Service
Workshop Manual
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail)
Engine ID
CDC CDB CNE CSH CNF CNF
A
A
A
A
A
B
Edition 04.2013
do
c
um
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
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
26 - Exhaust system
r
fo
ng
28 - Glow plug system
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
23 - Mixture preparation - injection
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
21 - Turbocharging/supercharging
ht
rig
py
Co
t.
20 - Fuel supply system
ility
ab
y li
an
pt
ce
19 - Cooling
un
le
17 - Lubrication
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2013 Volkswagen AG, Wolfsburg
D4B80260554
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.1
2
2.1
2.2
2.3
2.4
2.5
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety precautions when working on injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety precautions when working on charge air system . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety precautions during road tests in which testing and measuring equipment is used . .
Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General notes on the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General notes on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rules for cleanliness when working on fuel supply system/injection system . . . . . . . . . . . .
Rules for cleanliness when working on charge air system . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions for working on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To avoid any risk of injuries to persons and/or the destruction of the injection and glow plug
system, the following must be noted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions for hose connections with screw-type clips . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
5
5
6
7
7
7
8
8
9
10
11
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1
1.1
1.2
1.3
2
2.1
Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Securing engine on engine and gearbox support VAS 6095 . . . . . . . . . . . . . . . . . . . . . .
Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
26
27
31
31
. Volkswage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
13 - Crankshaft group
gen A.G. . . . . . .n.AG
does
swa
olk
no
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
y V block (pulley end) . . . . . . .t .gu.a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
Cylinder
db
ran
e
s
ri
1.1 thoAssembly
overview - cylinder block . . . . .te.e o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
u
r
1.2ss a Assembly overview - sealing flange, belt pulleyacend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3
Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4
Assembly overview - poly V-belt drive, vehicles without A/C system . . . . . . . . . . . . . . . . . .
1.5
Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6
Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7
Removing and installing ancillary bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8
Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.9
Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.10 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Ancillary drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
Assembly overview - ancillary drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
Retrofitting preparation for ancillary drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1
Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2
Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3
Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2
Checking piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3
Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4
Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5
Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
thi
sd
o
cu
m
en
Contents
34
34
36
37
39
40
42
43
44
46
48
51
51
51
54
54
55
57
66
66
68
69
70
71
i
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
4.6
4.7
5
5.1
5.2
5.3
5.4
5.5
Bearing shells - installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
72
73
73
74
74
75
76
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing injector seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fresh air supply system, belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - fresh air supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing blower for fresh air supply system . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing air filter housing for fresh air supply system . . . . . . . . . . . . . . . .
Removing and installing bracket for fresh air supply system . . . . . . . . . . . . . . . . . . . . . . . .
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - valve gear . . . . a.g.e.n A
.G
. .. V.o.lk.s.w.ag. e.n.A.G. d.o. . . . . . . . . . . . . . . . . . . . . . . . .
es
sw
k
l
o
Measuring axial clearance of camshaft
. . . . . . . . . . . . . . . . . .no.t .gu. . . . . . . . . . . . . . . . . . . .
yV
b
ar
d
Measuring radial clearanceorof
ise camshafts . . . . . . . . . . . . . . . . . . . . a.n.te. . . . . . . . . . . . . . . .
e
h
ut
Removing and installing acamshafts
. . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a.c. . . . . . . . . . . . .
s
s
Removing and installing
camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking hydraulic compensation element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
un
le
ility
ab
y li
an
pt
ce
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
2
2.1
2.2
3
3.1
3.2
3.3
3.4
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
5
5.1
5.2
5.3
78
78
81
85
93
99
102
103
105
105
107
116
116
117
117
118
119
119
121
122
123
129
131
132
135
135
135
136
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
r
te o
iva
r
rp
fo
g
n
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Contents
ht
rig
py
Co
t.
ii
Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing oil pump, vehicles with balancer shaft module . . . . . . . . . . . . . .
Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . .
Removing and installing dipstick tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - oil filter housing with engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing oil filter housing with engine oil cooler . . . . . . . . . . . . . . . . . . . . . .
Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measure oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
do
c
um
en
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
2
2.1
2.2
2.3
2.4
2.5
2.6
137
137
140
146
146
147
147
148
150
150
151
154
156
157
157
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
3
3.1
4
4.1
4.2
4.3
4.4
5
5.1
5.2
Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing a new balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing a previously used balancer shaft module again . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing oil supply line to turbocharger, 120 kW and 132 kW engines . . . .
Removing and installing oil pressure line to turbocharger - 90 kW and 103 kW engine . .
159
159
161
161
163
165
168
170
170
172
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - coolant pump/ball thermostat (4/2-way valve) . . . . . . . . . . . . . . . . . .
Assembly overview - Continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - circulation pump V55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing coolant temperature sender at radiator outlet G83 . . . . . . . . . .
Removing and installing continued coolant
lkswagen AG pump V51 . . . . . . . . . . . . . . . . . .
. Vocirculation
gen AG
a
w
s
Removing and installing Y-thermostat
. . . . . . . . . . . d.o.es. n.o.t . . . . . . . . . . . . . . . . . . . . . . . .
k
Vol
g
y
db
Removing and installingiserecirculation
pump V55 . . . . . . . . .ua. r.an. . . . . . . . . . . . . . . . . . . . .
tee
r
ho
Radiator, radiator fan
ut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a. . . . . . . . . . . . . . . . . .
a
ss - radiator/ radiator fan V7 . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . .
Assembly overview
Assembly overview - radiator cowl and radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing radiator cowl with radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . .
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
1
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
3
3.1
3.2
3.3
3.4
175
175
178
180
182
187
187
188
189
190
191
196
197
198
199
200
202
202
204
204
207
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Procedure when filling with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure when filling with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine is not running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine is running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking low-pressure fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking fuel low-pressure at high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking flow rate at high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking fuel low-pressure ahead of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking flow rate ahead of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing filler neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
thi
sd
o
cu
m
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
1
1.1
1.2
1.3
2
2.1
2.2
2.3
2.4
3
3.1
3.2
3.3
3.4
4
4.1
4.2
5
5.1
Contents
210
210
210
211
213
213
215
218
222
226
226
228
229
232
236
236
237
238
238
iii
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
5.2
5.3
6
6.1
6.2
7
7.1
7.2
Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking fuel delivery rate of fuel pump (fuel low pressure) . . . . . . . . . . . . . . . . . . . . . . . .
Checking voltage supply of fuel pump (fuel low pressure) . . . . . . . . . . . . . . . . . . . . . . . . . .
Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
239
239
242
242
245
248
248
249
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
2.8
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
2.7
ility
ab
y li
an
pt
ce
1.4
1.5
2
2.1
2.2
2.3
2.4
2.5
2.6
Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing intake air temperature sender G42 with charge air pressure sender
G31 . . . . . . . . . . . . . . . . . . . . . . . . k.s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
n AG. Vol wagen AG do
Removing and installinglkexhaust
gas flap valve N220
............................
es n
wage
s
ot g
o
yV
u
b
Checking charge air
system
for
leaks
.
.
.
.
.
.
.
.
.
.
.
.
.
a.ra. . . . . . . . . . . . . . . . . . . . . . . . . .
ed
nt
ris
o
Turbocharger uth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e.e o.r . . . . . . . . . . . . . . . . . . . . . . .
ac
a
ss
Assembly overview
- turbocharger, 120 kW and 132 kW engines
....................
Assembly overview - turbocharger, 90 kW and 103 kW engines . . . . . . . . . . . . . . . . . . . .
Removing and installing turbocharger - 120 kW and 132 kW engines . . . . . . . . . . . . . . . .
Removing and installing turbocharger - 90 kW and 103 kW engines . . . . . . . . . . . . . . . . . .
Removing and installing charge pressure sender 2 G447 . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing regulating flap potentiometer G584 and vacuum unit for
turbocharger, 120 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing regulating flap potentiometer G584 and vacuum unit for
turbocharger, 132 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing charge pressure control solenoid valve N75 . . . . . . . . . . . . . . . .
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
1
1.1
1.2
1.3
250
250
251
254
255
256
260
260
264
267
272
277
278
290
300
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Contents
ht
rig
py
Co
t.
iv
Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematic overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting location overview - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling/bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematic diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing vacuum system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injectors and high-pressure accumulator (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview of injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injector delivery calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing injectors (piezo injectors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing injectors (solenoid valves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing high-pressure accumulator (rail) . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . .
High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing throttle valve module J338 with throttle valve potentiometer G69 and
intake manifold flap motor V157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
thi
sd
o
cu
m
en
1
1.1
1.2
1.3
1.4
1.5
2
2.1
2.2
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4
4.1
4.2
5
5.1
5.2
5.3
302
302
304
311
316
316
318
318
321
327
327
327
328
332
338
340
343
347
347
350
354
354
354
357
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
n(2.0
ise
4-cylinder
diesel
engine
tee l
r
o
h
t
or
u
ac
a
ss
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing exhaust pressure sensor 1 G450 . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . .
Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ility
ab
y li
an
pt
ce
6
6.1
6.2
6.3
6.4
6.5
7
7.1
7.2
8
8.1
8.2
Amarok 2011 ➤
engine, common rail) - Edition 04.2013
359
359
360
362
364
365
368
368
370
372
372
372
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
Exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleansing exhaust emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - emission control (diesel particulate filter) . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - emission control (catalytic converter) . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - exhaust gas recirculation, 132 kW engine . . . . . . . . . . . . . . . . . . . .
Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing exhaust gas recirculation cooler, 132 kW engine . . . . . . . . . . . .
Removing and installing exhaust gas recirculation valve N18 , 132 kW engine . . . . . . . .
Removing and installing changeover valve for exhaust gas recirculation cooler N345 . . . .
Checking exhaust gas recirculation cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
do
c
um
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
1
1.1
1.2
1.3
2
2.1
2.2
2.3
2.4
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
374
374
375
375
377
377
379
381
387
390
390
391
392
398
400
401
402
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
1
1.1
1.2
1.3
1.4
Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
404
404
405
406
407
v
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Contents
thi
sd
o
cu
m
en
vi
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
00 –
Technical data
1
Identification
(VRL005497; Edition 04.2013)
⇒ “1.1 Engine number,n Aengine
data”,
agen Apage 1
G. Volksw
G do
age
es n
ksw
ot g
Vol
y
ua
b
d
ran
e
tee
ris
o
h
t
or
New afour
digit
engine
codes
have
been
introduced
since
u
ac model
yearss 2008. The first 3 digits refer to the mechanical configuration
1.1
Engine number, engine data
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
ility
ab
y li
an
pt
ce
of the engine. They are stamped onto the engine. The fourth digit
denotes the power output of the engine and depends on the en‐
gine control unit. The four digit engine code can be found on the
identification plate, the vehicle data sticker and the engine control
unit.
The engine number (“engine code” and “serial number”) can be
found at the joint between engine and gearbox -arrow-.
In addition, there is a sticker attached to the toothed belt guard
showing the “engine code” and “serial number”.
The engine code is also included on the vehicle data sticker.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (maximum 4 characters) makes up the
“engine code”, and the second part (6 characters), the “serial
number”. If more than 999,999 engines were produced with the
same code letters, the first of the six digits is replaced by a letter.
r
fo
ng
Capacity
EU 3 standard
EU 4 standard
EU 5 standard
2.0
120/4000
EU 3 standard
EU 4 standard
EU 5 standard
2.0
90/3750
EU 3 standard
EU 4 standard
EU 5 standard
2.0
90/3750
l
kW at
rpm
Nm at
rpm
400/
1500 - 2000
1968
340/
1750 - 2250
1968
340/
1600 - 2000
1968
cm3
∅ mm
mm
01.10 ►
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Torque
CNFA
from
to
Emissions fulfil
Capacity
Output
CDBA
agen
lksw
Vo
by
Manufactured
CDCA
ht
rig
py
Co
t.
Engine code
Bore
81.0
81.0
81.0
Stroke
95.5
95.5
95.5
Valves per cylinder
4
4
4
Compression ratio
16.5
16.5
16.0
Fuel
accord‐
DIN EN 590
DIN EN 590
DIN EN 590
ing to
Firing order
1-3-4-2
1-3-4-2
1-3-4-2
Balancer shaft module
no
no
no
Catalytic converter
yes
yes
yes
Exhaust gas recirculation
yes
yes
yes
Turbocharging/supercharg‐
yes
yes
yes
ing
Charge air cooler
yes
yes
yes
Particulate filter
yes, in the case of EU 5 yes, in the case of EU 5 yes, in the case of EU 5
1. Identification
1
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Engine code
Selective catalytic reduction
(SCR system)
standards.
no
standards.
no
CNFA
No; on vehicles compli‐
ant with EU 3 and EU 4
standards.
no
ility
ab
y li
an
pt
ce
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Particulate filter
AG. Volkswagen AG d
agen
oes
ksw CDCA
notCDBA
l
o
V
gu
y
b
ara
d
nte compli‐
ise No; on vehicles compli‐ No; on vehicles
r
o
eo
h
t
u
r a EU 4
ant
with
EU
3
and
EU
4
ant
with
EU
3
and
a
c
s
s
Emissions fulfil
Capacity
Output
Torque
cm3
∅ mm
mm
EU 4 standard
EU 5 standard
2.0
132/4000
EU 4 standard
EU 5 standard
2.0
132/4000
400/
1500 - 2250
1968
420/
1750
1968
Bore
81.0
Stroke
95.5
Valves per cylinder
4
Compression ratio
16.5
Fuel
accord‐
DIN EN 590
ing to
Firing order
1-3-4-2
Balancer shaft module
no
Catalytic converter
yes
Exhaust gas recirculation
yes
Turbocharging/super‐
yes
charging
Charge air cooler
yes
Particulate filter
yes, in the case of EU 5
Particulate filter
No; on vehicles compli‐
ant with EU 3 and EU 4
standards.
Selective catalytic reduc‐
no
tion
(SCR system)
81.0
95.5
4
16.0
DIN EN 590
CNFB
EU 4 standard
EU 5 standard
2.0
103/3500
do
c
um
en
Capacity
l
kW at
rpm
Nm at
rpm
01.10 ►
AG.
from
to
CSHA
agen
lksw
Vo
by
Manufactured
CNEA
ht
rig
py
Co
t.
Engine codes
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
1) Present in the case of engines compliant with EU 5 standard and/or in conjunction with dual clutch gearboxes.
340/
1600 - 2250
1968
81.0
95.5
4
16.0
DIN EN 590
1-3-4-2
yes
yes
yes
yes
1-3-4-2
no
yes
yes
yes
yes
yes, in the case of EU 5
No; on vehicles compli‐
ant with EU 3 and EU 4
standards.
no
yes
yes, in the case of EU 5
No; on vehicles compli‐
ant with EU 3 and EU 4
standards.
no
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
2) Present in the case of engines compliant with EU 5 standard and/or in conjunction with dual clutch gearboxes.
2
Rep. gr.00 - Technical data
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2
Safety instructions
⇒ “2.1 Safety precautions when working on fuel supply system”,
page 3
lkswagen AG
⇒ “2.2 Safety precautions when working on injection
AG. Vosystem”,
does
agen
ksw
not
page 4
l
o
V
g
y
db
e
⇒ “2.3 Safety precautions when working
on charge air system”,
ris
ho
t
page 5
au
ua
ran
tee
2.1
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
⇒ “2.5 Safety precautions during road tests in which testing and
measuring equipment is used”, page 6
Safety precautions when working on
fuel supply 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.
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
ht
rig
py
Co
t.
♦ Fuel and fuel lines in fuel system can become very hot
(danger of scalding)!
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
⇒ “2.4 Safety precautions when working on cooling system”, page
5
or
ac
ility
ab
y li
an
pt
ce
ss
AG.
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!
When removing and installing fuel gauge sender or fuel pump
(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
♦ Even before work commences, the extraction hose of an ac‐
tivated fume extraction system has to be placed in the vicinity
of the assembly opening of the fuel tank to extract any escap‐
ing fumes. If no exhaust gas extraction system is available, a
radial fan with a displacement greater than 15 m3/h can be
used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
2. Safety instructions
3
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2.2
Safety precautions when working on in‐
jection system
WARNING
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.
♦ The engine must not be run when the fuel return line is
disconnected, this is because the coupling chamber will
be emptied due to the lack of the counterpressure.
Note
Diesel direct injection system control unit is equipped with an
event memory. Read event memory before and after making re‐
pairs or adjustments ⇒ Vehicle diagnostic tester.
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
♦ If test and measuring instruments are operated fromefront
Volkswagen AG
AG. pas‐
does
ag n there
senger seat and the vehicle is involved in an oaccident,
ksw
not
l
V
gu
yseat
is a possibility that the person sitting in this
may
receive
b
ara
d
e
nte
ris
serious injuries when the airbag is triggered.
o
e
h
t
au
or
ac
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
To prevent injuries to persons and/orssdestruction of the injection
and glow plug system, the following must be noted:
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
♦ The ignition must be switched off before connecting or dis‐
connecting preglow and injection system wiring as well as test
equipment leads.
♦ Before disconnecting battery, obtain radio code for radios with
anti-theft coding.
♦ Disconnecting and connecting the battery must only be done
with the ignition switched off, as otherwise the control unit for
diesel direction injection system could become damaged.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Rep. gr.00 - Technical data
do
c
um
en
4
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2.3
Safety precautions when working on
charge air system
WARNING
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.
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.
2.4
Safety precautions when working on
n AG. Volkswagen AG do
es n
wage
s
k
cooling system
l
ot g
Vo
ua
ran
tee
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
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.
Caution
or
ac
ility
ab
y li
an
pt
ce
un
le
WARNING
by
ed
ris
o
th
au
ss
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.
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
♦ To avoid damage to lines, ensure sufficient clearance from
all moving or hot components.
agen
lksw
Vo
by
2. Safety instructions
5
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
ua
ran
tee
b
ed
ris
o
th
au
ss
pe
rm
itte
d
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Note
or
ac
ility
ab
y li
an
pt
ce
un
le
Amarok 2011 ➤
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o rail) - Edition 04.2013
4-cylinder diesel engine (2.0 l engine, common
yV
♦ When the engine is warm, the cooling system is under pres‐
♦ Hoses are secured with spring-type clips. In case of repair,
♦ When installing or removing spring-type clips, we recommend
c
o
p
yri
gh
t
.
