be shrunk again after
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pushed on. This is done in 2 stages. The procedure is described
th eo
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below. ss c
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Step 1 of calibration (adaptation) of Teflon ring is carried out with

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calibration sleeve -T10133/7- .
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– Using a twisting movement (approx. 180°) and applying slight

h re
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pressure, slide calibration sleeve -T10133/7- over injector as

far as it will go. Turn calibration sleeve -T10133/7- in opposite spec
direction. t to the co
Step 2 of calibration (adaptation) of Teflon ring is carried out with

calibration sleeve -T10133/8- .
rrectness o
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2. Injectors 213
Amarok 2011 ➤
– Using a twisting movement (approx. 180°) and applying slight

pressure, slide calibration sleeve -T10133/7- over injector as
far as it will go. Turn calibration sleeve -T10133/7- in opposite
direction.
– Renew O-ring on injector. Before installing, lightly moisten O-
ring with clean engine oil.
– Teflon ring must not be oiled.
– Before installing injectors, thoroughly clean injector bores in

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

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

(free of oil and grease). Ensure injectors are positioned cor‐
rectly in cylinder head.
AG. Volkswagen AG d
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♦ The injector must insert easily. If necessary, wait until the
ss a c
combustion chamber seal has contracted sufficiently.
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♦ Ensure the injectors are correctly seated and positioned in the

itte
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cylinder head.
ab
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♦ If it is not possible to insert the injector by hand, use the puller
wit
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- T10133/2A- -2- with a hammer - T10133/3- to insert the in‐
h re
hole
jector.
spec
es, in part or in w
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Installing
rrectness of i
• Moisten O-rings of high-pressure injectors with clean engine
l purpos
oil to aid insertion into fuel rail.

• Renew all gaskets.
nform
ercia
• Fuel rail must be placed on injectors and evenly pressed in.

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com
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• Install intake manifold with fuel rail ⇒ page 229 .

on in
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Specified torques
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2.4 Cleaning injectors C py
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♦ Ultrasonic cleaner - VAS 6418-
♦ Mounting plate for injection modules - VAS 6418/1-
♦ Cleaning fluid - VAS 6418/2-

Amarok 2011 ➤
Cleaning
– Remove injectors ⇒ page 210 .
Note
Observe ultrasonic unit safety regulations and operating instruc‐

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

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

VAS 6418/1- as far as stop -2-.
– Dip injectors together with mounting plate for injection mod‐

ules - VAS 6418/1- into cleaning fluid. wage
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Vol t gu
– Set a temperature of 50 degrees with
ed
byrotary knob -4-. ara
is nte
or
– Set rotary knob -5- to a cleaning
au time of 30 minutes.
th eo
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– Press button -3- to switch ultrasonic unit on.
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Note ab
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As soon as the cleaning temperature is 50 degrees, the set time h re

hole
will begin to elapse.

spec
es, in part or in w
t to the co
– Each time after cleaning injector, renew combustion chamber

ring seal (Teflon ring seal) ⇒ page 212 .
rrectness of i
– Then reinstall injectors ⇒ page 210 .

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2. Injectors 215
Amarok 2011 ➤
3 Air filter
⇒ “3.1 Assembly overview - air filter housing”, page 216
⇒ “3.2 Removing and installing air filter housing”, page 218
⇒ “3.3 Removing and installing air filter element”, page 220
3.1 Assembly overview - air filter housing

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1 - Air duct d b ua
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❑ Check for secure en‐ autho
or
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gagement. ss
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2 - Rubber bush un
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❑ Clipped into lower part
erm
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of air filter
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3 - Air filter lower part
h re
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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 218
ss
❑ Clipped onto lower part
o
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f
of air filter.
inform
mer
❑ Make sure it is mounted
atio
in correct position on
om
n
longitudinal member
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❑ Clean if soiled.
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6 - Filter element
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❑ Renew. ⇒ page 220 .

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7 - Air filter upper part
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8 - Bolt
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❑ 2 Nm
9 - O-ring
10 - Intake manifold pressure
sender - G71-
11 - Bolt
❑ 1.6 Nm
12 - Retainer
❑ For coolant hose mounting.
13 - O-ring
14 - Air mass meter - G70-
15 - Bolt
❑ 1.6 Nm

Amarok 2011 ➤
16 - Screw-type clip
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.
17 - Intake hose
❑ 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.
❑ Do not use lubricants containing oil.
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❑ To turbocharger. agen oes
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❑ With heater element for iscrankcase
ed b breather - N79- and connection
ara for crankcase breather/cylinder head
nte
cover connecting pipe.
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18 - Screw-type clip ss
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Caution
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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
hole
5.5 Nm. If the torque is
spec
es, in part or in w
too low or too high, the
t to the co
charge air hose may slip
off the charge air pipe
during vehicle operation.
rrectness of i
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19 - Vacuum hose
20 - Retainer
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❑ For wiring harness.

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21 - Heat shield
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22 - Bolt
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❑ 2 Nm
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23 - Mounting for air duct

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❑ Check for secure engagement. cop Vo
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24 - Bolt
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❑ 8.5 Nm
3. Air filter 217

Amarok 2011 ➤
AG. Volkswagen AG d
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Water drainage pipe on lower part of air filter o lksw not
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– Water drainage pipe -1- is clipped into lower part
thori of air filter eo
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3.2 Removing and installing air filter hous‐
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Removing
– Detach vacuum hose -2- from air filter upper part and air duct
-3- from air filter lower part -1-.