C
op
yi
using spring-type clip pliers - VAS 6340- or
Prote
cted
by
do not come into contact with other components (observe
markings on coolant connection and hose).
♦ Arrows on the coolant pipes and on the ends of the hoses must
be aligned with each other.
♦ Only demineralised / distilled water to standard VDE-0510
may be used for mixing. Tap water does not have the required
quality to ensure the coolant's function.
2.5
Safety precautions during road tests in
which testing and measuring equipment
is used
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Test and measuring instruments must always be secured to
the rear seat and operated by a second person from this lo‐
cation.
♦ Operating from the front passenger seat may result in an ac‐
cident caused by releasing the front passenger air bag which
can cause injuries to the person sitting there.
6
Rep. gr.00 - Technical data
AG.
♦ When installing coolant hoses, route stress-free so that they
agen
lksw
Vo
by
♦ … hose clip pliers - VAS 6362- recommended.
ht
rig
py
Co
t.
only use spring-type clips.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
sure. If necessary, release pressure before beginning repair
work.
⇒ “3.2 General notes on fuel system”, page 7
⇒ “3.3 Rules for cleanliness when working on fuel supply system/
injection system”, page 8
⇒ “3.4 Rules for cleanliness when working on charge air system”,
page 8
⇒ “3.5 Instructions for working on fuel system”, page 9
⇒ “3.6 To avoid any risk of injuries to persons and/or the destruc‐
tion of the injection and glow plug system, the following must be
noted”, page 10
⇒ “3.7 Instructions for hose connections with screw-type clips”,
page 11
c
o
p
yri
gh
t.
C
op
yi
Note
ht
rig
py
Co
t.
r
fo
ng
General notes on the lubrication system
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
Repair instructions
⇒ “3.1 General notes on the lubrication system”, page 7
3.1
Amarok 2011 ➤
common rail) - Edition 04.2013
ility
ab
y li
an
pt
ce
3
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nlteengine,
ise
4-cylinder
diesel
engine
(2.0
r
o
eo
h
t
u
ra
a
c
s
s
The oil level must not be above the max. mark - danger of damage
to catalytic converter!
agen
lksw
Vo
by
AG.
Prote
cted
by
Caution
Finding metal shavings or a large quantity of small metal par‐
ticles during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To prevent this
from causing further damage, perform the following repairs:
♦ Thoroughly clean oil passages,
♦ Renew oil spray jets,
♦ Renew engine oil cooler,
♦ Renew oil filter element.
3.2
General notes on fuel system
Caution
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.
3. Repair instructions
7
Amarok 2011 ➤
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
4-cylinder diesel engine (2.0 l engine, common yrail)
Vo - Edition 04.2013
ua
ran
tee
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Note
or
ac
ility
ab
y li
an
pt
ce
b
ed
ris
o
th
au
ss
♦ When the engine is warm, the cooling system is under pres‐
sure. If necessary, release pressure before beginning repair
work.
♦ When installing or removing spring-type clips, we recommend
Prote
cted
by
♦ 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).
♦ Arrows on the coolant pipes and on the ends of the hoses must
be aligned.
3.3
Rules for cleanliness when working on
fuel supply system/injection system
When working on the fuel supply and injection system, pay careful
attention to the following “6 rules” for cleanliness:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes or similar).
♦ When system is open, do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
3.4
Rules for cleanliness when working on
charge air system
When working on the charge air system, pay careful attention to
the following rules for cleanliness:
8
Rep. gr.00 - Technical data
AG.
♦ … hose clip pliers - VAS 6362- recommended.
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
using spring-type clip pliers - VAS 6340- or
ht
rig
py
Co
t.
only use spring-type clips.
do
c
um
en
♦ Hoses are secured with spring-type clips. In case of repair,
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes or similar).
♦ Existing transport and protective packaging and sealing caps
must only be removed immediately prior to installation.
♦ When making repairs, remove oil from connection and hose
ends.
♦ Do not use substances containing oil, silicone or grease when
assembling.
♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
3.5
Volkswagen AG
AG.fuel
does
Instructions for working
on
system
agen
n
lksw
o
yV
♦ If fuel system components between fuel tank and fuel highpressure pump are removed or renewed, initial fuel filling must
be carried out.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
♦ If a fuel pump, fuel line (between fuel tank and fuel high-pres‐
sure pump) or fuel filter is removed or renewed
♦ Fuel system must be bled before starting engine for first time.
♦ If the high-pressure fuel pump is removed or renewed, the fuel
system must be bled before engine is started for the first time.
♦ Initial fuel filling procedure ⇒ page 316 .
Clean tools and workbench etc. before working on injection
system.
•
Thoroughly clean all unions and surrounding areas before dis‐
connecting.
•
When removing components, plug all open connections im‐
mediately with suitable clean sealing caps.
•
Do not remove sealing caps from components until immedi‐
ately prior to installation. Place removed components in new
sealable plastic bags (if available, use original packaging of
new components).
•
If high-pressure lines are not renewed, they must be labelled
on removal. High-pressure fuel lines must always be re-instal‐
led in their original positions (i.e. on the same cylinder).
•
Clean sealing surface of injector in cylinder head and injector
bore.
•
Only cleaning set - VAS 6811- may be used for cleaning seal‐
ing surface of injector bore.
•
For detailed information on how to use the cleaning set as well
as the order in which its components are applied, refer to the
⇒ operating manual provided with the cleaning set - VAS
6811- .
ht
rig
py
Co
t.
•
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ot g
ua
ran
tee
or
ac
ility
ab
y li
an
pt
ce
b
ed pump from running while it is
To prevent the high-pressure fuel
ris
o
empty and to ensure that theuengine
starts quickly after parts have
th
a to observe the following:
been renewed, it is important
ss
3. Repair instructions
9
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
•
The following components and seals/O-rings must always be
renewed when the injectors are removed and installed: “cop‐
per seal”, “O-ring for injector bore”, “O-ring for injector return
connection”, “injector return connection clip”
•
The following components and seals/O-rings must always be
renewed when an injector is renewed: “copper seal”, “O-ring
for injector shaft” and “O-ring for injector return connection”
“injector return clip”
•
Always fit new copper seals for the injectors. Check all new Orings for damage before installing. O-rings must be moist when
installed (assembly oil or clean engine oil). Use assembly tool
to install the “O-ring for injector return connection”.
•
a
ksw
Take care not to damage the injectors when removing the old
Vol
y
b
copper seals.
ed
•
th
Align high-pressure lines free from tension. First tighten
all
au
s
s
unions hand-tight and then tighten to torque.
•
Never attempt to reshape high-pressure fuel lines.
•
When working on any part of the high-pressure fuel system,
tools may only be used for loosening and tightening pipe un‐
ions. All other components must always be removed and
installed by hand without using tools or other equipment.
•
Disassembling individual common rail components is not per‐
mitted.
•
The components should be replaced as complete units if faul‐
ty.
•
Never attempt to bleed the common rail system by loosening
high-pressure components after starting the engine.
•
Do not carry out any installation work on common rail system
whilst engine is running.
•
In particular, do not open or release high-pressure lines and
electrical connectors.
•
All cable ties which were opened or cut open during removal
must be replaced with new ties in same position during instal‐
lation.
•
When the fuel system is open: do not work with compressed
air if this can be avoided. Do not move vehicle unless abso‐
lutely necessary.
•
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.
Prote
cted
by
♦ Always switch off the ignition before connecting or discon‐
necting injection and glow plug system wiring or tester cables.
♦ Always switch off ignition before cleaning engine.
♦ The battery should only be disconnected and reconnected
with ignition switched off.
10
Rep. gr.00 - Technical data
AG.
♦ No fuel lines may be opened while the engine is running.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
♦ Persons wearing a pacemaker should not lean over the engine
compartment while the engine is running, as the injectors use
high voltage pulses.
thi
sd
o
cu
m
en
To avoid any risk of injuries to persons
and/or the destruction of the injection
and glow plug system, the following
must be noted
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
3.6
ht
rig
py
Co
t.
is
or
. Volkswagen AG
gen AG
does
not
gu
ara
nte
eo
ra
c
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Certain tests may lead to a fault being detected by the control
unit and stored. Therefore, after completing all checks and re‐
pairs, the fault memory must be read and if necessary cleared.
3.7
Instructions for hose connections with
screw-type clips
Caution
The screw-type clips on the charge air lines must always be
tightened to 5.5 Nm. If the torque is too low or too high, the
charge air hose may slip off the charge air pipe during vehicle
operation.
Normal screw-type clips are used on the hose connections on the
“intake side”.
On the hose connections on the “delivery side”, there are screwtype clips with “barbs” -arrows-.
Caution
•
with the hose.
– Screw-type clips with “locking hooks” -arrows- may only be
loosened. Loosen bolt of screw-type clips sufficiently to re‐
move hoses.
Screw-type clips that are only loosened can be reused.
Hose and clip are supplied together as one part.
– Do not use substances containing oil, silicone or grease when
assembling. Only use clean water.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
•
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
Vthese screw-type clips and pull
gback
y
Do not loosen
over
ua
b
d
r
ise hose. Risk of damage to the hose! ante
the delivery
r
eo
ho
ut
ra
c
s a has been removed, it must be renewed together
If a sclip
do
c
um
en
3. Repair instructions
11
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
10 –
Removing and installing engine
1
Removing and installing engine
⇒ “1.1 Removing engine”, page 12
⇒ “1.2 Securing engine on engine and gearbox support VAS 6095
”, page 26
⇒ “1.3 Installing engine”, page 27
1.1
AG. Volkswagen AG d
oes
not
gu
ara
nte
eo
ra
c
gen
Removing
swa
kengine
Vol
un
le
ility
ab
y li
an
pt
ce
by
ed
ris
o
h
ut workshop
Special tools and
sa
s
equipment required
♦ Support bracket - 10 - 222
A♦ Hook - 10 - 222 A /10♦ Shackle - 10 - 222 A /12♦ Adapter - 10 - 222 A /16-
AG.
Rep. gr.10 - Removing and installing engine
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
12
ht
rig
py
Co
t.
r
fo
ng
♦ Adapter - 10 - 222 A /20qty. 2
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
♦ Lifting tackle - 3033-
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Torque wrench - V.A.G
1331♦ Torque wrench - V.A.G
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-
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
do
c
um
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
1. Removing and installing engine
13
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Drip tray for workshop hoist
- VAS 6208♦ Step - VAS 6292/4♦ Hose clip pliers - VAS
6340♦ Hose clip pliers - VAS
6362♦ Bracket - T10014♦ High-temperature grease G 052 133 A2♦ Cable ties
♦ Wooden block 10 x 30 x
10 cm
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Note
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Procedure:
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
♦ 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
♦ Collect drained coolant in a clean container for re-use or dis‐
Rep. gr.10 - Removing and installing engine
Prote
cted
by
14
AG.
posal.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
set - VAS 6122- .
ht
rig
py
Co
t.
♦ Seal open lines and unions with clean plugs from engine bung
do
c
um
en
is removed must be renewed/replaced in the same position
when the engine is installed.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Caution
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damage to lines, ensure sufficient clearance from
all moving or hot components.
♦ Cut through cable ties carefully and install new ones in the
same position.
– Remove bonnet ⇒ General body repairs, exterior; Rep. gr.
55 ; Bonnet .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing starter .
– Remove front left wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 50 ; Wheel housing liner .
– Remove underbody guard, if fitted ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody guard .
– Drain coolant ⇒ page 182 .
– Detach coolant hose -2- with both brackets -1-.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
r
te o
iva
r
rp
fo
g
n
do
c
um
en
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
– Unscrew bolts -1-.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
– Release connector -2- on circulation pump - V55- -3- and pull
off.
ht
rig
py
Co
t.
un
le
– Unscrew bolts -3-.
1. Removing and installing engine
15
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Detach circulation pump - V55- -2- from bracket with hoses
attached.
– Pull latch -1- back.
ility
ab
y li
an
pt
ce
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
un
le
– Press retaining lever -2- down and pull connector
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
ac
off.s au
s
– Open clip -1- and remove hose -2- from turbocharger.
WARNING
♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
AG.
Prote
cted
by
Rep. gr.10 - Removing and installing engine
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
16
ht
rig
py
Co
t.
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!
do
c
um
en
r
te o
iva
r
rp
fo
g
n
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Separate fuel lines -1-, -2- and -3-.
Vehicles with air conditioning system:
Note
To prevent damage to condenser or to refrigerant lines and ho‐
ses, ensure that lines and hoses are not stretched, kinked or bent.
To facilitate removing and installing engine without opening re‐
frigerant circuit:
– Secure air conditioner compressor to body so that the refrig‐
erant lines and hoses are not under tension.
– Remove AC compressor with hoses connected and secure to
body ⇒ Heating, air conditioning system; Rep. gr. 87 ; Re‐
moving and installing air conditioner compressor .
Continuation for all vehicles
G. Volkswagen AG d
oes
not
o
V
gu
by
ara
d
Remove cover from fuse
box
above
battery.
e
nte
is
r
o
eo
h
ut
ra
a
c
s
Unscrew nut -2- ofs battery positive cable -1-.
nA .
age374
– Remove front exhaust pipe ⇒ page
lksw
ility
ab
y li
an
pt
ce
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
–
un
le
–
– Unhook clips -1- and -3-.
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
– Lay wiring harness -2- to one side.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
– Release and pull off connectors -2- and -3-.
– Remove shear bolts -1- and remove bow -4-.
1. Removing and installing engine
17
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unhook clips -2- and -3-.
– Release and pull off connector -1-.
– Open retainer -4- and detach wiring harness.
– Carefully cut through cable ties -arrows-.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
– Remove bolt -4-.
Caution
•
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
– Release and pull off connector -3-.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
– Lay wiring harness on engine and secure.
Do not loosen screw-type clips and pull back over pres‐
sure hose. Risk of damage to the delivery hose!
Removing screw-type clips ⇒ page 11 .
AG.
Rep. gr.10 - Removing and installing engine
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
18
ht
rig
py
Co
t.
– Open clip -2- and remove coolant hose -1-. Guide coolant hose
downwards and allow coolant to drain.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
– Remove hose/pipe -1- completely. To do this, loosen clips
-2- and -5- sufficiently to enable hose/pipe -1- to be pulled off.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Pull line -2- out of brake servo.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
– Open clip -1- and remove coolant hose -3-.
– Open clips -2- and -4- and remove coolant hoses -1- and -3-.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
– Open clip -3- and remove coolant hose -6-.
ht
rig
py
Co
t.
– Pull off hose -2- from turbocharger.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
– Remove vane pump with hoses connected, and secure it to
vehicle body ⇒ Running gear, axles, steering; Rep. gr. 48 ;
Hydraulic power steering .
– Pull hose -4- off union -5- and detach from clip -7-.
– Lay clip -1- aside with lines.
– Pull off hose -arrow- from turbocharger.
1. Removing and installing engine
19
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Detach hoses from intake hose -3- bracket -arrow-.
– Remove pipe -5- from cylinder head cover.
– Release and pull off wiring harness connector -2-. Detach wir‐
ing harness -2- from intake hose retainer -3-.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
ility
ab
y li
an
pt
ce
un
le
– Open clips -1- and -4- and remove intake hose -3-.
– Open clips -arrows- and remove toothed belt guard -1-.
ht
rig
py
Co
t.
r
fo
ng
– Open bracket -1- and detach coolant hose -2-.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
– Release connector -arrow- and pull off from exhaust temper‐
ature sender 1 - G235- . Free wiring harness from fittings and
secure it to engine.
20
Rep. gr.10 - Removing and installing engine
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
– Detach vacuum hose -2- from toothed belt guard -1-.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Release connector -2-.
– Open clip -3- and remove coolant hose -4-.
– Pull all clips -5- off radiator cowl.
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
– Remove bolts -1-.
– Release cowling -2- at left and right. To do this, press retaining
lever -1- forwards using a screwdriver, and raise radiator cowl
-2- slightly.
– Remove radiator cowl -2- with assistance of a 2nd mechanic.
do
c
um
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
– Unscrew bolts -1- from left engine mounting -A-.
– Unscrew bolts -1- from right engine mounting -A-.
1. Removing and installing engine
21
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Detach gearbox breather line -1- from clip -2- (on coolant hose
on rear right of engine).
– Unscrew bolt -1- for fuel lines -2- from bracket through wheel
housing.
– Install support bracket - 10 - 222 A- .
. Volkswagen AG
r
fo
ng
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Rep. gr.10 - Removing and installing engine
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
22
ht
rig
py
Co
t.
ss
ed
ris
o
h
t
au
does
not
gu
ara
nte
eo
ra
c
ility
ab
y li
an
pt
ce
un
le
G
gen Ato
– Secure adapter - 10 - 222 A /16- and hook - 10 - 222ksA
wa/10l
o
V
support bracket - 10 - 222 A- .
by
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Engage hook - 10 - 222 A /10- in transport eye.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
un
le
ility
ab
y li
an
pt
ce
– Engage hook - 10 - 222 A /2- in transport eye -arrow-.
pe
rm
itte
d
– Engage shackle - 10 - 222 A /12- with hook - 10 - 222 A /2- on
adapter - 10 - 222 A /16- .
Note
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– Raise engine until left engine mounting is raised approx. 15
mm and right engine mounting approx. 35 mm.
ht
rig
py
Co
t.
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
– Lower engine using support bracket - 10 - 222 A- until gearbox
-2- rests completely on square timber -1- and support bracket
- 10 - 222 A- is relieved.
do
c
um
en
– Insert square timber -1-.
r
te o
iva
r
rp
fo
g
n
Raise engine only sufficiently to allow a square timber to be in‐
serted between chassis and gearbox.
AG.
Caution
•
Do not unscrew the two upper bolts -1-.
1. Removing and installing engine
23
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Remove bolts -2- and -3-.
– Only unscrew bolt -1- beneath starter.
– Unscrew all connecting bolts for lower and centre engine/
gearbox. The two upper bolts initially remain screwed in.
– Remove support bracket - 10 - 222 A- .
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
un
le
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
– Install retainer - T10014- to front right of engine.
– Engage lifting tackle - 3033- on workshop hoist - VAS 6100and attach to engine.
– Engage adapter - 10 - 222 A /20- in lifting tackle - 3033- and
transport eye -arrow- and secure with retaining clip.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Rep. gr.10 - Removing and installing engine
ht
rig
py
Co
t.
24
do
c
um
en
r
te o
iva
r
rp
fo
g
n
– Engage adapter - 10 - 222 A /20- in lifting tackle - 3033- and
retainer - T10014- and secure with retaining clip.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unscrew the two upper bolts -1-.
– If necessary, disconnect all connecting, coolant, vacuum and
lkswageninAG
intake hoses that have to be disconnected from
G. Voengine
Athe
does
agen
order to remove it.
ksw
not
l
o
V
y
db
ss
gu
ara
nte
eo
ra
c
♦ 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.
– When raising and lowering engine, make sure that neither
vacuum hose -1- nor union -2- on vacuum pump are damaged.
– Guide vacuum hose -1-, union -2- and vacuum pump past ple‐
num chamber when raising and lowering.
– When raising and lowering engine, pay attention to lines and
hoses to prevent these from being damaged.
ht
rig
py
Co
t.
r
fo
ng
– When raising and lowering engine, make sure that rollers of
belt drive and turbocharger do not damage radiator.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
Caution
un
le
e
– Carefully pull engine from gearbox
ris in longitudinal direction. Do
tho crankshaft whilst doing this.
not damage needle bearing inauthe
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
– Check needle bearing -arrow- in crankshaft. If it is damaged
or has turned blue, it must be renewed ⇒ page 76 .
– If it is not damaged, lightly grease with high-temperature
grease - G 052 133 A2- .
– Slightly grease the journal (not the teeth) of the gears as well.
1. Removing and installing engine
25
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
1.2
Securing engine on engine and gearbox support - VAS 6095-
Special tools and workshop
equipment required
♦ Lifting tackle - 3033♦ Adapter - 10 - 222 A /20♦ Engine and gearbox sup‐
port - VAS 6095♦ Workshop hoist - VAS
6100♦ Bracket - T10014-
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Procedure:
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Secure engine to engine and gearbox support - VAS 6095- to
carry out repairs.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Rep. gr.10 - Removing and installing engine
thi
sd
o
cu
m
en
26
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Engage lifting tackle - 3033- with both adapters - 10 - 222 A /
20- -1- and retainer - T10014- -1- on engine.
Flywheel end: position 3.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
1.3
ht
rig
py
Co
t.
r
fo
ng
– Secure engine in engine and gearbox support - VAS 6095- .
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
Belt drive end: position 9
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
Installing engine
Special tools and workshop equipment required
♦ vehicle diagnostic tester
Installation is carried out in the reverse order; note the following:
Caution
♦ Only a few millimetres of space are available between
plenum chamber and radiator/lock carrier for removing
and installing the engine. The engine must therefore be
guided carefully when raising and lowering.
♦ Raise and lower the engine slowly with the assistance of
a second mechanic.
♦ The workshop hoist - VAS 6100- must also be guided
carefully when raising and lowering the engine.
1. Removing and installing engine
27
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
. Volkswagen AG
gen AG
does
a
– When raising and lowering engine, make
ksw sure that neither
not
Vol
gu
y
ara
vacuum hose -1- nor union -2- onevacuum
pump are damaged.
db
is
or
un
le
– When raising and lowering engine, pay attention to lines and
hoses to prevent these from being damaged.
– Check whether dowel sleeves for centering engine/gearbox
are in cylinder block and install if necessary (gearbox re‐
moved).
– Check clutch release bearing for wear and, if necessary, re‐
place (gearbox removed).
Caution
•
When bringing engine and gearbox together, make sure
that needle bearing -arrow- is not damaged.
r
fo
ng
Bring engine and gearbox together in longitudinal direc‐
tion, not at an incline.
Prote
cted
by
Rep. gr.10 - Removing and installing engine
AG.
28
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
– First tighten the two upper bolts -1-.
ht
rig
py
Co
t.
•
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
– When raising and lowering engine, make sure that rollers of
belt drive and turbocharger do not damage radiator.
nte
eo
ra
c
ility
ab
y li
an
pt
ce
th
– Guide vacuum hose -1-, union
au -2- and vacuum pump past ple‐
s
s and lowering.
num chamber when raising
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
ht
rig
py
Co
t.
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
– Tighten new bolts -1- for left engine mounting -A-.
1. Removing and installing engine
29
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Tighten new bolts -1- for right engine mounting -A-.
– Install front exhaust pipe ⇒ page 374 .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 .
– Install vane pump ⇒ Running gear, axles, steering; Rep. gr.
48 ; Hydraulic power steering .
– Install underbody guard, if fitted previously ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody guard .
– Install front left wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 50 ; Wheel housing liner .
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Removing and
installing starter .
– Install bonnet ⇒ General body repairs, exterior; Rep. gr. 55 ;
Bonnet .
To prevent the high-pressure pump from running while it is empty
and to ensure that the engine starts quickly after parts have been
renewed, it is important to observe the following:
♦ If components of the fuel system between the fuel tank and
the high-pressure pump are removed or renewed, it is neces‐
sary for the fuel system to be bled. To do this, perform the
“Bleeding fuel system” function using the ⇒ Vehicle diagnostic
tester ⇒ page 316 .
♦ This process takes 130 seconds. Fuel pumps are actuated a
total of 3 times in the process. The process must not be ter‐
minated prematurely.
– Check oil level ⇒ page 147 .
Note
– Replenish coolant ⇒ page 182 .
ility
ab
y li
an
pt
ce
♦
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
♦
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
Only reuse drained coolant if neither cylinder head nor cylinder
by
ara
d
e
nte
is
block have been renewed.
r
o
eo
h
ut
ra
a
c
s
Soiled coolant must not be reused.
s
Specified torques
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Carry out road test and read event memory ⇒ Vehicle diag‐
nostic tester.
♦ ⇒ “2.1 Removing and installing assembly mountings”,
page 31
♦ ⇒ “2.2 Assembly overview - emission control (catalytic con‐
verter)”, page 379
♦ ⇒ “2.1 Assembly overview - emission control (diesel particu‐
late filter)”, page 377
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Rep. gr.10 - Removing and installing engine
do
c
um
en
30
2
Amarok 2011 ➤
common rail) - Edition 04.2013
2.1
Removing and installing assembly
mountings
Left and right engine support to crankcase
Caution
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Assembly mountings
ility
ab
y li
an
pt
ce
⇒
wagen AG diesel engine (2.0 l engine,
AG. Volks4-cylinder
does
agen
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s Removing and installing assembly mountings”, page
“2.1
31
•
Nut -2- must not be loosened.
•
If nut -2- is loosened, engine mounting must subsequently
be renewed.
♦ Engine mounting connection to engine support may only
be loosened if engine mounting is to be renewed.
– Secure engine support -1- to crankcase with bolts -3-.
Specified torque
ht
rig
py
Co
t.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Component
Specified torque
Bolts -3-
50 Nm +180°
agen
lksw
Vo
by
AG.
Left engine mounting to frame
do
c
um
en
– Bolts -3- must always be renewed.
– Secure engine mounting -A- to frame with bolts -1-.
– Bolts -1- must always be renewed.
Specified torque
Component
Specified torque
Bolts -1-
50 Nm + 90°
Right engine mounting to frame
– Secure engine mounting -A- to frame with bolts -1-.
– Bolts -1- must always be renewed.
Specified torque
Component
Specified torque
Bolts -1-
50 Nm + 90°
2. Assembly mountings
31
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Left engine mounting to engine support
– Bolt new engine mounting -3- to engine support -1- with nut
-2-.
– Nut -2- must always be renewed.
Specified torque
Component
Specified torque
Nut -2-
90 Nm + 90°
Right engine mounting to engine support
– Bolt new engine mounting -3- to engine support -2- with nut
-1-.
– Nut -1- must always be renewed.
Specified torque
Component
Specified torque
Nut -1-
90 Nm + 90°
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
Gearbox mounting to gearbox
ir se
tee
o
h
t
or
– Secure gearboxs aumounting -A- to gearbox with bolts -1-.
ac
s
pe
rm
itte
d
un
le
ility
ab
y li
an
pt
ce
– Bolts -1- must always be renewed.
Specified torque
Bolts -1-
50 Nm + 90°
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Specified torque
Gearbox mounting to gearbox cross member
– Secure gearbox mounting -A- to gearbox cross member with
bolts -1-.
– Bolts -1- must always be renewed.
Specified torque
Bolts -1-
30 Nm + 90°
AG.
Prote
cted
by
Rep. gr.10 - Removing and installing engine
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
32
ht
rig
py
Co
t.
Component
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Specified torque
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Component
do
c
um
en
un
le
pe
rm
itte
d
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Crankshaft group
ht
rig
py
Co
t.
13 –
Amarok 2011 ➤
l engine, common rail) - Edition 04.2013
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
o
eo
4-cylinder diesel enginete(2.0
h
t
ra
au
c
ss
1. Cylinder block (pulley end)
33
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
1
Cylinder block (pulley end)
⇒ “1.1 Assembly overview - cylinder block”, page 34
⇒ “1.2 Assembly overview - sealing flange, belt pulley end”, page
36
⇒ “1.3 Assembly overview - poly V-belt drive”, page 37
⇒ “1.4 Assembly overview - poly V-belt drive, vehicles without A/
C system”, page 39
⇒ “1.5 Removing and installing gpoly
gen AG40
. Volkswapage
en AGV-belt”,
does
n
a
lksw
ot g
o
⇒ “1.6 Removing and installing
tensioner for poly V-belt”,
yV
ua
db
ran
e
page 42
is
te
or
eo
ra
c
h
ut
un
le
ility
ab
y li
an
pt
ce
a
⇒ “1.7 Removing
ss and installing ancillary bracket”, page 43
pe
rm
itte
d
⇒ “1.8 Removing and installing vibration damper”, page 44
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
⇒ “1.10 Removing and installing sealing flange on pulley end”,
page 48
Assembly overview - cylinder block
r
te o
iva
r
rp
fo
g
n
4 - Gaskets
❑ Renew after removing
5 - Oil filter bracket
❑ Oil filter bracket and en‐
gine oil cooler
⇒ page 151 .
6 - Bolt
❑ Renew after removing
❑ First fit upper left and
lower right bolts and
then tighten all four bolts
diagonally.
❑ 14 Nm +180°
34
Rep. gr.13 - Crankshaft group
AG.
3 - Spreader clip
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
2 - Guide tube
❑ Renew O-ring.
do
c
um
en
1 - Cylinder block
❑ Removing and installing
sealing flange on belt
pulley end ⇒ page 48 .
❑ Removing and installing
dual-mass flywheel
⇒ page 55 .
❑ Removing and installing
sealing flange on fly‐
wheel end ⇒ page 57 .
❑ Removing and installing
crankshaft
⇒ page 73 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 66
ht
rig
py
Co
t.
1.1
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
⇒ “1.9 Renewing crankshaft oil seal - belt pulley end”,
page 46
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
7 - Bolt
❑ 13 Nm
8 - Thermostat (4/2-way valve)
❑ Thermostat is firmly installed in valve.
❑ Can only be renewed complete.
❑ Removing and installing ⇒ page 187
9 - O-ring
❑ Renew after removing
10 - Lifting eye
11 - Bracket for ancillaries
❑ Observe tightening sequence ⇒ page 43 .
❑ Removing and installing ⇒ page 43
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
thi
sd
o
cu
m
en
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
15 - Bolt
❑ 15 Nm
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
14 - Oil sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant ⇒ Electronic Parts Catalogue (ETKA) .
❑ Removing and installing ⇒ page 140 .
ht
rig
py
Co
t.
13 - Bolt
❑ 25 Nm
ility
ab
y li
an
pt
ce
12 - Bolt
❑ Observe different prescribed
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
torques sand
tightening sequence ⇒ page 43 .
s
1. Cylinder block (pulley end)
35
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
1.2
Assembly overview - sealing flange, belt pulley end
1 - Bolt
❑ Renew after removing
❑ Loosen and tighten with
counterhold - 3415❑ Do not additionally oil
the thread and shoulder.
❑ 120 Nm + 90°
pe
rm
itte
d
un
le
ility
ab
y li
an
pt
ce
2 - Crankshaft toothed belt pul‐
ley
AG. Volkswagen AG d
agen
oes
ksw
not
l
❑ Contact surface be‐
o
gu
yV
b
ara
d
tween toothed belt pul‐
e
nte
is
r
ley and crankshaft must tho
eo
u
ra
a
be free from oil
c
s
s
❑ Fitting possible in one
position only.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
3 - Crankshaft oil seal for belt
pulley end
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip.
❑ Before installing, re‐
move oil residue from
crankshaft journal using
a clean cloth.
❑ Renewing ⇒ page 46 .
r
te o
iva
r
rp
fo
g
n
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
6 - Dowel pin
7 - Bolt
❑ Specified torque and tightening sequence ⇒ page 36 .
Sealing flange at belt pulley end - Prescribed torque and tighten‐
ing sequence
– Tighten bolts for sealing flange at belt pulley end in the se‐
quence -1 … 10- in 3 stages as follows:
1.
Screw bolts -1 ... 10- in as far as stop by hand.
2.
Tighten bolts -1 … 6- in diagonal sequence to 15 Nm.
3.
Tighten bolts -7 … 10- to 15 Nm.
36
Rep. gr.13 - Crankshaft group
ht
rig
py
Co
t.
5 - Cylinder block
do
c
um
en
4 - Sealing flange at belt pulley
end
❑ Insert with silicone seal‐
ant ⇒ Electronic Parts
Catalogue (ETKA) .
❑ Must seat on dowel
pins.
❑ Removing and installing
⇒ page 48 .
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
1.3
Assembly overview - poly V-belt drive
1 - Poly V-belt
❑ Mark direction of rota‐
tion before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing and installing
⇒ page 40
2 - Bolt
❑ Renew after removing
❑ 10 Nm + 90°
3 - Belt pulley and vibration
damper
❑ Installation position:
hole in vibration damper
must align over protru‐
sion on crankshaft
toothed belt pulley.
❑ Can only be installed in
one position. Holes are
offset.
4 - Bolt
❑ 20 Nm
5 - Idler roller
❑ For toothed belt
n AG. Volkswagen AG do
es n
ot g
ua
ran
tee
or
ac
pe
rm
itte
d
un
le
ility
ab
y li
an
pt
ce
wage
6 - Dowel sleeve
olks
yV
b
❑ Check for correct seat‐ sed
ri
ing in ancillary bracket.
tho
u
a
❑ Inserted in hole for
ss the
left-hand (direction of
travel) bolt -11- on the
rear side of the bracket.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
7 - Bracket for ancillaries
❑ Observe prescribed torque and tightening sequence during installation ⇒ page 38
8 - High-pressure pump
❑ Removing and installing ⇒ page 347 .
9 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 .
10 - Bolt
❑ When reusing bolt, tighten to 20 Nm plus 90° further.
❑ New bolt: 20 Nm + 180°
r
te o
iva
r
rp
fo
g
n
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
13 - Bolt
❑ 25 Nm
ht
rig
py
Co
t.
12 - Bolt
❑ Observe tightening sequence ⇒ page 38 .
❑ 40 Nm + 90°
do
c
um
en
11 - Centre hex stud
❑ Observe tightening sequence ⇒ page 38 .
❑ 40 Nm + 90°
1. Cylinder block (pulley end)
37
olkswagen AG
en AG. V
does
wag
Amarok 2011 ➤
not
olks
gu
yV
b
ara
4-cylinder diesel engine (2.0sledengine, common rail) - Edition 04.2013
n
ri
ho
ut
a
ss
tee
or
ac
un
le
16 - Nut
❑ For bracket of Hall sender - G40- .
❑ 25 Nm
17 - Bolt
❑ Observe tightening sequence ⇒ page 38 .
❑ 40 Nm +180°
23 - Bolt
❑ Renew after removing
❑ 20 Nm + 90°
AG.
22 - Bolt
❑ 23 Nm
agen
lksw
Vo
by
21 - Bolt
❑ 25 Nm
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
20 - Belt pulley
ht
rig
py
Co
t.
19 - Bolt
❑ 25 Nm
r
fo
ng
18 - Vane pump
❑ Removing and installing ⇒ Running gear, axles and steering; Rep. gr. 48 .
24 - Idler roller
❑ For poly V-belt.
25 - Air conditioner compressor
❑ Removing and installing ⇒ Heating, air conditioning system; Rep. gr. 87 .
26 - Bolt
❑ Prescribed torque ⇒ Electrical system; Rep. gr. 27 .
27 - Poly V-belt tensioning element
❑ Swing with ring spanner to slacken ribbed belt ⇒ page 40
Ancillary bracket - specified torques and tightening sequence
– Insert securing bolts for ancillary bracket as follows:
♦ Bolts -1- and -2♦ Bolts -3- and -4♦ Bolts -5- and -6– Tighten securing bolts for ancillary bracket in sequence
-1 … 6- in 2 stages as follows:
1.
Screw all bolts in to stop by hand.
2.
Tighten all bolts to 40 Nm.
3.
Turn bolts -1, 2, 5 and 6- 90° further.
4.
Turn bolts -3- and -4- 180° further.
38
Rep. gr.13 - Crankshaft group
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
15 - Bracket
ility
ab
y li
an
pt
ce
14 - Sleeve
❑ Before installing, push vane pump back slightly.
4-cylinder
Assembly overview - poly V-belt drive, vehicles without A/C system
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
4 - Bolt
❑ 20 Nm
do
c
um
en
3 - Belt pulley and vibration
damper
❑ Installation position:
hole in vibration damper
must align over protru‐
sion on crankshaft
toothed belt pulley.
❑ Can only be installed in
one position. Holes are
offset.
ht
rig
py
Co
t.
2 - Bolt
❑ Renew after removing
❑ 10 Nm + 90°
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
1 - Poly V-belt
❑ Mark direction of rota‐
tion before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing and installing
⇒ page 40
ility
ab
y li
an
pt
ce
1.4
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
Amarok
2011 ➤
gu
yV
b
ara
d
e
diesel engine
(2.0 l engine, common rail) - Edition
nt04.2013
is
r
ee
tho
or
ac
au
s
s
5 - Idler roller
❑ For toothed belt
6 - Dowel sleeve
❑ Check for correct seat‐
ing in ancillary bracket.