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

– Loosen screw-type clip -4- and remove intake hose from air
mass meter - G70- .
– Unscrew securing bolt -2- for air filter housing -1- in area of
coolant expansion tank.
– Pull air filter out of mountings.
Installing
Specified torques
♦ ⇒ “3.1 Assembly overview - air filter housing”, page 216 AG. Volkswagen AG d
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mer
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c
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or
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Cop py
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rig ht
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by lksw
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Prote AG.
3. Air filter 219

Amarok 2011 ➤ agen
AG. Volkswagen AG d
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4-cylinder injection engine (2.0 l bdirect
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3.3 Removing and installing air filter ele‐ th or
au ac
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ment
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Removing
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ab
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– Disconnect electrical connector from air mass meter G 70 and
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intake manifold pressure sender G 71 -1 and 3-.
, is n
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hole
– Open hose clip on air duct -4- and remove from air mass meter.
spec
es, in part or in w
– Detach vacuum hose.
t to the co
– Unscrew all bolts from air filter upper part and remove upper
part.
rrectness of i
– Remove air filter insert upwards.
l purpos
Installing
nf
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Note
or c
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♦ Always use genuine part for air filter element.
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♦ Hose connections and hoses for charge air system must be
en
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free of oil and grease before assembly. Do not use lubricants
Co
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containing silicone during installation.
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♦ Air filter housings must be clean.
by c lksw
cted agen
Prote AG.
♦ To prevent malfunctions, cover all critical engine air ducting
components such as air mass meter, intake pipes, etc. with a
clean cloth when blowing out the air filter housing with com‐
pressed air.
♦ Observe environmental regulations for disposal.
– Check for salt residue, dirt and leaves in air mass meter and
intake hose (engine intake side).
– Check air intake hose of air ducting for contamination.

Amarok 2011 ➤
4 Senders and sensors

⇒ “4.1 Removing and installing air mass meter G70 ”, page 221
⇒ “4.2 Removing and installing fuel pressure sender -G247- ”,
page 222
⇒ “4.3 Checking fuel pressure sender G247 ”, page 223
⇒ “4.4 Checking double non-return valve”, page 226
4.1 Removing and installing air mass meter

- G70-
AG. Volkswagen AG d
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Removing
wit
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– Pull off connector -3- for air mass meter - G70- .
hole
spec
es, in part or in w
– Loosen screw-type clip -4- and remove intake hose from air
t to the co
mass meter - G70- .
rrectness of i
l purpos
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mercia
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com
tion in
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Prote AG.
4. Senders and sensors 221

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.
AG. Volkswagen AG d
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Installing Vo lksw
oes
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Installation is carried out in the reverse
orise order; note the following: nte
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u ra
To ensure the proper function ss a
of the air mass meter - G70- , it is c
important to observe the following notes and instructions.
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ab
Note
ility
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♦ If the air filter element is very dirty or wet, dirt or water could
h re
hole
reach the air mass meter - G70- and affect the air mass value.
spec
This would lead to loss of power, since a smaller injection
es, in part or in w
t to the co
quantity is calculated.
♦ Always use genuine part for air filter element.
rrectness of i
♦ Use a lubricant (silicon) to amount the air intake hose.
l purpos
– Check for salt residues, dirt and leaves in air mass meter -
G70- and air intake hose (pure air side).
nf
ercia
or
– Check intake channel for contamination as far as air filter el‐
m
m
atio
ement. If contamination is found, remove salt residues, dirt
om
n in
and leaves from top and bottom part of air filter housing by
or c
rinsing out or using a vacuum cleaner if necessary.
thi
te
sd
iva
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Specified torques
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♦ ⇒ “3.1 Assembly overview - air filter housing”, page 216

t.
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4.2 Removing and installing fuel pressure
p by
co Vo
by lksw
cted
sender -G247-
agen
Prote AG.

♦ Double hexagon socket, 1/2, 27mm - VAS 5301/7- or com‐

mercially available 27 mm socket

Amarok 2011 ➤
Removing
Note
If fuel pressure sender - G247- fails, fuel pressure regulating valve

- N276- is switched off, electric fuel pump is fully actuated, and
engine is operated with available fuel pressure. Engine torque is
drastically reduced as a result.
WARNING
The fuel system is pressurised! The fuel pressure in the high-

pressure part of the injection system must be reduced to a
residual pressure prior to opening; for procedure see
⇒ page 7 .
– Unscrew coolant line bolt -arrow- from intake manifold.
lkswage es n
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ss
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un
pt
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d
itte
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ab
pe
ility
ot
wit
, is n
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– Disengage connector from fuel pressure sender - G247- with

hole
spec
assembly tool - T10118- .

es, in part or in w
t to the co
– Unscrew fuel pressure sender - G247- using double hexagon

socket 1/2", 27 mm - VAS 5301/7- .
rrectness of i
Installing
l purpos

– Check tightening torque of connection before installing fuel
nform
ercia
pressure sender - G247- .

m
Specified torques
com
tion in

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4.3 Checking fuel pressure sender - G247-

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Special tools and workshop equipment required t. Cop py
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♦ Pressure sensor tester - VAS 6394/1- pyri by
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♦ Adapter - VAS 6394/2- Prote AG.

Amarok 2011 ➤
♦ Test adapter - VAS 5570-
lkswage es n
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un
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d
itte
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erm
ab
ility
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is n
h re
ole,
spec
t to the co
rrectness o
cial p
f
♦ Double hexagon socket, 1/2", 27 mm - VAS 5301/7-
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.
♦ Vehicle diagnosis tester

Procedure
– Remove fuel pressure sender - G247- ⇒ page 222 .
– Moisten tapered seal of adapter - VAS 6294/2- with clean en‐
gine oil and screw into fuel rail.
Specified torque
Tapered seal of adapter - VAS 27 Nm
6294/2-

Amarok 2011 ➤
– Unscrew plug -2- and screw fuel pressure sender - G247- into
tester - VAS 6394/1- .
Specified torque
Fuel pressure sender - G247- in 27 Nm
tester - VAS 6394/1-
– Connect pressure line of tester - VAS 6394/1- to adapter - VAS
6394/2- . n AG. Volkswagen A G do
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th or
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– Connect fuel pressure sender
ss and electrical connector of fuel
pressure sender using test instrument adapter - VAS 5570- .
ce
e
nl
pt
du
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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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nf
ercia
orm
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atio
om
n in
or c
thi
te
sd
iva
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Switch on tester - VAS 6394/1- by briefly pressing the -A- but‐

ton once.
Note
♦ Press button -A- for 2 seconds, then light will be switched on agen AG. Volkswagen AG do
for 20 seconds. Vol
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ran
♦ If the digital pressure gauge - VAS 6394/1- reading risis not 0
e
tee
tho
bar, carry out a zero calibration procedure ⇒ operating
au in‐ or
ac
structions . ss
ce
le
un
pt
an
d
itte
– Connect ⇒ Vehicle diagnostic tester to diagnostic connector.
y li
erm
ab
ility
– Switch ignition on.
ot p
wit
is n
– Follow instructions on display of ⇒ Vehicle diagnostic tester.
h re
ole,
spec
– Read measured value block with ⇒ Vehicle diagnostic tester.
t to the co
– Start engine.
– Compare pressure on tester - VAS 6394/1- with actual value
displayed on ⇒ Vehicle diagnostic tester.
rrectne
• A maximum pressure deviation of 5 bar is permissible.
ss o
– If deviation is greater than 5 bar, renew fuel pressure sender
cial p
f i
- G247- .
nform
mer
atio
m
WARNING
o
n
c
i
or
n thi
te
Tester - VAS 6394- is under high fuel pressure! With engine
sd
iva
o
r
running, detach connector from fuel pressure sender - G247- .