❑ Inserted in hole for the
left-hand (direction of
travel) bolt -11- on the
rear side of the bracket.
7 - Bracket for ancillaries
❑ Observe prescribed torque and tightening sequence during installation ⇒ page 40
8 - High-pressure pump
❑ Removing and installing ⇒ page 347 .
9 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 .
10 - Bolt
❑ Renew after removing
❑ 20 Nm +180°
11 - Centre hex stud
❑ Observe tightening sequence ⇒ page 40 .
❑ 40 Nm + 90°
12 - Bolt
❑ Observe tightening sequence ⇒ page 40 .
❑ 40 Nm + 90°
13 - Bolt
❑ 25 Nm
1. Cylinder block (pulley end)
39
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
14 - Sleeve
❑ Push back slightly before installing vane pump.
15 - Bracket
16 - Nut
❑ For bracket of Hall sender - G40- .
❑ 25 Nm
17 - Bolt
❑ Observe tightening sequence ⇒ page 40 .
❑ 40 Nm +180°
18 - Vane pump
❑ Removing and installing ⇒ Running gear, axles and steering; Rep. gr. 48 .
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
pulleyaut
ra
c
s
s
19 - Bolt
❑ 25 Nm
20 - Belt
un
le
pe
rm
itte
d
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
23 - Poly V-belt tensioning element
❑ Swing with ring spanner to slacken ribbed belt ⇒ page 40
Ancillary bracket - specified torques and tightening sequence
– Insert securing bolts for ancillary bracket as follows:
♦ Bolts -1- and -2♦ Bolts -3- and -4-
2.
Tighten all bolts to 40 Nm.
3.
Turn bolts -1, 2, 5 and 6- 90° further.
4.
Turn bolts -3- and -4- 180° further.
– Tighten securing bolts for ancillary bracket in sequence
-1 … 6- in 2 stages as follows:
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Removing and installing poly V-belt
Special tools and workshop equipment required
40
ht
rig
py
Co
t.
1.5
Screw all bolts in to stop by hand.
Rep. gr.13 - Crankshaft group
do
c
um
en
1.
r
te o
iva
r
rp
fo
g
n
♦ Bolts -5- and -6-
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
22 - Bolt
❑ Prescribed torque ⇒ Electrical system; Rep. gr. 27 .
ility
ab
y li
an
pt
ce
21 - Bolt
❑ 25 Nm
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Removing
ility
ab
y li
an
pt
ce
♦ Locking pin - T10060 A-
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
4-cylinder
AG. Volkswagen AG d
agen
oes
ksw
notAmarok 2011 ➤
l
o
V
gu
y
b
ara
d
dieselrisengine
(2.0 l engine, common rail) - Edition
e
nte 04.2013
o
eo
h
t
u
ra
a
c
s
s
– Remove underbody guard, if fitted ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody guard .
– Mark direction of rotation of poly V-belt.
do
c
um
en
– Turn the tensioning element -1- in -direction of arrow- with ring
spanner SW 16 -2- to slacken the poly-V belt.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
– Lock tensioning element using locking pin - T10060 A- .
– Remove poly V-belt.
Installing
Installation is carried out in the reverse order; note the following:
Note
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐
nator, air conditioner compressor, power steering vane pump)
are secured tightly.
♦ When installing poly V-belt, check direction of belt rotation and
proper seating of belt in pulleys.
♦ Place the poly-V belt last on the tensioning element.
– Remove locking pin - T10060 A- .
After completing repair, always:
– Start engine and check belt running.
1. Cylinder block (pulley end)
41
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Belt drive without air conditioner compressor
1-
Tensioning roller
2-
Alternator pulley
3-
Vane pump
4-
Poly V-belt
5-
Crankshaft pulley
2-
Tensioning roller
3-
Alternator pulley
4-
Vane pump
5-
Air conditioner compressor pulley
6-
Poly V-belt
7-
Idler roller
Removing and installing tensioner for
poly V-belt
Removing
– Remove poly V-belt
⇒ “1.5 Removing and installing poly V-belt”, page 40 .
– Remove alternator ⇒ Electrical system; Rep. gr. 27 .
AG.
Prote
cted
by
Rep. gr.13 - Crankshaft group
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
42
ht
rig
py
Co
t.
r
fo
ng
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
1.6
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Crankshaft pulley
ility
ab
y li
an
pt
ce
1-
un
le
Belt drive with air conditioner compressor
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Remove bolt -arrow- for tensioning element -1- and remove
tensioning element in -direction of arrow-.
Installing
Installation is carried out in the reverse order; note the following:
– Install alternator ⇒ Electrical system; Rep. gr. 27 .
– Install poly V-belt
⇒ “1.5 Removing and installing poly V-belt”, page 40 .
– Connect battery ⇒ Electrical system; Rep. gr. 27 .
– Re-learn window lifter, enter radio code, set clock and, if nec‐
essary recode control units which have fault entries.
Specified torques
♦ ⇒ “1.3 Assembly overview - poly V-belt drive”, page 37
♦ ⇒ “1.4 Assembly overview - poly V-belt drive, vehicles without
A/C system”, page 39
1.7
Removing and installing ancillary brack‐
et
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Removing
– Remove high-pressure pump ⇒ page 347 .
– Remove the generator ⇒ Electrical system; Rep. gr. 27 .
WARNING
The air conditioner refrigerant circuit must not be opened.
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87
– Secure air conditioner compressor to body so that the refrig‐
erant lines and hoses are not under tension.
ht
rig
py
Co
t.
– Screw off vane pump for power assisted steering together with
connected lines and fasten to body ⇒ Running gear, axles,
steering; Rep. gr. 48
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
1. Cylinder block (pulley end)
43
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unscrew deflection rolls -1- and -2- and screw out bolt of
toothed belt guard -arrow-.
– Pull connector -1- out of bracket -2-.
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
Note
ua
b
d
ran
ir se
tee
o
h
t
or
u or felt. A small hand-held mirror is required
Nut -3- cannot be seen
ac
a
ss
pe
rm
itte
d
un
le
ility
ab
y li
an
pt
ce
to unscrew and insert nut -3-.
– Unscrew bolts -1….6- and remove ancillary bracket.
Installing
– Make sure that the dowel sleeve ⇒ Item 6 (page 37) on the
rear of the bracket is in the hole for the bolt. If the dowel sleeve
is missing, it must be replaced.
c
o
p
yri
gh
t
.
C
op
yi
AG.
Prote
cted
by
Specified torques
agen
lksw
Vo
by
– Installing high-pressure pump ⇒ page 347 .
ht
rig
py
Co
t.
– Installing the generator ⇒ Electrical system; Rep. gr. 27 .
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 105
♦ ⇒ “1.3 Assembly overview - poly V-belt drive”, page 37
♦ ⇒ “1.4 Assembly overview - poly V-belt drive, vehicles without
A/C system”, page 39
1.8
Removing and installing vibration damp‐
er
Special tools and workshop equipment required
44
Rep. gr.13 - Crankshaft group
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Installation is carried out in the reverse order; note the following:
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– Remove nut -3- and bracket -2-.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Torque wrench - V.A.G 1410-
Removing
– Remove poly V-belt ⇒ page 40 .
– Loosen bolts -arrows- for vibration damper, counterholding on
crankshaft toothed belt pulley bolt with a ring spanner.
– Unscrew bolts and remove vibration damper.
Installing
Installation is carried out in the reverse order; note the following:
– Tighten bolts -arrows- for vibration damper, counterhold on
crankshaft toothed belt pulley bolt with a ring spanner.
Specified torques
♦ ⇒ “1.3 Assembly overview - poly V-belt drive”, page 37
♦ ⇒ “1.4 Assembly overview - poly V-belt drive, vehicles without
A/C system”, page 39
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
– Install vibration damper with new bolts -arrows-.
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
The vibration damper hole must be positioned over the projection
on the toothed belt pulley -arrow-.
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
s
s
Assembly of the vibration damper is only possible in one position:
1. Cylinder block (pulley end)
45
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
1.9
Renewing crankshaft oil seal - belt pulley end
Special tools and workshop
equipment required
♦ Oil seal extractor - 3203♦ Counterhold tool - 3415♦ Assembly tool - T10053♦ Torque wrench (5…50 Nm)
- V.A.G 1331n AG. Volkswagen AG do
es n
ot g
ua
ran
tee
or
ac
r
fo
ng
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Removing
– Remove toothed belt ⇒ page 107 .
– Remove crankshaft toothed belt pulley. To do this, lock tooth‐
ed belt pulley using counterhold - 3415- .
– To guide seal extractor - 3203- , screw centre bolt into crank‐
shaft as far as stop by hand.
– Unscrew inner part of oil seal extractor 2 turns (approx. 3 mm)
from the outer part and lock in position with the knurled screw.
– Oil threaded head of oil seal extractor.
46
Rep. gr.13 - Crankshaft group
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ss
e
ris
ho
t
au
ility
ab
y li
an
pt
ce
un
le
♦ Torque wrench (40…200olkswage
Nm) - V.A.G 1332- d by V
–
Installing
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Amarok 2011 ➤
common rail) - Edition 04.2013
ility
ab
y li
an
pt
ce
un
le
–
olkswagen AGdiesel engine (2.0 l engine,
AG. V4-cylinder
does
agen
ksw
not
l
o
V
gu
y
arainto oil seal.
Screw oil seal
d b extractor forcibly as far as possible
e
nte
is
r
o
eo
h
ut knurled screw and turn inner part against crankshaft
Loosen
ra
a
c
s
untils the oil seal is pulled out.
Installation is carried out in the reverse order; note the following:
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
Note
The oil seal sealing lip must not be additionally oiled or greased.
– Remove oil residues from crankshaft journal with a clean cloth.
– Fit guide sleeve - T10053/1- onto crankshaft journal.
ht
rig
py
Co
t.
r
fo
ng
– Slide seal over guide sleeve - T10053/1- onto crankshaft jour‐
nal.
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
– Press oil seal in as far as stop with press sleeve - T10053- and
central bolt.
AG.
– Install crankshaft toothed belt pulley.
– Install toothed belt ⇒ page 107 .
Specified torques
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 105
♦ ⇒ “1.3 Assembly overview - poly V-belt drive”, page 37
♦ ⇒ “1.4 Assembly overview - poly V-belt drive, vehicles without
A/C system”, page 39
1. Cylinder block (pulley end)
47
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
1.10
Removing and installing sealing flange on pulley end
Special tools and workshop
equipment required
♦ Counterhold tool - 3415♦ Assembly tool - T10053♦ Torque wrench (5…50 Nm)
- V.A.G 1331♦ Torque wrench (40…200
Nm) - V.A.G 1332♦ Hand drill with plastic brush
♦ Flat scraper
♦ Silicone sealant ⇒ Elec‐
tronic Parts Catalogue (ET‐
KA)
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Removing
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
– Remove toothed belt ⇒ page 107 .
– Remove crankshaft toothed belt pulley. To do this, lock tooth‐
ed belt pulley using counterhold - 3415- .
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Rep. gr.13 - Crankshaft group
thi
sd
o
cu
m
en
48
agen
lksw
Vo
by
– Remove sump ⇒ page 140 .
ht
rig
py
Co
t.
– Drain off engine oil.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unscrew bolts -1 … 10- and carefully remove sealing flange
from the glued joint.
– Remove sealing flange. If necessary, loosen sealing flange
using light blows with a rubber headed hammer.
– Remove sealant residues from cylinder block with a flat scra‐
per.
– Remove residual sealant on sealing flange using a rotating
plastic brush (wear protective goggles).
– Clean sealing surfaces. They must be free of oil and grease.
Installing
Installation is carried out in the reverse order; note the following:
Note
♦ Observe expiry date of sealing compound.
♦ The sealing flange must be installed within 5 minutes
lkswagen A
. Voap‐
AGof
plying the silicone sealant.
ility
ab
y li
an
pt
ce
seal.
G do
es n
ot g
ua
ran
tee
or
ac
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
♦
n
wage
olks
V
by
ed
Sealant bead must be no thicker thanris2…3
mm. Excess seal‐
o
ant can find its way into the sump and
th block the strainer in the
u
a
suction line and drip on the sealing
ss surface of the crankshaft
♦ Before applying sealant bead, cover sealing surface of oil seal
with a clean cloth.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Cut off nozzle on tube at front marking (∅ of nozzle approx.
3 mm).
do
c
um
en
– Apply a thin bead of sealant at the edge of the joint between
the cylinder block and the sump -arrows-.
ht
rig
py
Co
t.
1. Cylinder block (pulley end)
49
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Apply silicone sealant bead as shown in the illustration to clean
sealing surface of sealing flange.
–
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
e
ris
Thinly coat lowerthosealing
surface -shaded area- on sealing ntee
or
flange with sealant.
ac
au
ss
pe
rm
itte
d
un
le
– Fit sealing flange immediately and lightly tighten all bolts.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
♦ When fitting sealing flange with oil seal installed use the guide
sleeve - T10053/1- .
♦ Sealing compound must dry for approx. 30 minutes after in‐
stallation. Only then fill with engine oil.
– Tighten sealing flange securing bolts diagonally and alternate‐
ly.
– Install crankshaft toothed belt pulley.
– Install sump ⇒ page 140 .
Specified torques
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 105
ht
rig
py
Co
t.
♦ ⇒ “1.3 Assembly overview - poly V-belt drive”, page 37
c
o
p
yri
gh
t.
C
op
yi
♦ ⇒ “1.4 Assembly overview - poly V-belt drive, vehicles without
A/C system”, page 39
agen
lksw
Vo
by
Prote
cted
by
♦ ⇒ “1.1 Assembly overview - sump, oil pump”, page 137
Rep. gr.13 - Crankshaft group
AG.
50
do
c
um
en
r
te o
iva
r
rp
fo
g
n
– Install toothed belt and adjust the valve timing ⇒ page 107 .
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Note
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2
Ancillary drive
⇒ “2.1 Assembly overview - ancillary drive”, page 51
⇒ “2.2 Retrofitting preparation for ancillary drive”, page 51
2.1
Assembly overview - ancillary drive
1 - Hub
❑ Note marking when in‐
stalling
2 - Bolt
❑ Renew after removing
❑ 20 Nm +180°
3 - Belt pulley
4 - Bolt
❑ Renew after removing
❑ 20 Nm + 90°
5 - Plug
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ht
rig
py
Co
t.
c
o
p
yri
gh
t.
C
op
yi
Special tools and workshop equipment required
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Retrofitting preparation for ancillary
drive
do
c
um
en
2.2
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
2. Ancillary drive
51
agen
lksw
Vo
by
AG.
Prote
cted
by
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Torque wrench - V.A.G 1331-
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Procedure
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
– Remove poly V-belt ⇒ page 40 .
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
WARNING
Always use the original TDC mark for all adjustments to the
engine.
Note
♦ Contact surfaces must be free of oil, wax and grease. To clean
them, remove vibration damper.
♦ Set engine to TDC.
– Set mark on hub -arrow- to “12 o'clock” during assembly be‐
cause holes in damper and hub align in this position.
52
Rep. gr.13 - Crankshaft group
AG.
The hub fits in only one position. If incorrectly positioned, the bolt
holes will be offset.
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Note
ht
rig
py
Co
t.
– Clean contact surfaces thoroughly.
do
c
um
en
– Remove vibration damper ⇒ page 44 .
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Then secure vibration damper -2- to hub -1- using new bolts.
– Set ancillary drive belt pulley -1- on hub using new bolts and
tighten.
– Clip plug -arrow- into place.
– Install poly V-belt ⇒ page 40 .
Specified torque
♦ ⇒ “2.1 Assembly overview - ancillary drive”, page 51
After completing repair, always:
– Start engine and check that belt runs properly.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
do
c
um
en
2. Ancillary drive
53
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
3
Cylinder block (gearbox end)
⇒ “3.1 Assembly overview - cylinder block, gearbox end”,
page 54
⇒ “3.2 Removing and installing dual-mass flywheel”, page 55
⇒ “3.3 Removing and installing sealing flange on gearbox side”,
page 57
3.1
Assembly overview - cylinder block, gearbox end
1 - Seal
❑ Do not apply additional
oil or grease the sealing
lip of the oil seal.
❑ Before installing, re‐
move oil residue from
crankshaft journal using
a clean cloth.
❑ Renew crankshaft oil
seal (belt pulley end)
⇒ page 46 .
5 - Dual-mass flywheel
❑ To loosen securing
bolts, lock using 3067.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
4 - Bolt
❑ Renew after removing
❑ 60 Nm + 90°
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
3 - Cylinder block
❑ Removing and installing
crankshaft
⇒ page 73 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 66 .
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
ility
ab
y li
an
pt
ce
2 - Sealing flange
❑ Must sit on dowel
sleeves.
❑ Insert with silicone seal‐
ant ⇒ Electronic Parts
Catalogue (ETKA) .
❑ Removing and installing
⇒ page 48 .
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
8 - Sealing flange with oil seal
❑ With sender wheel for engine speed.
❑ Renew complete unit only.
❑ Do not apply additional oil or grease the sealing lip of the oil seal.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Use support sleeve supplied when installing.
AG.
Rep. gr.13 - Crankshaft group
agen
lksw
Vo
by
54
ht
rig
py
Co
t.
7 - Bolt
❑ 15 Nm
do
c
um
en
6 - Intermediate plate
❑ Must sit on dowel sleeves.
❑ Do not damage or bend when assembling.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
❑ Removing and installing ⇒ page 57 .
9 - Engine speed sender - G28❑ 5 Nm
❑ Removing and installing ⇒ page 406 .
3.2
Removing and installing dual-mass fly‐
wheel
Special tools and workshop equipment required
♦ Counterhold tool - 3067-
Removing
n AG. Volkswagen AG do
es n
wage
ot g
ua
ran
tee
or
ac
To prevent damage to the dual-mass flywheel when removing,
the bolts -B- must not be removed with an impact wrench or
similar. The bolts may only be removed by hand.
– Mark position of dual-mass flywheel in relation to engine.
– Rotate dual-mass flywheel -A- so that bolts -B- align centrally
with the holes -arrows-.
ht
rig
py
Co
t.
r
fo
ng
– When unscrewing bolts -B-, ensure that bolt heads do not
come into contact with the dual-mass flywheel -arrows-. The
flywheel will otherwise be damaged when turning further.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
r
ho
ut
a
ss
ility
ab
y li
an
pt
ce
Caution
un
le
ks
– Remove gearbox ⇒ Power transmission; yRep.
Vol gr. 34 ; Re‐
b
d
moving and installing gearbox .
ise
agen
lksw
Vo
by
3. Cylinder block (gearbox end)
55
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Insert counterhold - 3067- in hole on cylinder block -B-.
– Unbolt dual-mass flywheel.
Installing
Installation is carried out in the reverse order; note the following:
– Insert counterhold - 3067- in hole on cylinder block -A-.
Specified torques
♦ ⇒ “3.1 Assembly overview - cylinder block, gearbox end”, page
54
AG. Volkswagen AG d
agen
o
es n
ot g
ua
ran
tee
or
ac
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Rep. gr.13 - Crankshaft group
do
c
um
en
56
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
w
olks
yV
b
ed
ris
ho
t
au
ss
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
3.3
Removing and installing sealing flange on gearbox side
Special tools and workshop
equipment required
♦ Assembly tool - T10134♦ Torque wrench V.A.G 1331♦ Tool insert 24 mm - V.A.G
1332/11-
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
thi
sd
o
cu
m
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
♦ Depth gauge - VAS 6082-
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
♦ 3 hexagon bolts M6 x 35 mm
♦ 2 hexagon bolts M7 x 35 mm
3. Cylinder block (gearbox end)
57
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Removing
Note
♦ For the sake of clarity, the work is performed with the engine
removed.
♦ The procedure is identical whether the engine is installed or
removed.
– Removing gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox .
Pressing out sealing flange with sender wheel
– Remove flywheel.
– Remove intermediate plate.
– Turn crankshaft to the TDC for cylinder 1 as shown.
– Remove sump ⇒ page 140 .
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
– Remove engine speed sender - G28- -arrow– Unscrew bolts of sealing flange.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Note
Sealing flange and sender wheel are pressed off the crankshaft
together using 3 M6 x 35 mm bolts.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Rep. gr.13 - Crankshaft group
do
c
um
en
58
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Screw in 3 M6 x 35 mm bolts into threaded holes of sealing
flange -arrows-.
– Screw bolts (max. 180° per bolt) into sealing flange alternately
in order to press it and the sender wheel of crankshaft togeth‐
er.
Pressing in sealing flange with sender wheel
Note
♦ Sealing flange with PTFE seal is equipped with a sealing lip
support ring. This support serves as an assembly sleeve. It
must not be removed before installation.
♦ Sealing flange and sender wheel must not be separated or
turned after removal from packaging.
♦ The sender wheel is held in its installation position on the as‐
sembly device - T10134- by a locating pin.
olkswagen AG
en AG. V
does
ag
♦ The sealing flange and sealoare
nbe
lksw one unit. They can only
o
pe
rm
itte
d
crankshaft.
ility
ab
y li
an
pt
ce
t gu
ara
nte
is
r
o
eo
h
The assembly device
ut - T10134- is held in its position relative
ra
a
c
s
to the crankshafts by a guide pin inserted into a hole in the
un
le
♦
yV
renewed together with ethe
d b sender wheel.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Assembly tool - T10134A - Clamping surface
B - Hexagon nut
C - Assembly housing
D - Locating pin
E - Hexagon socket head bolt
F - Guide pin for diesel engines (black knob)
G - Guide pin for petrol engines (red knob)
A - Fit seal with sender wheel on assembly tool - T10134-
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
do
c
um
en
– Screw on nut -B- until just before it touches the clamping sur‐
face -A- of the threaded spindle.
3. Cylinder block (gearbox end)
59
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
. Volkswagen AG
gen AG
does
swa
not
4-cylinder diesel engine (2.0 l engine, common rail)Vo-lkEdition
04.2013
g
ua
ran
tee
sur‐
or
ac
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
– Clamp assembly device - T10134- in a vice
face -A- of threaded spindle.
y
db
ise
r
on clamping
tho
au
s
s
– Press assembly housing -C- downwards until it lies on nut
-B- -arrow-.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
– Screw nut onto threaded spindle until inner part of assembly
device and assembly housing are at same height.
– Remove safety clip -arrow- of the new sealing flange.
Note
Prote
cted
by
60
Rep. gr.13 - Crankshaft group
AG.
– Push sealing lip support ring -A- downwards in direction of ar‐
row until it lies on flat surface.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
– Place sealing flange with front side facing down on a clean
level surface.
ht
rig
py
Co
t.
– Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
thi
sd
o
cu
m
en
The sender wheel must not be taken out of the sealing flange or
twisted.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Upper edge of sender wheel and front edge of sealing flange
must align -arrows-.
– Place sealing flange with front side facing downwards onto
assembly tool - T10134- so that locating pin -B- can be inser‐
ted in sender wheel hole -A-.
Note
Ensure sealing flange lies flat on assembly tool.
– Push sealing flange and support ring for sealing lip -B- against
surface of assembly tool - T10134- whilst tightening the 3
knurled screws -A- so that locating pin cannot slide out of
sender wheel hole.
Note
un
le
•
Crankshaft flange must be free of oil and grease.
•
Engine is positioned at TDC of cylinder 1
– Screw nut -B- on until it reaches end of threaded spindle.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
flange
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
n
l
o
V
gu
When installing dsealing
flange, ensure that senderotwheel
by
ara remains
e
nte
fixed in assembly
device.
is
r
eo
ho
ut
ra
a
c
s
s
B - Fit assembly
tool - T10134- with sealing flange on crankshaft
– Press threaded spindle of assembly tool - T10134- in direction
of arrow, until hexagon nut -B- lies against assembly housing
-A-.
ht
rig
py
Co
t.
r
fo
ng
– Align flat side of assembly housing to crankcase's sealing sur‐
face on the oil sump side.
3. Cylinder block (gearbox end)
61
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Secure assembly tool - T10134- to crankshaft flange with hex‐
agon socket head bolts -A-.
Note
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
prox. 5 full turns).
– To guide sealing flange into cylinder block, screw in 2 M7 ×
35 mm bolts -A-.
C - Bolting assembly tool - T10134- onto crankshaft flange
–
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Note
The guide pin for petrol engines (red knob) -F- must not be inser‐
ted in threaded hole of crankshaft.
– Tighten the two hexagon socket head bolts of the assembly
tool hand-tight.
– Screw nut -E- onto threaded spindle by hand until it lies against
assembly housing -C-.
D - Pressing sender wheel onto crankshaft flange using assembly
tool - T10134-
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Rep. gr.13 - Crankshaft group
ht
rig
py
Co
t.
62
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
– Push guide pin for diesel engines (black knob) -D- into hole in
crankshaft. This ensures that the sender wheel reaches its fi‐
nal installation position.
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
Push assembly housing -C-orby
is hand in direction of arrow until
eo
h
sealing lip support ring -But touches crankshaft flange -A-.
ra
a
c
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Tighten nut of assembly tool - T10134- using torque wrench V.A.G 1331- and flared ring spanner tool insert AF A24
- V.A.G
G. Volkswagen AG d
agen
oes
1332/11- .
n
lksw
Specified torque
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Note
torque
35 Nm
pe
rm
itte
d
Tighten nut of assembly tool T10134-
ot g
ua
ran
tee
or
ac
ility
ab
y li
an
pt
ce
un
le
Component
o
yV
db
ir se
ho
ut
a
Specified
ss
After hexagon nut is tightened to 35 Nm, a small air gap must still
be present between cylinder block and sealing flange.
E - Checking sender wheel installation position on crankshaft
– Screw nut -E- on until it reaches end of threaded spindle.
– Unscrew 2 bolts -A- from cylinder block.
– Unscrew the three knurled screws -B- out of sealing flange.
– Remove sealing lip support ring.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
– The sender wheel is in the correct installation position on the
crankshaft if a gap -a- = 0.5 mm exists between crankshaft
flange -A- and sender wheel -B-.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
– Remove assembly tool - T10134- .
– Place caliper gauge on crankshaft flange.
– Measured distance -a- between crankshaft flange and sender
wheel.
If dimension -a- is too small:
– Re-press sender wheel ⇒ page 64 .
If dimension -a- is achieved:
– Tighten new sealing flange securing bolts diagonally and al‐
ternately.
3. Cylinder block (gearbox end)
63
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Install engine speed sender - G28- -arrow- and tighten secur‐
ing bolt.
– Install sump ⇒ page 140 .
– Install intermediate plate.
– Install flywheel with new bolts.
F - Re-pressing sender wheel
– Secure assembly tool - T10134- to crankshaft flange with hex‐
agon socket head bolts -A-.
– Tighten the two hexagon socket head bolts hand-tight.
– Push the assembly tool - T10134- against the sealing flange
by hand.
– Screw nut -E- onto threaded spindle by hand until it lies against
assembly housing -C-.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Rep. gr.13 - Crankshaft group
do
c
um
en
64
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Tighten nut of assembly tool - T10134- using torque wrench V.A.G 1331- and flared ring spanner tool insert AF 24 - V.A.G
1332/11- .
Specified torque
Component
Specified torque
Tighten nut of assembly tool T10134-
40 Nm
– Check the sender wheel installation position on crankshaft
again ⇒ page 63
If dimension -a- is too small again:
– Tighten nut of assembly tool - T10134- as follows:
Component
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
Tighten nut of assembly tool T10134-
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
Specified
torque
eo
h
ut
ra
a
c
s
s 45 Nm
– Check the sender wheel installation position on crankshaft
again ⇒ page 63
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
thi
sd
o
cu
m
en
ht
rig
py
Co
t.
Specified torque
agen
lksw
Vo
by
3. Cylinder block (gearbox end)
65
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
4
Pistons and conrods
⇒ “4.1 Assembly overview - pistons and conrods”, page 66
⇒ “4.2 Checking piston and cylinder bore”, page 68
⇒ “4.3 Piston and cylinder dimensions”, page 69
⇒ “4.4 Measuring piston projection at TDC”, page 70
⇒ “4.5 Checking radial clearance of conrods”, page 71
⇒ “4.6 Bearing shells - installation position”, page 71
⇒ “4.7 Separating new conrod”, page 72
4.1
Assembly overview - pistons and conrods
1 - Piston rings
❑ Offset gaps by 120°.
❑ Use piston ring pliers to
remove and install.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
⇒ page 67 .
Volkswagen AG
❑ Checking ring-to-groove swagen AG.
does
k
not
l
o
clearance ⇒ page 68 b.y V
gu
a
d
se
ran
tee
or
ac
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
ri
2 - Piston
ho
ut
a
❑ With combustion
cham‐
ss
ber.
❑ Mark installation posi‐
tion and cylinder num‐
ber.
❑ Installation position and
allocation of piston to
cylinder ⇒ page 68 .
❑ Arrow on piston crown
points to belt pulley end.
❑ Checking ⇒ page 68 .
❑ Install using piston ring
clamp.
❑ If piston skirt is cracked,
renew piston.
❑ Checking piston projec‐
tion at TDC
⇒ page 70 .
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
4 - Circlip
5 - Conrod
❑ Mark cylinder allocation -A- with coloured pen.
❑ Installation position: Marking -B- faces towards pulley end.
❑ With industrially cracked conrod cap.
❑ Measuring radial clearance ⇒ page 71
66
Rep. gr.13 - Crankshaft group
thi
sd
o
cu
m
en
3 - Piston pin
❑ If difficult to remove,
heat piston to 60 °C.
❑ Remove and install us‐
ing drift - VW 222- .
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
6 - Bearing shell
❑ Note installation position ⇒ page 71 .
❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi‐
cation: Black line on bearing surface in area of joint.
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
❑ Check for secure seating.
❑ Axial clearance, wear limit: 0.37 mm
❑ Check radial clearance with Plastigage; wear limit: 0.08 mm.
❑ Do not rotate crankshaft when checking radial clearance.
7 - Cylinder block
❑ Checking cylinder bores ⇒ page 69 .
❑ Piston and cylinder dimensions ⇒ page 69 .
8 - Conrod bearing cap
❑ Note installation position.
9 - Oil spray jet
❑ For piston cooling.
10 - Bolt
❑ Insert without sealant.
❑ 25 Nm
un
le
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
11 - Conrod bolt
b
d
ran
ir se
tee
o
❑ Renew afterthremoving
or
u
ac
a
❑ Oil threads
ss and contact surface.
Checking piston ring gap
Special tools and workshop equipment required
ht
rig
py
Co
t.
r
fo
ng
♦ Feeler gauges
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
❑ Use old bolt for measuring radial clearance.
❑ 30 Nm + 90°
c
o
p
yri
gh
t
.
C
op
yi
– Push piston ring at right angle from above down into lower
cylinder bore to approx. 15 mm from bottom end of cylinder.
Prote
cted
by
0.20 … 0.40
0.20 … 0.40
0.25 … 0.50
AG.
1st compression ring
2nd compression ring
Oil scraper ring
New
agen
lksw
Vo
by
Piston ring
dimensions in mm
Wear limit
1.0
1.0
1.0
4. Pistons and conrods
67
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Checking ring-to-groove clearance
Special tools and workshop equipment required
♦ Feeler gauges
– Clean annular groove before check.
Piston ring
dimensions in mm
1st compression ring
2nd compression ring
Oil scraper ring
New
Wear limit
0.06 … 0.09
0.05 … 0.08
0.03 … 0.06
0.25
AG. Volkswagen AG d
agen
oes
not
0.25 Volksw
gu
by
ara
d
e
nte
0.15
is
r
o
un
le
ility
ab
y li
an
pt
ce
Installation position and allocation of piston to
eo
ra
c
th
au
s
cylinder
s
Checking piston and cylinder bore
Checking piston
– Using a micrometer (75 … 100 mm), measure approx. 15 mm
from the lower edge, perpendicular to the piston pin axis.
68
Rep. gr.13 - Crankshaft group
AG.
Piston must be renewed if piston shaft reveals cracking.
agen
lksw
Vo
by
Note
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Nominal dimension ⇒ page 69
r
fo
ng
Maximum deviation from nominal dimension: 0.04 mm
ht
rig
py
Co
t.
•
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
4.2
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Arrow on piston crown -arrows- points in direction of cylinder 1.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Checking cylinder bores
Special tools and workshop equipment required
♦ Internal dial test indicator 50…100 mm
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-. Difference between actual
and nominal diameter max. 0.10 mm.
Note
un
le
80.96
81.01
r
fo
ng
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Cylinder bore Ø
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
mm
Piston Ø
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
Basic di‐
mension
Piston and cylinder dimensions
ht
rig
py
Co
t.
4.3
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d when the cylinder block is
Cylinder bores must not be measured
ran
ir se
tee
o
secured to engine and gearboxthsupport - VAS 6095- , as meas‐
or
ac
urements may be incorrect. ss au
4. Pistons and conrods
69
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
4.4
Measuring piston projection at TDC
Special tools and workshop
equipment required
♦ Measuring bridge VW 382/7- from measuring
tool - VW 382♦ Measuring plate VW 385/17- from measur‐
ing tool - VW 385♦ Dial gauge - VAS 6079-
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Test procedure
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
♦ The piston projection in the genuine part must be measured
on all pistons when installing new pistons or a short engine.
♦ If you have measured the piston projection and it is not same
for all pistons, use the highest value to determine the correct
gasket size.
♦ Depending on piston projection, fit the appropriate cylinder
head gasket according to following table.
♦ Turn crankshaft clockwise to measure.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Rep. gr.13 - Crankshaft group
ht
rig
py
Co
t.
70
do
c
um
en
– Secure dial gauge - VAS 6079- with measuring bridge VW 382/7- and measuring plate -VW 385/17- to cylinder block
as shown in the illustration.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
olkswagen AG
en AG. V
doethe
ag
s notwo points marked
– Measure the projection
of each piston at
ksw
t gu
Vol
y
with -arrowsb (at the rear side and front side of
athe
d
ran piston seen
e
tee
ris
in theholongitudinal
direction of the engine).
t
au
or
a
Identification
Holes/notches
4.5
1
2
3
Checking radial clearance of conrods
Special tools and workshop equipment required
♦ Plastigage
ht
rig
py
Co
t.
Procedure
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
0.91 mm … 1.00 mm
1.01 mm … 1.10 mm
1.11 mm … 1.20 mm
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Piston projection
ility
ab
y li
an
pt
ce
c upon
– Install
the appropriate cylinder head gasket depending
ss
piston projection, according to following table:
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
– Remove conrod bearing cap. Clean bearing cap and bearing
journal.
agen
lksw
Vo
by
AG.
– Place a Plastigage corresponding to the width of the bearing
on the journal or into the bearing shells.
– Fit conrod bearing cap and tighten to 30 Nm without turning
further angle and without rotating crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
Radial clearance:
•
Wear limit: 0.08 mm
– Renew conrod bolts.
4.6
Bearing shells - installation position
Bearing shell -1- with oil hole -arrow- for conrod.
Bearing shell -2- without oil hole for conrod bearing cap.
– Position bearing shells in centre of conrod and conrod bearing
cap when fitting.
Dimension -a- must be identical on both sides.
4. Pistons and conrods
71
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
4.7
Separating new conrod
Procedure:
On new conrods it is possible that the breaking point is not fully
separated. Proceed as follows if the conrod bearing cap cannot
be removed by hand:
– Mark allocation of conrod to cylinder.
– Lightly clamp the conrod in a vice using aluminum vice clamps,
as shown in the illustration.
Note
♦ Only clamp the conrod lightly in order to avoid damaging it.
♦ Conrod is clamped below the dashed line.
– Unscrew bolts -arrows- around 5 turns.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
– Using a plastic hammer, carefully knock against conrod bear‐
ing cap in -direction of arrow- until it is loose.
do
c
um
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Rep. gr.13 - Crankshaft group
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
72
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
5
Crankshaft
⇒ “5.1 Assembly overview - crankshaft”, page 73
⇒ “5.2 Crankshaft dimensions”, page 74
⇒ “5.3 Measuring axial clearance of crankshaft”, page 74
⇒ “5.4 Measuring radial clearance of crankshaft”, page 75
⇒ “5.5 Renewing needle bearing in crankshaft”, page 76
5.1
Assembly overview - crankshaft
pe
rm
itte
d
un
le
ility
ab
y li
an
pt
ce
1 - Bearing shells 1, 2, 4 and 5
n AG. Volkswagen AG do
es n
wage
s
❑ For bearing cap without
k
l
ot g
Vo
y
ua
b
oil groove.
d
ran
ir se
tee
o
h
❑ For cylinder block with
t
or
u
ac
a
oil groove.
ss
❑ Do not interchange
used bearing shells
(mark).