p
cum
r
fo
This reduces fuel pressure to approx. 6 bar. Switch off ignition.
en
ng
t.
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Place a cleaning cloth around fuel pressure sender - G247- ,
Co
op py
then reduce residual pressure by carefully loosening fuel pres‐ t. C rig
gh ht
sure sender - G247- . pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Repeat test with new fuel pressure sender - G247- and com‐
pare two readings.
If readings again fail to correspond:
– Perform line test⇒ vehicle diagnostic tester .
4.4 Checking double non-return valve

♦ Auxiliary measuring set - V.A.G 1594C-

Amarok 2011 ➤
Test prerequisite
• Activated charcoal filter solenoid valve 1 - N80- has been
checked with ⇒ Vehicle diagnostic tester and is OK.
– Detach connector -1- and breather hose -3- from activated
charcoal filter solenoid valve 1 - N80- -2-.
lkswage es n
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nl
pt
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itte
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ab
ility
ot p
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, is n
h re
hole
spec
es, in part or in w
t to the co
sition -A- for "vacuum".
rrectness of i
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nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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– Connect hand vacuum pump - VAS 6213- to activated char‐

m
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en
ng
t.
coal filter solenoid valve 1 - N80- .
yi Co
Cop py
t. rig
– Connect contacts of solenoid valve to battery using auxiliary
gh ht
yri by
leads -1-. This opens the activated charcoal filter system sol‐
cop Vo
by lksw
enoid valve 1 - N80- .
cted agen
Prote AG.
Then operate hand vacuum pump - VAS 6213- several times.

• Vacuum must build up.
– Disconnect battery again (cut power).
– Renew double non-return valve -1-.
Double non-return valve, activated charcoal filter solenoid valve
1 - N80- and plastic hoses form a single component. To replace
it, the intake manifold must be removed.

lkswage es n
o ot g
byV ua
d ran
Amarok 2011 ➤ ho
ir se tee
t or
4-cylinder injection engine (2.0 l direct injection engine,
au turbocharger) - Edition 04.2013 ac
ss
ce
e
nl
pt
du
an
5 Intake manifold
itte
y li
erm
ab
ility
ot p
⇒ “5.1 Assembly overview - intake manifold”, page 228
wit
, is n
h re
⇒ “5.2 Removing and installing intake manifold”, page 229
hole
spec
⇒ “5.3 Removing and installing throttle valve module J338 ”, page
es, in part or in w
233
t to the co
⇒ “5.4 Cleaning throttle valve module J338 ”, page 234
rrectness of i
⇒ “5.5 Checking intake manifold change-over”, page 234
l purpos
5.1 Assembly overview - intake manifold
nf
ercia
o
1 - Bolt
rm
m
atio
m
❑ 9 Nm
o
n in
or c
2 - Intake air temperature
thi
te
sd
a
sender - G42-
iv
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cu
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m
- Activated charcoal filter sole‐
f
en
ng
t.
noid valve 1 - N80-
yi Co
Cop py
❑ With double non-return
t. rig
gh ht
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valve, checking ⇒ Vehi‐
p by
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by lksw
cle diagnostic tester. Prote
cted AG.
agen
4 - Intake manifold
⇒ page 229 .
5 - Vacuum unit for air flow
control flaps (intake manifold
flaps)
6 - Bolt
❑ 20 Nm
7 - Connection for fuel supply
line
❑ From fuel tank
8 - Fuel pressure regulating
valve - N276-
9 - High-pressure pump
❑ With fuel pressure regu‐
lating valve - N276- .

Amarok 2011 ➤
that no dirt enters the fuel system.
❑ The fuel system must not be under pressure when installing the high-pressure pump; procedure for
reducing fuel pressure ⇒ page 7 .
❑ Install fuel lines free of stress.
10 - Roller tappet
❑ Can remain inserted in vacuum pump after removal of high-pressure pump, removable
11 - Connection for fuel supply line
❑ 40 Nm
12 - High-pressure fuel line
❑ Fuel lines must be free of tension when installed.
❑ 27 Nm
13 - Intake manifold flap air flow control valve - N316-
14 - Injectors
❑ Renew O-ring and Teflon ring
❑ Check installation location is correct
15 - Intake manifold support
16 - Bolt
❑ 23 Nm
17 - Nut
❑ 10 Nm lkswage es n
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18 - Bolt ir se
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❑ 10 Nm aut or
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19 - Throttle valve module - J338- , throttle valve drive for electric throttle operation - G186-
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❑ Throttle valve drive angle sender 1 for electric throttle - G187- and throttle valve drive angle sender 2 for
itte
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electric throttle - G188-

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❑ After removing, installing or renewing throttle valve module - J338- it must be re-adapted to engine control
wit
is n
unit - J623- using ⇒ Vehicle diagnostic tester.

h re
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spec
20 - Seal

t to the co
rrectne
5.2 Removing and installing intake manifold

s

s o
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f i

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5. Intake manifold 229

Amarok 2011 ➤
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♦ Special wrench, long reach - T10347- d by
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Removing
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Note
nf
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orm
♦ After fuel rail has been removed or renewed, intake manifold
m
atio
m
flap potentiometer - G336- must be adapted to engine control

o
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c
unit - J623- . Use ⇒ Vehicle diagnostic tester to do this.

or
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♦ The injectors can only be accessed after removal of the intake

iv
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manifold and fuel rail.

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♦ Combustion chamber ring seal (Teflon) and O-ring must al‐
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ways be renewed. t. C rig
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WARNING
Fuel system is under pressure! The fuel pressure in the high-

pressure part of the injection system must be reduced to a
residual pressure prior to opening; for procedure see
⇒ page 7 .
– Disconnect battery from negative terminal.

– Remove pressure pipe ⇒ page 190 .
– Remove throttle valve module ⇒ page 233 .
– Disconnect coolant hose ⇒ Item 19 (page 149) from intake
manifold.
– Disconnect coolant hose at front ⇒ Item 14 (page 149) and
rear from coolant pipe ⇒ Item 10 (page 148) .
– Unclip wiring harness for oil pressure switch - F1- from intake
manifold.

Amarok 2011 ➤
– Disconnect vacuum line -arrow- to activated charcoal filter.

– Unplug following electrical connectors.
1 - Activated charcoal filter solenoid valve 1 - N80-
2 - For knock sensor 1 - G61-
3 - From variable intake manifold valve - N316- , fuel pressure
sender - G247- and Hall sender - G40-
4 - From injectors
5 - Throttle valve module - J338-
6 - Intake air temperature sender - G42-
– Detach connector -1- from Hall sender - G40- .
lkswage es n
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ir se tee
– Unclip vacuum hose uth to air filter -2- and detach from air filter
o
or
housing -1-. ss
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spec
es, in part or in w
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– Detach vacuum hose -1- at disconnection point -2-.

l purpos
– Remove crankcase breather hose -3-.

nform
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Amarok 2011 ➤
4-cylinder injection engine (2.0 l direct injection engine, turbocharger). V-oEdition
lkswage 04.2013 AG n AG d
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– Detach vacuum hose -3- from vacuum pump -2- and brake d by V gu
ara
booster. ris
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spec
es, in part or in w
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– Open spring-type clip -upper arrow- and detach fuel pressur‐
rrectness of i
isation line from high-pressure pump.
l purpos
– Loosen union nut of high-pressure fuel line -lower arrow- at

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

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♦ Collect escaping fuel with a clean cloth.
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♦ Seal open connections with clean caps. It is essential to en‐
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sure that no dirt enters the fuel system.
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– Disconnect connector from coolant temperature sender -
agen
Prote AG.
G62- .
– Unclip wiring harness from support.
– Loosen securing nut -1- and unscrew bolt -2- completely.

Amarok 2011 ➤
– Release oil filter with Hazet securing strap - 2171-1- or with oil
filter tool - 3417- and remove oil filter.
– Unscrew bolts from intake manifold using socket - T10347- .
Note
♦ To unscrew inaccessible bolts without socket - T10347- , throt‐

tle valve module - J338- has to be removed.
♦ Injectors can remain in fuel rail.
♦ Seal intake ports with a clean cloth.
– Carefully pull intake manifold with fuel rail slightly away from
cylinder head.
– Disconnect intake manifold from fuel rail ⇒ page 229 .
Installing
Note
Ensure injectors are installed correctly.
– Fit intake manifold onto studs (left and right) on cylinder head.
Specified torques
♦ ⇒ “5.1 Assembly overview - intake manifold”, page 228 agen
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♦ ⇒ “2.1 Assembly overview - fuel rail with injectors”, epage by V 209 gu
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5.3 Removing and installing throttle valve s a c
s
ce
le
module - J338-
un
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Removing
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– Open hose clip -arrow- of air duct and detach this downwards
wit
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from throttle valve module - J338- .

h re
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– Detach electrical connector -1- from throttle valve module - spec

es, in part or in w
J338- .
t to the co
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Prote AG.

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

remove throttle valve module - J338- .
Installing
AG. Volkswagen AG d
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– Clean sealing surface for O-ring. olksw not
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– Renew seal. hor is nte
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– After renewing throttle valve module - J338-
ss it must be re- c
adapted to engine control unit - J623- using ⇒ Vehicle diag‐
ce
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nl
pt
du
nostic tester.
an
itte
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erm
ab
Specified torques
ility
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hole
spec
5.4 Cleaning throttle valve module - J338-
es, in part or in w
t to the co
Procedure
– Remove throttle valve module - J338- ⇒ page 233 .
rrectness of i
– Open throttle valve by hand and lock it in open position using
l purpos
a suitable object (e.g. wood or plastic wedge) -arrow-.
nf
ercia
WARNING
orm
m
atio
m
Acetone is highly inflammable. Observe accident prevention

o
n in
or c
regulations and safety notes when handling highly inflammable
thi
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fluids. Do not use compressed air when cleaning throttle valve.

t
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Wear eye protection and protective clothing to avoid eye inju‐
r
rp
cu
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ries and skin contact.
f
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t.
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Cop py
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rig ht
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Note
agen
Prote AG.
When cleaning the throttle valve nozzle it must not be scratched.
– Thoroughly clean throttle valve connection, especially around

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

Perform check only if there is a loss of torque. This means when
there is a lack of elasticity or a lack of pulling power.

Amarok 2011 ➤
Test prerequisite
♦ Variable intake manifold valve - N316- has been checked with
⇒ Vehicle diagnostic tester.
If the intake manifold flap valve - N316- is OK, perform the fol‐
lowing tests:
– Start engine and run at idling speed.
– Have second person abruptly increase engine speed (throttle
burst). Observe intake manifold changeover vacuum unit.
• Actuator must move -arrow-.
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If changeover does not operate as indicated: Volkswa not
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– Check vacuum system for leaks. orise nte
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– Check changeover mechanism sfor
s ease of movement . To do
a c
this, operate rods by hand.
ce
e
nl
pt
du
an
– Check that vacuum lines are correctly connected.
itte
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ab
– Check vacuum hoses for porosity.
ility
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wit
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hole
spec
es, in part or in w
t to the co
– Remove vacuum hose -1- leading to actuator for intake mani‐
fold valve flap - N316- from intake manifold flap valve - N316-
-2-.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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rig ht
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Prote AG.

Amarok 2011 ➤
sition -A- for "vacuum".
– Connect hand vacuum pump - VAS 6213- to actuator for intake

manifold flap valve - N316- .
– Operate hand vacuum pump - VAS 6213- several times.
vacuum unit -arrows- must move.
– If the vacuum unit does not move, renew it.
AG. Volkswagen AG d
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mer
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Cop py
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Prote AG.