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
2 - Bolt
❑ Renew after removing
❑ To measure radial clear‐
ance, tighten to 65 Nm
but not further.
❑ 65 Nm + 90°
r
te o
iva
r
rp
fo
g
n
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
4 - Thrust washer
❑ For bearing cap 3.
❑ Note fixing arrange‐
ment.
do
c
um
en
3 - Bearing cap
❑ Bearing cap 1: belt pul‐
ley end.
❑ Bearing cap 3 with re‐
cesses for thrust wash‐
ers.
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
5 - Bearing shell 3
❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove.
❑ Do not interchange used bearing shells (mark).
6 - Needle bearing
❑ Removing and installing ⇒ page 76 .
7 - Crankshaft
❑ With toothed belt pulley for oil pump drive. Toothed belt pulley is not available as separate part.
❑ Axial clearance new: 0.07…0.17 mm; wear limit: 0.37 mm
❑ Measure radial clearance with Plastigage , new: 0.03…0.08 mm; wear limit: 0.17 mm
❑ Do not rotate crankshaft when checking radial clearance.
❑ Crankshaft dimensions ⇒ page 74 .
5. Crankshaft
73
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
8 - Thrust washer
❑ For cylinder block, bearing 3
5.2
Crankshaft dimensions
(Dimensions in mm)
Main
journal ∅
Basic dimension 54.00
5.3
-0.022
-0.042
Conrod
journal ∅
50.90
-0.022
-0.042
Measuring axial clearance of crankshaft
Special tools and workshop equipment required
♦ Universal dial gauge bracket - VW 387-
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Procedure
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
♦ Dial gauge - VAS 6079-
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
– Fit dial gauge - VAS 6079- with universal dial gauge holder VW 387- to cylinder block as shown in the illustration and set
against crank web.
•
Wear limit: 0.37 mm
74
Rep. gr.13 - Crankshaft group
AG.
New: 0.07…0.17 mm
agen
lksw
Vo
by
•
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Axial clearance:
ht
rig
py
Co
t.
– Push crankshaft away from dial gauge and read off measured
value.
do
c
um
en
– Set dial gauge to “0”.
r
te o
iva
r
rp
fo
g
n
– Press crankshaft against dial gauge by hand.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
5.4
Measuring radial clearance of crank‐
shaft
Special tools and workshop equipment required
♦ Plastigage
Procedure:
Note
♦ Mark used bearings for re-installation but not on bearing sur‐
face.
♦ If bearing shells have worn down to nickel layer, they must be
renewed.
– Remove bearing cap and clean crankshaft journal.
– Place a Plastigage corresponding to the width of the bearing
on the journal or into the bearing shells.
•
The Plastigage must lie in the middle of the bearing shell.
– Fit bearing cap and tighten. Do not rotate crankshaft.
Component
•
Wear limit: 0.17 mm
AG.
New: 0.03 … 0.08 mm
agen
lksw
Vo
by
•
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Radial clearance:
r
fo
ng
– Compare width of Plastigage with the measurement scale.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
– Remove bearing cap again.
un
le
Bearing cap
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
Specified
torque
nte
is
r
o
eo
h
ut
ra
a
30
Nm
c
s
s
ht
rig
py
Co
t.
Specified torque
5. Crankshaft
75
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
5.5
Renewing needle bearing in crankshaft
Special tools and workshop
equipment required
♦ Internal puller - Kukko 21/2and internal puller - Kukko
22/1-
ility
ab
y li
an
pt
ce
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Removing
•
Gearbox is separated from engine.
– Pull needle bearing out using commercially available internal
puller, e.g. KUKKO 21/2 and KUKKO 22/1, -A-.
Installing
Note
The lettering on the needle bearing must be visible when installed.
76
Rep. gr.13 - Crankshaft group
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
un
le
♦ Drift - VW 207 C-
ht
rig
py
Co
t.
♦ Centring mandrel -
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
3176is
r
o
eo
h
ut
ra
a
c
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Drive in needle bearing using drift - VW 207 C- or centring
mandrel - 3176- .
– Drive needle bearing in carefully.
– Constantly measure insertion depth when driving in.
– Renew bearing, if driving depth is too deep.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
Installation depth dimension -a- = 1.5 to 1.8 mm.
5. Crankshaft
77
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
15 –
Cylinder head, valve gear
1
Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 78
⇒ “1.2 Assembly overview - cylinder head cover”, page 81
⇒ “1.3 Removing and installing cylinder head”, page 85
⇒ “1.4 Removing and installing cylinder head cover”, page 93
⇒ “1.5 Removing and installing injector seals”, page 99
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
⇒ “1.6 Removing and installing vacuum pump”, page 102
⇒ “1.7 Checking compression”, page 103
Note
♦ The plastic packing pieces for protecting the open valves must
not be removed until immediately before fitting cylinder head.
♦ If the cylinder head is replaced, all the coolant in the system
r
fo
ng
AG.
Prote
cted
by
Rep. gr.15 - Cylinder head, valve gear
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
78
ht
rig
py
Co
t.
must also be renewed.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
Assembly overview - cylinder head
ility
ab
y li
an
pt
ce
1.1
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
1 - Cylinder head
❑ After renewing, renew
entire coolant.
❑ Check for distortion
⇒ page 80 .
❑ Removing and installing
⇒ page 85 .
2 - Washer
3 - Cylinder head bolt
❑ Renew after removing
❑ Before installing, place
washers in cylinder
head
⇒ Item 2 (page 79) .
❑ Observe sequence
when loosening and
tightening ⇒ page 80 .
6 - Lifting eye
7 - Glow plug
❑ 18 Nm
8 - Gasket
❑ Renew after removing
9 - Vacuum pump
DANGER!
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
The vacuum pump may,
under no circumstances,
be dismantled as the
vacuum part could other‐
wise malfunction. This
would result in the failure
of the brake servo.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
5 - Centre hex stud
❑ 25 Nm
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
4 - Oil pressure switch - F1n AG. Volkswagen AG do
❑ Identification: green
es n
wage
s
k
l
ot g
o
ua
❑ 0.5 bar d by V
ran
ir se
tee
o
❑ If sealthis leaking, nip
or
u
ac
a
open
and
renew.
ss
❑ Checking ⇒ page 156 .
❑ Removing and installing
⇒ page 154 .
❑ 22 Nm
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
❑ Removing and installing ⇒ page 102 .
10 - Bolt
❑ 10 Nm
11 - Clip
12 - Coolant temperature sender - G6213 - Seal
❑ Renew after removing
1. Cylinder head
79
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
14 - Bolt
❑ 10 Nm
15 - Coolant hose connection
16 - Gasket
❑ Renew after removing
17 - Bolt
❑ 25 Nm
18 - Lifting eye
19 - Cylinder head gasket
❑ Renew after removing
❑ Note marking ⇒ page 81 .
20 - Hall sender - G40❑ For camshaft position.
❑ Removing and installing ⇒ page 407 .
Max. permissible distortion: 0.1 mm.
80
Rep. gr.15 - Cylinder head, valve gear
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
AG.
♦ Feeler gauge -1-
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
♦ Straightedge 500 mm - VAS 6075-
do
c
um
en
Special tools and workshop equipment required
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Checking cylinder head for distortion
ility
ab
y li
an
pt
ce
Observe tightening sequence of cylinder head bolts.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
ht
rig
py
Co
t.
21 - Bolt
❑ 10 Nm
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Note
Reworking diesel cylinder heads is not permissible.
Cylinder head gasket identification
♦ Part No. = arrow 1
♦ Holes = arrow 2
♦ Production control code = arrow 3 (can be disregarded)
Note
♦ Different thicknesses of cylinder head gasket are fitted de‐
pending on the piston projection. When renewing gasket,
install new gasket with same identification.
♦ Piston projection in genuine part must be determined when
installing new pistons or a short engine ⇒ page 70 .
1.2
Assembly overview - cylinder head cover
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
un
le
4 - Injector
❑ If the injectors are to be
re-installed, they must
always be re-fitted on
the same cylinder.
❑ Before re-using “highpressure line”, perform
ht
rig
py
Co
t.
r
fo
ng
3 - Fuel return line
❑ Cannot be renewed
separately
❑ To fuel tank.
❑ The fuel return line must
not be kinked, damaged
or blocked.
❑ The fuel return lines
must not be dismantled.
❑ Removing ⇒ page 83
❑ Checking catches
⇒ page 83 .
❑ Fitting ⇒ page 83
❑ Lock ⇒ page 84
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
2 - Bolt
❑ 22 Nm
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
ility
ab
y li
an
pt
ce
1 - High-pressure accumulator
(fuel rail)
❑ Do not attempt to re‐
shape high-pressure
lines.
❑ Observe rules for clean‐
liness ⇒ page 7 .
❑ Removing and installing
high-pressure lines
⇒ page 338 .
1. Cylinder head
81
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
visual check of taper
seals for damage, e.g. transverse scores or corrosion. Always renew pipe if damaged.
❑ Removing and installing ⇒ page 327 .
5 - O-ring
❑ Renew after removing
6 - Bolt
❑ Renew after removing
❑ 8 Nm +180°
7 - O-ring
❑ Renew after removing
8 - Seal
❑ Renew after removing
9 - Clamping plate
un
le
12 - Cylinder head cover
❑ Removing and installing ⇒ page 93 .
13 - Bolt
❑ Renew seal if damaged
❑ Tightening sequence ⇒ page 84 .
❑ 10 Nm
14 - Gasket
❑ Renew if damaged or leaking.
15 - Vacuum hose
16 - Pipe assembly
❑ For crankcase ventilation.
❑ Press release buttons to remove.
20 - Injector seal
❑ Renew if damaged or leaking ⇒ page 99 .
21 - Bracket
22 - Bolt
❑ 10 Nm
82
Rep. gr.15 - Cylinder head, valve gear
AG.
19 - Sealing bush for high-pressure accumulator (fuel rail)
❑ Renew if damaged or leaking.
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
18 - Grommet
ht
rig
py
Co
t.
r
fo
ng
17 - O-ring
❑ Renew if damaged or leaking.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
11 - Gasket
ility
ab
y li
an
pt
ce
10 - Cap
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Disconnecting fuel return lines
– With engine switched off, carefully pull return line connections
off at piezo injectors. To do this, press the two clips downwards
-arrow A- and, at the same time, pull the release bolt upwards
-arrow B-.
un
le
pe
rm
itte
d
Carefully pull fuel return lines upwards when disconnect‐
ing as the 4 catches -arrow- can fracture.
•
After disconnecting, check the 4 catches -arrow- to see
whether they are fractured or have broken off.
•
Always replace damaged fuel return lines.
•
A damaged fuel return line that becomes loose when en‐
gine is running causes damage to piezo injector. The
piezo injector must then be replaced.
– Apply a thin coating of diesel fuel to the new O-rings on the
return-line connections.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
– Connect fuel return line and press the two clips downwards as
far as they will go -arrows-.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
•
Fit fuel return line
ility
ab
y li
an
pt
ce
Caution
ht
rig
py
Co
t.
Check catches
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
1. Cylinder head
83
AG.
Prote
cted
by
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Lock fuel return line
– After fuel return line has been pushed on completely, press
the locking bolt downwards -arrow-.
Tightening sequence for cylinder head cover
– Hand-tighten cylinder head cover in the sequence -1 … 6-.
– Tighten bolts in the sequence -1 … 6-.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Rep. gr.15 - Cylinder head, valve gear
do
c
um
en
84
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
1.3
Removing and installing cylinder head
Special tools and workshop
equipment required
♦ Guide pins - 3070♦ Diesel injection pump lock‐
ing pin - 3359♦ Crankshaft stop - T10050♦ Counterhold tool - T10051♦ Puller - T10052♦ Bit XZN 10 - T10385-
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
do
c
um
en
1. Cylinder head
85
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Torque wrench - V.A.G
1331♦ Torque wrench - V.A.G
1332♦ Socket set 1/4", 22-piece VAS 5528♦ Engine bung set - VAS
6122-
r
fo
ng
AG.
Prote
cted
by
Rep. gr.15 - Cylinder head, valve gear
agen
lksw
Vo
by
86
c
o
p
yri
gh
t.
C
op
yi
♦ Hose clip pliers - VAS 6362-
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
♦ Vehicle diagnostic tester
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
ht
rig
py
Co
t.
♦ Drip tray for workshop hoist
- VAS 6208-
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Note
♦ Before carrying out further work, disconnect battery earth
strap. Check whether a coded radio is fitted. Obtain anti-theft
coding first if necessary.
♦ All cable ties which are opened or cut through when cylinder
head is removed must be fastened in the same position when
cylinder head is installed.
♦ All connectors which are separated during disassembly must
be reconnected in the original position when installing.
♦ Seal open lines and unions with clean plugs from engine bung
set - VAS 6122- .
♦ Collect drained coolant in a clean container for re-use or dis‐
posal.
♦ To avoid damage to lines, ensure sufficient clearance from
all moving or hot components.
Note
Glow plugs -arrows- project out of cylinder head. After removal,
the cylinder head must not be placed on the glow plugs. If nec‐
essary, remove glow plugs ⇒ page 405 .
Removing
– Remove underbody guard, if fitted ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody guard .
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
♦ 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.
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ment, pay attention to the following due to the cramped condi‐
tions:
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
Caution ise
nte
r
o
eo
h
t
u
ra
a
c
When doing anyssrepair
work, especially in the engine compart‐
ht
rig
py
Co
t.
c
o
p
yri
gh
t.
C
op
yi
– Disconnect battery earth strap with ignition switched off ⇒
Electrical system; Rep. gr. 27 ; Disconnecting and reconnect‐
ing battery .
agen
lksw
Vo
by
AG.
Prote
cted
by
– Drain coolant ⇒ page 182 .
– Remove toothed belt ⇒ page 107 .
– Remove camshaft pulley from hub.
– Remove camshaft hub. To do this, pull camshaft hub off using
puller - T10052- .
1. Cylinder head
87
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Counterhold hub with counter-hold tool - T10051- and release
hub bolt -1-.
– Unscrew hub bolt approx. 2 turns.
– Position puller - T10052- and align with hub holes.
– Tighten bolts -1-.
– Apply tension to hub by evenly tightening puller -2- until hub
separates from taper of camshaft. Hold puller with 30 mm
spanner whilst doing this.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
Prote
cted
by
Rep. gr.15 - Cylinder head, valve gear
AG.
c
o
p
yri
gh
t.
C
op
yi
88
do
c
um
en
– Release and pull off connector -1-.
agen
lksw
Vo
by
– Screw off Hall sender - G40- -arrow-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Unscrew bolt -arrow- from toothed belt guard.
ht
rig
py
Co
t.
– Remove hub from taper of camshaft.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Detach hoses from intake hose -3- bracket -arrow-.
n AG. Volkswagen AG do
– Remove pipe -5- from cylinder head cover.
e
wage
ks
Vol
y
– Release and pull off wiring harness
d bconnector -2-. Detach wir‐
iseretainer -3-.
r
ing harness -2- from intake hose
ho
t
au
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
– Open clips -1- and -4- andssremove intake hose -3-.
s no
t gu
ara
nte
eo
ra
c
– Remove air filter with attachments ⇒ page 370 .
– Remove particulate filter ⇒ page 381 .
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Remove turbocharger ⇒ page 267 .
– Unclip connector -2- on oil pressure switch - F1- .
do
c
um
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
– Disconnect connector -2- at coolant temperature sender G62- -1-.
Note
Components for coolant temperature sender - G62- are difficult
to see. A small hand-held mirror is required to unscrew and insert
coolant temperature sender - G62- .
– Loosen clamp for coolant hose -1- and pull off coolant hose
-1-.
– Loosen clamp for coolant pipe -4- and pull coolant pipe -4- out
at union -2-.
– Remove cylinder head cover ⇒ page 93 .
– Remove intake manifold ⇒ page 354 .
– Remove/pull off all necessary coolant hoses, vacuum lines
and plug-in electrical connectors.
1. Cylinder head
89
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Comply with specified sequence when undoing cylinder head
bolts.
Note
♦ A second mechanic is required to remove and install the cyl‐
inder head.
♦ Before removing cylinder head, remove toothed belt tensioner
from stud. Make sure that toothed belt tensioner does not fall
to the floor.
♦ Check that all necessary hoses and lines have been discon‐
nected.
♦ Do not place cylinder head onto dowel sleeves -A- when re‐
moving and installing.
AG. Volkswagen AG d
agen
oes
lksw pull slightly to
– First raise cylinder head on gearbox side
Voand
by tensioner from stud.
left. Whilst doing this, remove toothed
belt
d
se
i
or
Caution
Risk of damage to glow plug pins -arrow- when cylinder head
is being lowered.
AG.
Rep. gr.15 - Cylinder head, valve gear
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
90
ht
rig
py
Co
t.
r
fo
ng
♦ Do not lay removed cylinder head with installed glow plugs
down on sealing surface, as glow pins -arrow- project past
sealing surface.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
ility
ab
y li
an
pt
ce
h
ut
– When lifting cylinder head out, aguide
electrical lines and cool‐
s
s
ant hoses past transport eyelet.
not
gu
ara
nte
eo
ra
c
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Caution
un
le
♦ Carefully remove remains of emery and abrasives.
Installing
Installation is carried out in the reverse order; note the following:
Caution
Avoid damage to cylinder block.
♦ No oil or coolant may be contained in hole pockets for cyl‐
inder head bolts in cylinder block.
Danger of cylinder head gasket leaks.
♦ Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Avoid damage to open valves.
ht
rig
py
Co
t.
r
fo
ng
♦ Do not remove new cylinder head gasket from packaging
until it is ready to be fitted.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
♦ Carefully remove any sealant residue from the cylinder
head and cylinder block. Ensure that no long scores or
scratches are made on the surfaces.
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
Avoid damage to sealing surfaces:
b
ara
d
nte
ise
r
o
eo
h
♦ When using abrasive
paper
do
not
use
a
grade
less
than
t
u
ra
a
c
s
100.
s
♦ When installing an exchange cylinder head, the plastic
protectors fitted to protect the open valves should not be
removed until the cylinder head is ready to be fitted.