Amarok 2011 ➤
6 High-pressure pump
⇒ “6.1 Assembly overview - high-pressure pump”, page 237
⇒ “6.2 Removing and installing high-pressure pump”, page 238
⇒ “6.3 Check fuel holding pressure upstream of high-pressure
pump”, page 240
olkswagen AG
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6.1 Assembly
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oes
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WARNING
ce
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Fuel system is under high pressure! It is essential to reduce
erm
ab
fuel pressure before opening system. For procedure, please
ility
ot p
see ⇒ page 7 .
wit
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spec
es, in part or in w
t to the co
1 - Roller tappet
❑ Can remain inserted in
vacuum pump after re‐
rrectness of i
moval of high-pressure
pump
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2 - O-ring
nform
ercia

m
at
3 - High-pressure pump
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fuel system.
Prote AG.
❑ The fuel system must

not be under pressure
when installing the high-
pressure pump; proce‐
dure for reducing fuel
pressure ⇒ page 7 .
❑ Install fuel lines free of
stress.
⇒ page 238 .
4 - Fuel pressure regulating
valve - N276-
5 - Bore in vacuum pump for
high-pressure pump
6 - Injectors
❑ Renew O-ring and Tef‐
6. High-pressure pump 237

Amarok 2011 ➤
lon ring
❑ Check installation location is correct
8 - Inlet camshaft control valve 1 - N205-
9 - Bolt
❑ 20 Nm
10 - Connecting piece for fuel supply line from fuel tank
11 - Connection for fuel supply line
❑ Fuel pressurisation line must not be under tension when installed (ensure cleanliness)
❑ Connection: 40 Nm
❑ Union nut of fuel supply line: 27 Nm
6.2 Removing and installing high-pressure

pump swa
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WARNING ris
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Fuel system is under high pressure! It is essential to reduce
ce
le
un
pt
fuel pressure before opening system. For procedure, please
an
d
itte
see ⇒ page 7 .
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pe
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Note
spec
es, in part or in w
t to the co
♦ Engine must be cold before high-pressure pump is removed.
♦ When installing the high-pressure pump, it is essential to en‐
sure that no dirt enters the fuel system. rrectness of i
l purpos
♦ Collect escaping fuel with a cleaning cloth.

♦ O-ring must always be renewed.
nform
ercia
♦ Always ensure that high-pressure fuel line is free of tension

m
when installed.
a
com
tion in
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Removing
s
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rp
– Detach connector from fuel pressure regulating valve - N276-

cum
fo
-1-.
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.

Amarok 2011 ➤
– Open fuel lines -arrows-.
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– Remove 2 bolts -arrows-.
rm
ab
pe
ility
– Carefully pull out high-pressure fuel pump. Sleeve can remain
ot
wit
, is n
inserted in vacuum pump.
h re
hole
spec
Installing
es, in part or in w
t to the co
– Renew high-pressure pump O-ring.
rrectness of i
– Insert roller tappet in vacuum pump (first check roller tappet
for damage).
l purpos
nform
ercia
Note
m
a
com
t
♦ Roller tappet must be at bottom dead centre to enable high-
ion in
pressure pump to be installed.
r
te o
thi
s
iva
♦ If same or a used high-pressure pump is installed, connection
do
r
rp
c
for fuel pressurisation line (high-pressure side) must be re‐
um
fo
newed. See assembly overview - high-pressure pump item 11 en

ng
t.
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⇒ page 237 ht. Cop py
rig
rig ht
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– Turn crankshaft until roller tappet is at bottom dead centre.
co lksw
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– Insert high-pressure pump into vacuum pump and tighten.
– Tighten bolts hand tight.
– Renew high-pressure pump connection.
– Tighten bolts in diagonal sequence to specified torque.
– Tighten union nut of high-pressure line hand-tight. Align free
of tension.
– Reattach connector of fuel pressure regulating valve - N276- .
– Put back fuse if it has been removed.
Note
Check fuel system for leaks.
Specified torques
♦ ⇒ “6.1 Assembly overview - high-pressure pump”, page 237

AG. Volkswagen AG d
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Amarokaut 2011 ➤
ho eo
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4-cylinder
ss injection engine (2.0 l direct injection engine,c turbocharger) - Edition 04.2013
ce
le
un
pt
an
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6.3 Check fuel holding pressure upstream
itte
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ab
of high-pressure pump
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spec
♦ K-Jetronic pressure tester - V.A.G 1318-
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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♦ Measuring container, fuel-resistant

fo
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t.
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♦ Protective gloves t. Cop py
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Test prerequisites pyri by
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• Battery voltage at least 12.5 V Prote AG.
• Fuel filter OK.

• Fuel tank at least 1/4 full.
• Fuel pump control unit - J538- OK.
• Ignition switched off.
Checking fuel pressure
WARNING
♦ The pressure in the high-pressure part of the injection

system must be reduced to a residual pressure
⇒ page 7 .
♦ A clean cloth must then be wrapped around the connec‐
tion and the residual pressure dissipated by carefully loos‐
ening the connection.
– Release clip -2- and detach fuel line -3- from high-pressure
pump -1-.

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

adapter set - V.A.G 1318/17A- to K-Jetronic pressure tester -
V.A.G 1318- .
– Attach adapter adapter set - V.A.G 1318/17A- to detached fuel
pressurisation line.
– Screw adapter - V.A.G 1318/11- to K-Jetronic pressure tester
- V.A.G 1318- .
– Attach auxiliary hose -arrow- to pressure tester and hold it in
collecting container.
AG. Volkswagen AG d
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nl
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ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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Prote AG.

Amarok 2011 ➤
– Close shut-off tap of pressure tester.

• Lever is at right angle to direction of flow -arrow-.
– Connect ⇒ Vehicle diagnostic tester.
– Then select final control diagnosis.
– In selection list select Fuel pump electronics and press
Start .
Note
AG. Volkswagen AG d
This function actuates fuel pump. lksw
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– Read off fuel pressure at K-Jetronic pressure ttester
ho
r - V.A.G eo
1318- . s au ra
c
s
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• Specification: 5 to 8 bar
nl
pt
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– Stop procedure once fuel pressure no longer rises at K-Jet‐
y li
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ab
ronic pressure tester - V.A.G 1318- .
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If the specification is not attained:
, is n
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hole
– Checking fuel pump delivery rate ⇒ Rep. gr. 20
spec
es, in part or in w
Checking holding pressure
t to the co
– Check for leaks and check holding pressure by observing
pressure drop at K-Jetronic pressure tester - V.A.G 1318- .
rrectness of i
• After 10 minutes, there must be a residual pressure of at least
l purpos
3 bar.
If the holding pressure drops below 3 bar:
nform
ercia
♦ Check threaded connection between pressure gauge and fuel

m
at
line for leaks.
om
ion
c
in t
r
♦ Check pressure tester for leaks.

o
his
ate
do
riv
♦ Check fuel lines and their connections for leaks.

p
cum
for
en
g
♦ Check fuel pump delivery rate ⇒ page 168 .

n
t.
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op py
♦ Renew fuel filter with integrated fuel pressure regulator
t. C rig
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⇒ page 182 . p by
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cted agen
♦ Fuel pump non-return valve is defective ⇒ page 168 . Prote AG.
Assembly is carried out in the reverse order. When installing, note

the following:
Note
The fuel pressure must be reduced by opening the shut-off valve

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

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

-1- and attach clip -2- (ensure cleanliness).
Note
Check fuel system for leaks.
AG. Volkswagen AG d
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ility
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is n
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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
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t.
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Prote AG.

olkswagen AG
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Amarok 2011 ➤ ksw
ag does
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ed byengine, turbocharger) - Edition 04.2013
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7 Engine control unit
ce
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un
pt
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⇒ “7.1 Removing and installing engine control unit”, page 244
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ab
pe
ility
7.1 Removing and installing engine control
ot
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unit
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hole
spec
es, in part or in w
t to the co
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Removing C py
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– Before removing engine control unit, read the control unit iden‐ cop Vo
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tification and, with it, the coding of the control unit used up to cted agen
Prote AG.
now ⇒ Vehicle diagnostic tester.
– Disconnect battery ⇒ Battery; Rep. gr. 27 ; Disconnecting and
connecting battery .
– Remove shear bolts -1- and remove bow -4-.
– Release and pull off connectors -2- and -3-.
– Pull engine control unit out.
Installing
– Insert engine control unit.
– Insert and lock connectors -2- and -3-.
– Fit bow -4- and new shear bolts -1-.

– Connect battery ⇒ Battery; Rep. gr. 27 ; Disconnecting and
connecting battery .
– Check previous coding and code new control unit ⇒ Vehicle
diagnostic tester.

Amarok 2011 ➤
26 – Exhaust system olksw

agen
AG. Volkswagen AG d
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1 Exhaust pipes, silencers ris nte
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aut ra
ss c
⇒ “1.1 Assembly overview - silencers”, page 245
ce
e
nl
pt
du
an
⇒ “1.2 Removing and installing centre silencer”, page 246
itte
y li
erm
ab
⇒ “1.3 Removing and installing rear silencer”, page 248
ility
ot p
wit
, is n
⇒ “1.4 Checking exhaust system for leaks”, page 248
h re
hole
⇒ “1.5 Aligning exhaust system free of stress”, page 248
spec
es, in part or in w
t to the co
⇒ “1.6 Installation position of clamp”, page 249
1.1 Assembly overview - silencers
rrectness of i
l purpos
1 - Seal
nf
ercia
o
2 - Catalytic converter
rm
m
atio
❑ Protect catalytic con‐
om
n in
verter from damage by
or c
knocks and impact
thi
te
sd
iva
❑ Aligning exhaust sys‐
o
r
rp
cu
tem free of tension
o
m
f
en
ng
⇒ page 248 .
t.
yi Co
op py
t. C rig
gh ht
yri
⇒ page 251 . p by
o Vo
by c lksw
cted agen
3 - Bracket Prote AG.
4 - Bolt
❑ 20 Nm
5 - Nut
❑ Lubricate turbocharger
studs with high-temper‐
ature paste ⇒ Electronic
Parts Catalogue (ET‐
KA) .
❑ 40 Nm
6 - Centre silencer
❑ Cutting point
⇒ page 246
❑ Aligning exhaust sys‐
tem free of tension
⇒ page 248 .
7 - Mounting
❑ Check pretension
⇒ page 248
8 - Rear silencer
❑ Aligning exhaust system free of tension ⇒ page 248 .
9 - Rear clamp
❑ Tighten bolted connections evenly.
❑ Align exhaust system free of tension before tightening ⇒ page 248 .
1. Exhaust pipes, silencers 245

Amarok 2011 ➤
10 - Bolt
❑ 20 Nm
11 - Bracket
12 - Clamp
❑ Tighten bolted connections evenly.
❑ Align exhaust system free of tension before tightening ⇒ page 248 .
Installation position of front clamp

– Install clamp in illustrated angle position.
• Bolt connections point to the right.
• Nuts point upwards.
• α = approx. 20°
lkswage es n
o ot g
byV ua
d ran
ir se
Installation position of rear clamp tho tee
or
au ac
s
– Install clamp so that ends of bolts do not protrude beyond bot‐
s
ce
le
tom of clamp.
un
pt
an
d
itte
y li
• Bolt connections point downwards.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
1.2 Removing and installing centre silencer

ss o

cial p
f inform
♦ Engine and gearbox jack - V.A.G 1383 A-

mer
atio
m
Removing
o
n
c
i
or
n thi
– Support gearbox with engine and gearbox support - V.A.G

te
sd
a
1383 A- .
iv
o
pr
cum
r
fo
– Release gearbox mounting from gearbox. To do so, loosen

en
ng
t.
yi
bolts -1-.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
246 Rep. gr.26 - Exhaust system

Amarok 2011 ➤
– Remove cross member -2- for gearbox mounting -3-; to do so,

unscrew bolts -1-.
– Release double clip -2- to rear silencer; to do so, loosen se‐

curing nuts -1-.
AG. Volkswagen AG d
agen oes
– Release clip -2- to catalytic converter.
yV
olks
w not
gu
b ara
ed nte
oris
– Remove centre silencer downwards.
au
th eo
ra
ss c
Installing 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 double clamp so that end of bolt -arrow- does not extend
rrectness of i
beyond lower edge of double clamp.

l purpos
• Threaded connection faces to rear.