Avoid damage to valves and piston crowns after working on
valve gear.
♦ Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.
1. Cylinder head
91
Note
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
♦ Proceed with extreme caution. The assistance of a second
mechanic is vital.
♦ Always renew cylinder head bolts.
♦ Renew seals, gaskets, self-locking nuts, bolts tightened
through an additional specified angle and securing clamps.
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
♦ If an exchange cylinder head is installed, contact surfaces be‐
tween roller rocker fingers and running surface of cam must
be oiled.
♦ Hose unions and air intake pipes/hoses must be free of oil and
grease when installing.
♦ When cylinder head or cylinder head gasket is renewed, the
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
– To centre, screw guide pins -3070/9- into outer threaded holes
on intake side.
AG.
Prote
cted
by
•
Cylinder head gasket installation position: marking “top” or
part number towards cylinder head
– Position cylinder head gasket.
– Thread cylinder head into toothed belt guard and position belt
tensioner onto stud. When doing this, cylinder head must not
scrape over dowel sleeves -A-.
– Fit cylinder head.
– Insert 8 cylinder head bolts and screw in to stop by hand.
– Unscrew guide pins -3070/9- through bolt holes in cylinder
head and screw remaining cylinder head bolts in to stop by
hand.
92
Rep. gr.15 - Cylinder head, valve gear
ht
rig
py
Co
t.
entire coolant ⇒ page 182 and the engine oil must be
changed.
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
Amarok 2011 ➤
eo
h
t
u
ra
a
c
4-cylinder diesel
engine
(2.0
l
engine,
common
rail)
Edition
04.2013
s
s
Cylinder head bolt
1-
Tighten initially with torque wrench:
Stage I = 35 Nm
Stage II = 60 Nm
2-
Turn further with rigid spanner:
Stage III = 1/4 turn (90°)
Stage IV = 1/4 turn (90°)
– Secure bolt -arrow- of toothed belt guard.
– Install hub and camshaft pulley.
– Install toothed belt ⇒ page 107 .
– Installing turbocharger ⇒ page 267 .
– Install cylinder head cover ⇒ page 93 .
c
o
p
yri
gh
t.
C
op
yi
– Install intake manifold ⇒ page 354 .
agen
lksw
Vo
by
– Reconnect battery earth strap with ignition switched off ⇒
Electrical system; Rep. gr. 27 ; Disconnecting and reconnect‐
ing battery .
ht
rig
py
Co
t.
r
fo
ng
– Install particulate filter ⇒ page 381 .
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
– Tighten cylinder head in 4 stages in sequence shown as fol‐
lows:
Amarok 2011 ➤
rail) - Edition 04.2013
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
4-cylinder
diesel
engine
(2.0
l engine,
common
gu
y
b
ara
d
nte
ise
r
eo
tho sequence
tightening
ra
au
c
s
s
AG.
Prote
cted
by
To prevent the high-pressure pump from running while it is empty
and to ensure that the engine starts quickly after parts have been
renewed, it is important to observe the following:
♦ If components of the fuel system between the fuel tank and
the high-pressure pump are removed or renewed, it is neces‐
sary for the fuel system to be bled. To do this, perform the
“Bleeding fuel system” function using the ⇒ Vehicle diagnostic
tester ⇒ page 316 .
♦ This process takes 130 seconds. Fuel pumps are actuated a
total of 3 times in this case. The process must not be termi‐
nated prematurely.
– Carry out road test and read all event memories.
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 78
♦ ⇒ “1.2 Assembly overview - cylinder head cover”, page 81
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 105
♦ ⇒ “2.1 Assembly overview - emission control (diesel particu‐
late filter)”, page 377
1.4
Removing and installing cylinder head
cover
Special tools and workshop equipment required
1. Cylinder head
93
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Torque wrench - V.A.G 1410-
♦ Socket - T40055-
Observe safety precautions ⇒ page 3 .
Observe rules for cleanliness ⇒ page 7 .
– Unclip crankcase breather -1- from cylinder head cover -2-.
– Remove coolant hose -3- from exhaust gas recirculation cool‐
er connection -4-.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
94
Rep. gr.15 - Cylinder head, valve gear
ht
rig
py
Co
t.
– Pull connector -2- off fuel pressure sender - G247- -1-.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Removing
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unscrew bolts -2- for fuel line -1-.
– Remove vacuum hose -2- from toothed belt guard -1-.
– Open clips -arrows- and remove toothed belt guard -1-.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
– Pull vacuum hose -arrow- off from cylinder head cover.
Disconnecting fuel return lines
•
After disconnecting, check the 4 catches -arrow- to see
whether they are fractured or have broken off.
•
Always replace damaged fuel return lines.
•
A damaged fuel return line that becomes loose when en‐
gine is running causes damage to piezo injector. The
piezo injector must then be replaced.
r
te o
iva
r
rp
fo
g
n
Carefully pull fuel return lines upwards when disconnect‐
ing as the 4 catches -arrow- can fracture.
do
c
um
en
•
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Caution
1. Cylinder head
95
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– With engine switched off, carefully pull return line connections
off at piezo injectors. To do this, press the two clips downwards
-arrow A- and, at the same time, pull the release bolt upwards
-arrow B-.
– Pull all fuel return lines -1- off piezo injectors.
ility
ab
y li
an
pt
ce
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
– Release connectors -2- and pull them off piezo
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
injectors.
ir se
tee
o
h
t
or
u
ac
a
ss
– Unscrew union nuts -1- from piezo injectors.
– Ensure cleanliness. No dirt must be allowed to get into the
disconnected fuel return lines or the open connections on the
piezo injectors.
– Unscrew bolts -2- from high-pressure accumulator (fuel rail).
– Pull cable guide -3- from high-pressure accumulator (fuel rail).
AG.
Prote
cted
by
Rep. gr.15 - Cylinder head, valve gear
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
96
ht
rig
py
Co
t.
– Pull fuel hose -3- from high-pressure accumulator (fuel ail)
-4-.
thi
sd
o
cu
m
en
– Unclip connector -2- and pull off from fuel pressure regulating
valve - N276- -1-.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Remove high-pressure accumulator (fuel rail) -1-. Guide highpressure accumulator (fuel rail) past fuel return line and fuel
lines.
– Ensure cleanliness. No dirt may get into the injector holes on
the cylinder head cover.
– Remove injectors ⇒ page 327 .
– Unscrew cylinder head cover bolts in the sequence -6 … 1and remove cylinder head cover.
Installing
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
ility
ab
y li
an
pt
ce
un
le
Installation is carried out in the reverse order; note the following:
– Tighten bolts in the sequence -1 … 6-.
– Apply a thin coating of diesel fuel to the new O-rings on the
return-line connections.
ht
rig
py
Co
t.
r
fo
ng
– Connect fuel return line and press the two clips downwards as
far as they will go -arrows-.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
– Hand-tighten cylinder head cover in the sequence -1 … 6-.
1. Cylinder head
97
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– After fuel return line has been pushed on completely, press
the locking bolt downwards -arrow-.
– First, fit top part of toothed belt guard to middle -1- of toothed
belt guard from the rear.
– Then, fit toothed belt guard to middle -2- and -3- of toothed belt
guard at the top.
To prevent the high-pressure pump from running while it is empty
and to ensure that the engine starts quickly after parts have been
renewed, it is important to observe the following:
♦ If components of the fuel system between the fuel tank and
the high-pressure pump are removed or renewed, it is neces‐
sary for the fuel system to be bled. To do this, perform the Volkswa
gen AG
AG.
does
“Bleeding fuel system” function using the ⇒ Vehiclesdiagnostic
agen
k w
not
l
o
V
tester ⇒ page 316 .
gu
y
b
a
d
se
ran
tee
or
ac
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
♦ ⇒ “1.2 Assembly overview - cylinder head cover”, page 81
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Rep. gr.15 - Cylinder head, valve gear
thi
sd
o
cu
m
en
98
ht
rig
py
Co
t.
Specified torques
ility
ab
y li
an
pt
ce
ri
♦ This process takes 130 seconds. Fuel pumps
are actuated a
ho
ut
a
total of 3 times in the process. The process
must
not be ter‐
s
s
minated prematurely.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
1.5
Removing and installing injector seals
Special tools and workshop
equipment required
♦ Lambda probe open ring
spanner set - 3337♦ Tool set - T10055♦ Assembly tool - T10208/2♦ Torque wrench - V.A.G
1331♦ Tool set - T10133♦ Oil seal extractor - T 40195-
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
♦ Injector remover - T40402-
ht
rig
py
Co
t.
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
Observe safety precautions ⇒ page 4 .
thi
sd
o
cu
m
en
Removing
1. Cylinder head
99
AG.
Prote
cted
by
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Observe rules for cleanliness ⇒ page 8 .
Disconnecting fuel return lines
Caution
–
•
Carefully pull fuel return lines upwards when disconnect‐
ing as the 4 catches -arrow- can fracture.
•
After disconnecting, check the 4 catches -arrow- to see
whether they are fractured or have broken off.
•
Always replace damaged fuel return lines.
•
A damaged fuel return line that becomes loose when en‐
gine is running causes damage to piezo injectors. The
piezo injector must then be replaced.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
With engine switched
off, carefully pull return line connections
nte
ise
r
o
eo
h
off at piezoutinjectors. To do this, press the two clips downwards
ra
a
c
s
-arrow Aand,
at
the
same
time,
pull
the
release
bolt
upwards
s
pe
rm
itte
d
un
le
ility
ab
y li
an
pt
ce
-arrow B-.
– Remove noise insulation at injectors.
Caution
You must therefore proceed very carefully in order to avoid
unnecessary assembly work or further damage.
Ensure cleanliness. No dirt may get into the injector holes on
the cylinder head cover.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Rep. gr.15 - Cylinder head, valve gear
ht
rig
py
Co
t.
100
do
c
um
en
r
te o
iva
r
rp
fo
g
n
First remove leaked oil or fuel with workshop equipment.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– Remove only piezo injectors of which injector seal is to be re‐
newed.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Position puller - T10055- with puller - T10402- -1- and -2- as
shown and pull piezo injectors out upwards by tapping with
head of sliding hammer.
– Screw oil seal extractor - T40195- forcibly as far as possible
into seal by hand.
Pull injector seal out upwards by tapping using oil seal extractor
- T40195- , adapter - T101333/2- and slide hammer - T10133/3- .
– After removal, check whether the spring washer is still on the
old seal.
If not, check that spring washer does not remain in injector shaft.
Installing
Installation is carried out in the reverse order; note the following:
Caution
You must therefore proceed very carefully in order to avoid
unnecessary assembly work or further damage.
Remember that the cylinder head cover is made of plastic.
A plastic cylinder head cover is damaged easily during repairs.
Check cylinder head cover for damage.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
in to stop
using
assem‐
nte
is
r
o
eo
h
ut
ra
a
c
s
s
– Initially position new injector seal by hand.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
– Apply a thin coating of diesel fuel to the new O-rings on the
return-line connections.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Connect fuel return line and press the two clips downwards as
far as they will go -arrows-.
do
c
um
en
ht
rig
py
Co
t.
– Then carefully push new injector seal
bly tool - T10208/2- .
1. Cylinder head
101
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– After fuel return line has been pushed on completely, press
the locking bolt downwards -arrow-.
To prevent the high-pressure pump from running while it is empty
and to ensure that the engine starts quickly after parts have been
renewed, it is important to observe the following:
♦ If components of the fuel system between the fuel tank and
the high-pressure pump are removed or renewed, it is neces‐
sary for the fuel system to be bled. To do this, perform the
“Bleeding fuel system” function using the ⇒ Vehicle diagnostic
tester ⇒ page 316 .
♦ This process takes 130 seconds. Fuel pumps are actuated a
total of 3 times in the process. The process must not be ter‐
minated prematurely.
1.6
Removing and installing vacuum pump
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1410-
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
♦ Hose clip pliers - VAS 6340-
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
AG.
Prote
cted
by
Rep. gr.15 - Cylinder head, valve gear
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
102
do
c
um
en
The vacuum pump may, under no circumstances, be disman‐
tled as the vacuum part could otherwise malfunction. This
would result in the failure of the brake servo.
ht
rig
py
Co
t.
DANGER!
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Removing
– Place cloths under vacuum pump -1-.
– Pull vacuum line -2- off vacuum pump -1-.
– Unscrew bolts -arrows- for vacuum pump -1-.
– Remove vacuum pump -1- from cylinder head.
Installing
Installation is carried out in the reverse order; note the following:
Note
♦ Ensure that vacuum pump coupling seats properly in cam‐
shaft.
♦ The vacuum pump has been correctly seated in camshaft if it
is lying completely against the cylinder head.
♦ The seal must be renewed.
– Install vacuum pump -1- and tighten securing bolts -arrows-.
– Connect brake servo vacuum line -1- to vacuum pump.
Specified torques
AG do
es n
ot g
ua
ran
tee
or
ac
pe
rm
itte
d
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Checking compression
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
1.7
ss
agen
ksw
Vol
y
b
ed
ris
o
h
t
au
ility
ab
y li
an
pt
ce
un
le
♦ ⇒ “1.1 Assembly overview - cylinder head”,
page 78
AG. Volkswagen
Special tools and workshop equipment required
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
♦ Jointed spanner - 3220-
1. Cylinder head
103
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Compression tester - V.A.G 1763- with adapter - V.A.G
1763/8-
♦ Torque wrench (5…50 Nm) - V.A.G 1331Test prerequisite
•
Engine oil temperature min. 30 °C.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
Procedure:
r
o
eo
h
t
u
ra
c
s a the injectors.
– Pull connectors soff
– Screw in adapter - V.A.G 1763/8- in place of the glow plugs.
– Check compression using compression tester - V.A.G 1763- .
Using compression tester ⇒ operating instructions .
– Start engine until tester shows no further pressure increase.
Compression pressures:
New: 25…31 bar
Wear limit: 19 bar
Maximum permissible difference between all cylinders: 5 bar
– Install glow plugs with U/J extension and 10 mm socket - 3220⇒ page 405 .
AG.
Prote
cted
by
Rep. gr.15 - Cylinder head, valve gear
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
104
ht
rig
py
Co
t.
r
fo
ng
– Read engine control unit event memory ⇒ Vehicle diagnostic
tester.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
– Remove glow plug from relevant cylinder using U/J extension
and 10 mm socket - 3220- ⇒ page 405 .
ility
ab
y li
an
pt
ce
un
le
Test procedure
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2
Toothed belt drive
⇒ “2.1 Assembly overview - toothed belt drive”, page 105
⇒ “2.2 Removing and installing toothed belt”, page 107
2.1
Assembly overview - toothed belt drive
1 - Toothed belt
❑ Mark direction of rota‐
tion before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing and installing
⇒ page 107 .
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
3 - Crankshaft toothed belt pul‐
ley
8 - Bolt
❑ 20 Nm +45°
9 - Camshaft pulley
11 - Bolt
❑ 100 Nm
12 - Hub
❑ Use counterhold tool - T10051- to loosen and tighten.
❑ To remove, use puller - T10052- .
❑ Removing and installing ⇒ page 85 .
thi
sd
o
cu
m
en
10 - Bolt
❑ 20 Nm
AG.
7 - Tensioning roller
agen
lksw
Vo
by
6 - Nut
❑ 20 Nm +45°
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
5 - Idler roller
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
4 - Nut
❑ 20 Nm
ht
rig
py
Co
t.
2 - Bolt
❑ Renew after removing
❑ Use counterhold tool 3415- to loosen and
tighten.
❑ Do not additionally oil or
grease the threads and
shoulder.
❑ Turning further can be
done in several stages.
❑ 120 Nm + 90°
13 - Rear toothed belt guard
14 - Bolt
❑ 20 Nm
15 - Bolt
❑ Renew after removing
2. Toothed belt drive
105
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
❑ 10 Nm
16 - Idler roller
un
le
pe
rm
itte
d
ility
ab
y li
an
pt
ce
17 - Bolt
❑ Renew after removing
❑ 50 Nm + 90°
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
18 - Idler roller
20 - Nut
❑ 95 Nm
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
19 - Hub
❑ Use counterhold tool - T10051- to loosen and tighten.
❑ To remove, use puller - T40064- .
❑ Removing and installing ⇒ page 347 .
22 - Bolt
❑ Renew after removing
❑ 23 Nm
23 - Coolant pump
❑ Removing and installing ⇒ page 187
28 - Bolt
❑ Renew after removing
❑ 10 Nm + 90°
29 - Belt pulley and vibration damper
❑ Assembly through offset holes only possible in one position
❑ Removing and installing ⇒ page 44
106
Rep. gr.15 - Cylinder head, valve gear
AG.
27 - Bolt
❑ Renew after removing
❑ 10 Nm
agen
lksw
Vo
by
26 - Toothed belt guard lower part
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
25 - Toothed belt guard upper part
ht
rig
py
Co
t.
24 - Bolt
❑ 15 Nm
do
c
um
en
r
te o
iva
r
rp
fo
g
n
21 - Toothed belt pulley on high-pressure pump
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2.2
Removing and installing toothed belt
Special tools and workshop
equipment required
♦ Locking pin - 3359♦ Crankshaft stop - T10050♦ Counterhold tool - T10172♦ Special wrench, long reach
- T10264-
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
r
fo
ng
ht
rig
py
Co
t.
♦ Torque wrench (5…50 Nm) - V.A.G 1331-
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
♦ Locking tool - T10265-
agen
lksw
Vo
by
2. Toothed belt drive
107
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Torque wrench (40…200 Nm) - V.A.G 1332-
Removing
Note
Whenever adjustment work is done on toothed belts, it must be
performed only when the engine is cold, as the indicator position
on the tensioning element varies depending on the engine tem‐
perature.
AG. Volkswagen AG d
agen
oes
w
– Remove underbody guard, if fitted ⇒ GeneralVbody
olks repairs,
exterior; Rep. gr. 66 ; Underbody guard .sed by
– Remove poly V-belt ⇒ page 40 .
ri
ho
ut
a
ss
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
– Detach vacuum hose -2- from upper toothed belt guard -1-.
not
gu
ara
nte
eo
ra
c
– Open clips -arrows- and remove toothed belt guard -1-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Unscrew bolt -3- for bracket -1-.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Rep. gr.15 - Cylinder head, valve gear
do
c
um
en
108
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
. Volkswage AG to do this.