– Aligning exhaust system ⇒ page 248 .
nform
ercia
Specified torques
m
at
om
io

n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
1.3 Removing and installing rear silencer

Removing
– Release double clip -2- to rear silencer; to do so, loosen se‐
curing nuts -1-.
– Detach rubber connector -2- in -direction of arrow- from brack‐

et -1-.
– Remove rear silencer downwards.
Installing
– Aligning exhaust system ⇒ page 248 .
Specified torques AG. Volkswagen AG d
agen oes
lksw not
♦ ⇒ “1.1 Assembly overview - silencers”, page 245 byV
o gu
ara
ed
ris nte
ho eo
aut ra
ss c
1.4 Checking exhaust system for leaks
ce
le
un
pt
an
d
itte
y li
– Start engine and run at idling speed.
erm
ab
ility
ot p
– Plug tailpipes (e.g. with cloths or sealing plugs) and leave
wit
is n
plugged until leak test is complete.
h re
ole,
– Listen for noise at connection points (cylinder head/exhaust
spec
manifold, exhaust manifold/front exhaust pipe, etc.) to locate
t to the co
any leaks.
– Rectify any leaks that are found. rrectne
1.5 Aligning exhaust system free of stress

s

s o
cial p
f in
♦ Torque wrench (5…50 Nm) - V.A.G 1331-

form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
• The exhaust system must be aligned when cold.

Procedure
– Loosen bolts of double clamp -3-.

Amarok 2011 ➤
– Tighten bolts hand tight.

– Align exhaust system until the marking- 4- is visible.
– 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.
Specified torques
Bolts for double clamp 35 Nm
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise
1.6 Installation position of clamp r nte
tho eo
au ra
ss c
ce
le
un
pt
Note
an
d
itte
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rm
Gradual introduction of clamp with continuous clip. ab

pe
ility
ot
wit
, is n
h re
Specified torque and mounting dimensions of clamping sleeve.
hole
spec
Clamp -A- with 2 individual clips.

es, in part or in w
t to the co
Specified torque: 25 Nm.

Installation dimensions -a- 5 mm (only for front clamp)
rrectness of i
Clamp -B- with continuous clip.

l purpos
Specified torque: 35 Nm.

nform
ercia
Installation dimensions -a- 8.5 mm (only for front clamp)

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
Installation dimension -a- for vehicles with marking on front ex‐

fo
en
ng
haust pipe
t.
yi Co
Cop py
t. rig
1 - Clamp opyri
gh by
Vo
ht
c
2 - Front exhaust pipe
by lksw
cted agen
Prote AG.
a - Installation dimension
A - Marking

Amarok 2011 ➤
Installation position of front clamp

– Install clamp so that end of bolt -arrow- does not extend be‐
yond lower edge of clamp.
• Threaded connection faces right
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
Installation position of rear clamp erm
ab
ility
ot p
– Install clamp so that end of bolt -arrow- does not extend be‐
wit
, is n
yond lower edge of clamp.
h re
hole
spec
• Threaded connection faces to rear.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
lkswage es n
o ot g
2 Emission control
ir se
d byV ua
ran
tee
tho
or
⇒ “2.1 Removing
au and installing catalytic converter ”, page a251
c
ss
ce
e
2.1 Removing and installing catalytic con‐

nl
pt
du
an
itte
verter
y li
erm
ab
ility
ot p
Removing
wit
, is n
h re
– Detach connector for Lambda probe 1 heater, downstream of
hole
spec
catalytic converter - Z29- -arrow- and lay leads to one side.
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
– Detach connector -1- for Lambda probe downstream of cata‐

a
do
riv
lytic converter - G130- from bracket -2- and lay leads to one
p
cum
or
side.
f
en
ng
t.
yi Co
op
– Remove air filter housing ⇒ page 218 . C py
t. rig
gh ht
yri by
cop Vo
by lksw
exterior; Rep. gr. 66 ; Underbody guard . cted agen
Prote AG.
– Unscrew securing bolts -1- for catalytic converter -2-.
– Unscrew bolts -2- from bracket -1-.
2. Emission control 251

Amarok 2011 ➤
– Release clip -2- between catalytic converter and centre si‐

lencer.
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
– Unscrew nuts -arrows- and remove catalytic converter up‐
es, in part or in w
wards.
t to the co
Installing
rrectness of i
l purpos
Note
nform
ercia
Renew seals, gaskets and self-locking nuts.

m
at
om
ion
Specified torques
c
in t
or
his
te

a
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
28 – Ignition system
1 Ignition system
⇒ “1.1 Assembly overview - ignition system”, page 253
⇒ “1.2 Removing and installing ignition coils with output stage”,
AG. Volkswagen AG d
page 254 lksw
agen oes
n o ot g
yV ua
⇒ “1.3 Removing and installing
ris
ed
b
spark plugs”, page 255 ran
tee
tho or
⇒ “1.4 Removing andau installing knock sensor 1 G61 ”, ac
ss
page 257
ce
e
nl
pt
du
⇒ “1.5 Removing and installing engine speed sender G28 ”, page
an
itte
y li
257
erm
ab
ility
ot p
⇒ “1.6 Test data, spark plugs”, page 258
wit
, is n
h re
1.1 Assembly overview - ignition system
hole
spec
es, in part or in w
t to the co
1 - Knock sensor 1 - G61-
❑ On front of cylinder head
rrectness of i
under intake manifold
❑ Gold-plated contacts.
l purpos

⇒ page 257 .
nform
ercia
2 - Bolt
m
at
om
❑ The specified torque in‐ ion

c
in t
fluences the function of
or
his
e
the knock sensor.

at
do
priv
❑ 20 Nm
um
for
en
ng
t.
3 - Ignition coil with output
yi Co
op
stage - (N70, N127, N291,
C py
ht. rig
N292)-
rig ht
py by
co Vo
by lksw
❑ Removing and installing Prote
cted AG.
agen
⇒ page 254 .
4 - Spark plug
❑ If a spark plug is re‐
placed, regrease igni‐
tion coil with final output
stage ⇒ page 255
❑ Type and electrode gap
⇒ page 258 .
❑ Remove and install with
spark plug socket and
extension - 3122 B- .
❑ 25 Nm
5 - O-ring
6 - Engine speed sender -
G28-
❑ At lower left of front cyl‐
inder block, next to
coarse oil separator ⇒ page 135
7 - Bolt
❑ 10 Nm
1. Ignition system 253

Amarok 2011 ➤

❑ In cylinder head cover at front.
❑ Gold-plated contacts.
1.2 Removing and installing ignition coils

with output stage
♦ Puller - T40039-
wage es n
♦ Lubricating paste - G 052 141
yV
oA2-
lks ot g
b ua
ed ran
Removing horis tee
t or
au ac
ss
ce
le
Note
un
pt
an
d
itte
y li
rm
ab
♦ Observe safety precautions ⇒ page 6 .

pe
ility
ot
♦ To detach spark plugs, fit puller - T40039- onto uppermost,

wit
, is n
h re
thick rib -arrow- of ignition coils with final output stages.

hole
spec
♦ The lower ribs may be damaged if they are used.

es, in part or in w
t to the co
rrectness of i
l purpos
– Pull all ignition coils approx. 30 mm out of spark plug recess

using puller - T40039- .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
254 Rep. gr.28 - Ignition system

Amarok 2011 ➤
– Release connectors and simultaneously detach all connectors

from ignition coils -arrows-.
Installing
Note
♦ When fitting new spark plugs, the ignition coil must be re‐
greased using lubricating paste - G 052 141 A2- This will stop
the ignition coil sealing hose from »sticking« to the spark plug.
The lubricating paste must be distributed on the spark plug
when inserting on the ignition coil.
♦ New ignition coils with output stage are lubricated when de‐
livered.
– Apply a thin line of lubricating paste - G 052 141 A2- around

the ignition coil sealing hose -arrow-. The bead must be 1…2
mm thick.
– Insert all spark plugs loosely into spark plug recess.
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
– Align ignition coils with connectors -arrows- and push all con‐
ility
ot p
nectors simultaneously onto ignition coils.

wit
, is n
h re
– Evenly push ignition coils onto spark plugs by hand.

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
1.3 Removing and installing spark plugs

on
c
in t
or
his
te

a
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 ➤
♦ Torque wrench - V.A.G 1331/-
♦ Spark plug socket and extension - VAS 3122B-
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
♦ Puller - T40039-
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
Removing
rm
m
atio
m
– Pull all ignition coils approx. 30 mm out of spark plug recess

o
n in
or c
using puller - T40039- .

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 ➤

– Remove ignition coil with final output stage
– Unscrew spark plugs with spark plug spanner - VAS 3122B- .
Installing
– Insert all spark plugs with final output stage loosely into spark
plug recess.
– Align ignition coil plus final output stages with connectors

-arrows- and push on simultaneously.
Note
Do not strike with a hammer or similar tool.
– Evenly push all ignition coils plus final output stages onto spark
plugs by hand.
Specified torques
♦ ⇒ “1.1 Assembly overview - ignition system”, page 253
1.4 Removing and installing knock sensor 1

- G61-
Removing AG. Volkswagen AG d
agen oes
lksw n
– Detach connector -2-byfrom
Vo knock sensor I - G61- . ot gua
ed ran
ris tee
– Remove coolantutho pump ⇒ page 157 . or
a ac
ss
ce
le
un
pt
Note
an
d
itte
y li
erm
ab
The knock sensor I - G61- is located under the intake manifold

ility
ot p
behind the coolant pump.

wit
is n
h re
ole,
spec
– Unscrew knock sensor I - G61- .

t to the co
Installing
rrectne
Specified torques
ss o
cial p

inform
page 150
mer
atio
m
1.5 Removing and installing engine speed

o
n
c
i
or
n thi
sender - G28-
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 ➤
♦ Hexagon key extension, 4 mm - T10370-
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
Removing
es, in part or in w
t to the co
– Detach connector -2- from engine speed sender - G28- at right
below coarse oil separator -1-.
rrectness of i
l purpos
Note
To release electrical connector without assembly tool - T10118- ,
nf
ercia
o
press connector on engine speed sender - G28- in with a screw‐
rm
m
driver and at the same time raise release tab with a thin wire hook.
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.
– Loosen securing bolt -arrow- with socket AF 4 mm - T10370-

and remove speed sender.
Installing
Specified torques
1.6 Test data, spark plugs

Engine codes CFPA
Firing order 1-3-4-2
Spark plugs
VW/Audi 06H 905 601 A
Electrode gap 1.0 … 1.1 mm
Specified torque 25 Nm
Change interval ⇒ Maintenance ; Booklet ; Service ta‐
bles

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
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.

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Service

Service Department. Technical Information

matter of course, be observed.

1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3.3 Safety precautions during work on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3.3 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

3.6 Renewing balancer shaft for exhaust camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

4.5 Measuring axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

5.2 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

1.5 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

2.2 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

3.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

3.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

4.1 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

4.2 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

5 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

5.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

6.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

1 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

1.1 Assembly overview - charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

1.2 Removing and installing pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

1.3 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

1.4 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

2.3 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

6 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

6.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

7 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

1.3 Removing and installing rear silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

1.5 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

found at the joint between engine and gearbox -arrow-.

The engine number consists of up to nine characters (alphanu‐

“engine code”, and the second part (6 characters), the “serial

2 Rep. gr.00 - Technical data

2.1 General notes on the lubrication system

If large quantities of metal chips and abraded material are

2.2 General notes on ignition system

♦ For trouble-free operation of electrical components, a voltage

of at least 11.5 V is necessary.

♦ After completing work, read event memory of engine control

created during checks and repairs. The readiness code must

be generated if the event memory has been cleared ⇒ Vehicle

♦ If, after fault finding, repairs or component tests, the engine

In this case, the control unit may have to be adapted ⇒ Vehicle

2.3 General notes on fuel system

When doing any repair work, especially in the engine compart‐

♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair

♦ Hoses are secured with spring-type clips. In case of repair, t to the co

using spring-type clip pliers - VAS 6340- or

♦ When installing coolant hoses, route stress-free so that they

do not come into contact with other components (observe

markings on coolant connection and hose).

must be aligned with each other.

4 Rep. gr.00 - Technical data

protection and protective clothing to avoid eye injuries and