– Unscrew bolts -arrows-. Counterhold
gen AG at centralnbolt
d
wa
olks
oes
not
gu
ara
nte
eo
ra
c
ht
rig
py
Co
t.
r
fo
ng
– Remove lower toothed belt guard. To do this, unscrew bolts
-arrows-.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ss
e
ris
ho
t
au
ility
ab
y li
an
pt
ce
un
le
y V element.
– Relax poly V-belt tensioning
db
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
– Turn engine to TDC and lock crankshaft toothed belt pulley in
position with crankshaft stop - T10050- . To do this, push the
crankshaft stop into the teeth of the toothed belt pulley from
the latter's face side. The toothed segment of the camshaft
must be at the »12 o'clock position«.
Note
The markings on the crankshaft toothed belt pulley -2- and the
crankshaft stop - T10050- -1- must align. At the same time, the
pin of the crankshaft stop - T10050- must engage in the drilling in
the sealing flange.
The arrow on the camshaft pulley must be at almost »12 o'clock«.
– Mark direction of rotation of toothed belt.
2. Toothed belt drive
109
AG. Volkswagen A
G do
agen
es n
Amarok 2011 ➤
ksw
ot g
Vol
y
ua
b
4-cylinder diesel engine (2.0 l engine,
common
rail)
Edition
04.2013
d
ra
e
nte
eo
ra
c
ris
tho
u
a
locking
pin
ss
pe
rm
itte
d
un
le
ility
ab
y li
an
pt
ce
– Lock the camshaft hub with
- 3359- . To do this,
insert locking pin through outer free elongated hole into hole
in cylinder head.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– Loosen bolts -arrows- approx. 90°.
AG.
Prote
cted
by
110
Rep. gr.15 - Cylinder head, valve gear
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
– Turn eccentric of tensioning roller anti-clockwise -arrow- using
socket - T10264- , until the tensioning roller can be locked with
locking tool - T10265- .
ht
rig
py
Co
t.
– Loosen belt tensioner securing nut -1-.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
– Loosen bolts -2- approx. 90° for high-pressure pump toothed
belt pulley using bit XZN 10 - T10385- .
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Now turn tensioning roller eccentric clockwise -arrow- onto
stop and tighten securing nut -1- hand-tight.
– First remove toothed belt from camshaft pulley and then from
the other pulleys.
Installing
Installation is carried out in the reverse order; note the following:
Prerequisites
•
Ignition switched off.
•
Engine must be cold.
•
Tensioning roller must be locked with locking tool - T10265and secured at right stop.
•
Crankshaft locked in position with crankshaft stop - T10050- .
Note
♦ Whenever adjustment work is done on toothed belts, it must
be performed only when the engine is cold, as the indicator
position on the tensioning element varies depending on the
engine temperature.
♦ Renew securing bolts for camshaft pulley and high-pressure
pump pulley.
♦ If necessary, turn camshaft hub until it can be secured in po‐
sition with counter-hold tool - T10172- and adapters T10172/4- . To do this, hand-tighten at least one securing bolt
-1-.
– Lock the camshaft hub with locking pin - 3359- . To do this,
insert locking pin through outer free elongated hole into hole
in cylinder head.
. Volkswagen AG
gen AG
does
not
gu
ara
nte
eo
ra
c
r
fo
ng
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ht
rig
py
Co
t.
y
db
ise
r
tho
au
s
s
ility
ab
y li
an
pt
ce
un
le
– Loosen the hand-tightened bolts again. Volkswa
2. Toothed belt drive
111
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Turn hub of high-pressure pump at bolt heads with screwdriver
until it can be secured in position with diesel injection pump
locking pin - 3359- .
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Lock high-pressure pump hub with diesel injection pump lock‐
ing pin - 3359- . To do this, push locking pin into adjustment
hole outside toothed belt pulley.
– Turn camshaft pulley and toothed belt pulley of high-pressure
pump in their elongated holes clockwise to stop.
– Fit toothed belt to crankshaft toothed belt pulley, tensioning
roller, camshaft pulley, toothed belt pulley of coolant pump and
toothed belt pulley of high-pressure pump.
– Finally, place toothed belt onto idler roller.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Note
Ensure that belt tensioner seats correctly in rear toothed belt
guard -arrow-.
– Carefully turn belt tensioner eccentric clockwise using angle
driver - T10264- until indicator -2- is slightly above middle of
gap in base plate. The base plate corrects itself when preten‐
sion is applied.
Ensure that securing nut -1- does not turn as well.
– Hold tensioning roller in this position and tighten securing nut
of tensioning roller.
112
Rep. gr.15 - Cylinder head, valve gear
ht
rig
py
Co
t.
– Undo the fastening nuts of the tensioning roller and pull out
locking tool - T10265- .
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Fit counterhold - T10172- as shown. Press counter-hold tool T10172- in direction of arrow and keep camshaft pulley in
pretensioning position.
– In this position, tighten securing bolts -1- of camshaft pulley
and those of toothed belt pulley for high-pressure pump.
– Remove diesel injection pump locking pin - 3359- and crank‐
shaft stop - T10050- .
– Turn crankshaft at least two full rotations in engine direction of
rotation and set to slightly before TDC No. 1 cylinder.
– Place crankshaft stop - T10050- on the crankshaft toothed belt
pulley again.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Note
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
– Now turn crankshaft in engine direction of rotation until crank‐
shaft stop pin -arrow- engages in sealing flange whilst turning.
During the following checking procedure, only the camshaft and
crankshaft must be secured in position. It is very difficult to find
the securing position of the high-pressure pump hub again. How‐
ever, a slight deviation -arrow- does not influence the engine
operation.
– Check whether:
♦ Camshaft hub can be locked with locking pin - 3359- .
♦ Tensioning roller indicator is centred or maximum 5 mm to
right of base plate notch.
If camshaft hub cannot be locked:
r
fo
ng
– Pull crankshaft stop - T10050- back until pin uncovers hole.
– Twist crankshaft out at little above TDC by turning it in the
opposite direction of engine rotation.
ht
rig
py
Co
t.
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
– Now turn crankshaft slowly in direction of engine rotation until
camshaft hub can be secured in position.
AG.
– After locking, loosen securing nuts of crankshaft toothed belt
pulley.
If pin of crankshaft stop - T10050- is standing on left next to hole:
2. Toothed belt drive
113
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Turn crankshaft in engine direction of rotation until crankshaft
stop pin engages in sealing flange whilst turning.
– Tighten securing bolts of camshaft toothed belt pulley.
If pin of crankshaft stop - T10050- is standing on right next to hole:
– Turn crankshaft a little in direction opposite to engine direction
of rotation.
– Turn crankshaft in engine direction of rotation until crankshaft
stop pin arrow engages in sealing flange whilst turning.
– Tighten securing bolts of camshaft toothed belt pulley.
Continuation
– Remove locking pin - 3359- and crankshaft stop - T10050- .
– Turn crankshaft at least 2 rotations in engine direction of ro‐
tation and set again to TDC no. 1 cylinder.
– Repeat measurement.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
– If camshaft hub can be secured in position, tighten
bolts as follows:
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
securing
ss
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
♦ Camshaft pulley: tighten bolts. Counterhold with counterhold
- T10172- and adapters - T10172/4- .
♦ High-pressure pump pulley: tighten bolts. Counterhold with
counterhold - T10172- and adapters - T10172/8- .
– Install toothed belt guard - lower part.
– Install vibration damper/belt pulley.
– First, fit top part of toothed belt guard to middle -1- of toothed
belt guard from the rear.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Rep. gr.15 - Cylinder head, valve gear
ht
rig
py
Co
t.
114
do
c
um
en
– Then, fit toothed belt guard to middle -2- and -3- of toothed belt
guard at the top.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Secure toothed belt guard -3- with clips -arrows-.
– Clip vacuum hose -2- into upper toothed belt guard -1-.
– Tighten bolt -3- for bracket -1-.
– Install poly V-belt ⇒ page 40 .
– Install underbody guard, if fitted previously ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody guard .
Specified torques
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 105
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
do
c
um
en
2. Toothed belt drive
115
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
3
Fresh air supply system, belt drive
⇒ “3.1 Assembly overview - fresh air supply system”, page 116
⇒ “3.2 Removing and installing blower for fresh air supply sys‐
tem”, page 117
⇒ “3.3 Removing and installing air filter housing for fresh air sup‐
ply system”, page 117
⇒ “3.4 Removing and installing bracket for fresh air supply sys‐
tem”, page 118
3.1
Assembly overview - fresh air supply system
1 - Heat shield
❑ For air filter housing.
2 - Bolt
❑ 6 Nm
11 - Rubber sleeve
❑ Qty. 2.
❑ To air filter
❑ To toothed belt guard
13 - Bracket
14 - Air filter housing
❑ Removing and installing
⇒ page 117 .
❑ ⇒ ETKA (Electronic
Parts Catalogue)
15 - Bolt
❑ 6 Nm
116
Rep. gr.15 - Cylinder head, valve gear
thi
sd
o
cu
m
en
12 - Nut
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
10 - Bolt
❑ 6 Nm
Prote
cted
by
9 - Bracket
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
8 - Blower
❑ Removing and installing
⇒ page 117 .
AG.
7 - Hose clip
agen
lksw
Vo
by
6 - Spring-type clip
ility
ab
y li
an
pt
ce
5 - Hose
c
o
p
yri
gh
t
.
C
op
yi
4 - Bolt
❑ 6 Nm
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
ht
rig
py
Co
t.
3 - Air filter bracket
❑ Removing and installing
⇒ page 118 .
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
3.2
Removing and installing blower for fresh
air supply system
Removing
pe
rm
itte
d
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– Remove blower for fresh air supply system
Installing
Installation is carried out in the reverse order; note the following:
♦ ⇒ “3.1 Assembly overview - fresh air supply system”,
page 116
r
te o
iva
r
rp
fo
g
n
c
o
p
yri
gh
t.
C
op
yi
Removing
– Unscrew bolts -arrows- and remove heat shield -1-.
do
c
um
en
Removing and installing air filter hous‐
ing for fresh air supply system
ht
rig
py
Co
t.
3.3
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
– Loosen screw-type clip -1- and then remove bolts -arrowsfrom bracket.
ility
ab
y li
an
pt
ce
un
le
– Disconnect electrical connector -2-. Release clip -1- and de‐
tach hose.
3. Fresh air supply system, belt drive
117
agen
lksw
Vo
by
AG.
Prote
cted
by
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Loosen screw-type clip -arrow-, and remove air filter housing.
Installing
Installation is carried out in the reverse order; note the following:
♦ ⇒ “3.1 Assembly overview - fresh air supply system”,
page 116
3.4
Removing and installing bracket for
fresh air supply system
Removing
– Remove air filter housing ⇒ page 117 .
– Detach blower for fresh air supply system ⇒ page 117 .
– Release wiring harness.
– Remove bolts -arrows- and remove bracket.
Installing
Install in reverse order. In the process, note the following:
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Rep. gr.15 - Cylinder head, valve gear
ht
rig
py
Co
t.
118
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
♦ ⇒ “3.1 Assembly overview - fresh air supply system”,
page 116
Amarok 2011 ➤
4-cylinder diesel engine
(2.0
l
engine,
common
rail)
Edition 04.2013
k
s
l
w
o
a
V
g
.
e
G
n
AG
en A
4
Valve gear
s
ag
ksw
Vol
y
b
ed
ris
o
h
t
au
does
not
gu
ara
nte
eo
ra
c
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
s
⇒ “4.1 Assembly overview - valve gear”,
page 119
⇒ “4.2 Measuring axial clearance of camshaft”, page 121
⇒ “4.3 Measuring radial clearance of camshafts”, page 122
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
⇒ “4.4 Removing and installing camshafts”, page 123
⇒ “4.5 Removing and installing camshaft oil seal”, page 129
⇒ “4.6 Checking hydraulic compensation element”, page 131
⇒ “4.7 Renewing valve stem seals”, page 132
4.1
Assembly overview - valve gear
Note
♦ Cylinder heads with cracks between the valve seats may be
used without reducing engine life, provided the cracks are
small and not more than 0.5 mm wide.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
♦ When cylinder head is renewed, the coolant must be com‐
agen
lksw
Vo
by
AG.
pletely renewed as well.
ht
rig
py
Co
t.
not be removed until immediately before fitting cylinder head.
do
c
um
en
♦ The plastic packing pieces for protecting the open valves must
4. Valve gear
119
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2 - Bolt
❑ Observe sequence
when loosening and
tightening ⇒ page 121 .
❑ 10 Nm
3 - Retaining frame
❑ Seal with silicone seal‐
ant ⇒ Electronic Parts
Catalogue (ETKA) .
4 - Exhaust camshaft
❑ Removing and installing
⇒ page 123 .
agen
lksw
Vo
by
AG.
6 - Roller rocker finger
❑ Mark installation posi‐
tion.
❑ Do not interchange.
❑ Check roller bearing for
ease of movement.
❑ Oil contact surface.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
7 - Hydraulic compensation element
❑ Mark installation position.
❑ Lubricate contact surfaces before installing.
8 - Valve
❑ Do not rework. Only lapping in is permitted.
❑ Mark installation position for re-installation.
❑ Valve dimensions ⇒ page 136
❑ Checking valve guides ⇒ page 135 .
9 - Cylinder head
10 - Valve stem seal
11 - Valve spring
12 - Valve spring plate
13 - Valve cotter
14 - Cap
❑ Renew after removing
120
Rep. gr.15 - Cylinder head, valve gear
ht
rig
py
Co
t.
r
fo
ng
5 - Inlet camshaft
❑ Removing and installing
⇒ page 123 .
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
ility
ab
y li
an
pt
ce
1 - Seal
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip.
❑ Before installing, re‐
move residual oil from
Volkswagen AG
camshaft journal usingswaagen AG.
does
k
not
l
o
V
clean cloth.
gu
y
ara
db
e
nte
is off
r
❑ To install, mask
o
eo
h
t
ra
groove onaucamshaft
tap‐
c
s
s
er (e.g. using
Sellotape)
❑ Removing and installing
⇒ page 129 .
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Retaining frame - tightening sequence
Undoing the frame
– Unscrew bolts of support frame in sequence -24…1-.
Tightening
– First, tighten bolts of support frame hand-tight in sequence
-1….24-.
– Tighten retaining frame bolts in sequence -1…24-.
n AG. Volkswagen AG do
es n
ot g
ua
ran
tee
or
ac
age
Measuring axial clearance of camshaft
ksw
Vol
do
c
um
en
un
le
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
♦ Dial gauge - VAS 6079-
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
♦ Universal dial gauge bracket - VW 387-
ility
ab
y li
an
pt
ce
by
ed
ris
o
th
au
ss
Special tools and workshop equipment required
ht
rig
py
Co
t.
4.2
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Procedure
– Remove retaining frame ⇒ page 121 .
4. Valve gear
121
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Fasten dial gauge - VAS 6079- to cylinder head with universal
dial gauge bracket - VW 387- as shown in the illustration.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
Axial clearance of inlet and outlet camshafts:
•
Specification: 0.048…0.118 mm.
•
Wear limit: 0.17 mm.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
ility
ab
y li
an
pt
ce
Measuring radial clearance of cam‐
shafts
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
4.3
Special tools and workshop equipment required
♦ Plastigage
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Procedure
– Remove roller rocker finger.
– Remove bearing cap and clean crankshaft journal.
– Place a length of Plastigage corresponding to the width of the
bearing on the journal to be measured or into the bearings.
•
Plastigage must lie in the middle of the bearing.
– Fit retaining frame and tighten without rotating camshafts
⇒ page 121 .
– Remove retainer frame.
– Compare width of Plastigage with the measurement scale.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Rep. gr.15 - Cylinder head, valve gear
ht
rig
py
Co
t.
122
do
c
um
en
Radial clearance: 0.035 … 0.085 mm.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
4.4
Removing and installing camshafts
Special tools and workshop
equipment required
♦ Diesel injection pump lock‐
ing pin - 3359♦ Counterhold tool - T10051♦ Puller - T10052♦ Camshaft fitting tool T40094♦ Camshaft clamping tool T40095♦ Camshaft fitting tool T40096-
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
♦ Torque wrench - V.A.G 1331/-
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
thi
sd
o
cu
m
en
4. Valve gear
123
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Torque wrench - V.A.G 1332/-
olksw
agen AG
en AG. V
♦ Silicone adhesive sealant ⇒ Electronic Parts
(ET‐
does
wagCatalogue
not
olks
KA)
V
gu
by
Removing
or
ac
un
le
ility
ab
y li
an
pt
ce
– Remove fuel filter ⇒ page
ara
nte
e
ed
ris
ho
t
au
ss .
239
pe
rm
itte
d
– Removed toothed belt from camshaft and high-pressure pump
⇒ page 107 .
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– Remove cylinder head cover ⇒ page 93 .
– Unscrew and remove bolts -arrows- for toothed belt and cam‐
shaft.
– Counterhold hub with counter-hold tool - T10051- and release
hub securing bolt -1-.
AG.
Prote
cted
by
Rep. gr.15 - Cylinder head, valve gear
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
124
ht
rig
py
Co
t.
– Unscrew hub securing bolt approx. 2 turns.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
– Remove camshaft pulley from hub.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Position puller - T10052- and align with hub holes.
– Tighten securing bolts -1-.
– Apply tension to hub by evenly tightening puller -2- until hub
separates from taper of camshaft.
Note
Hold puller with a spanner 30 mm whilst doing this.
– Remove hub from taper of camshaft.
– Remove vacuum pump ⇒ page 102 .
– Unscrew retaining frame securing bolts in sequence -24…1-.
– Remove retaining frame.
– Carefully remove camshafts.
Installing
Installation is carried out in the reverse order; note the following:
Note
un
le
Camshafts may only be installed with camshaft fitting tool T40094- as described below. Otherwise the axial bearings in
the retaining frame will be destroyed and the cylinder head
must be replaced.
Make sure that no sealant residues get into the cylinder head
or the bearings.
– Remove remaining sealant and from cylinder block and re‐
taining frame using, for example, a rotating plastic brush.
– Clean sealing surfaces. They must be free of oil and grease.
– Oil running surfaces of both camshafts.
Set up camshaft fitting tool - T40094- for camshafts as follows:
AG.
Prote
cted
by
If the supports of the camshaft fitting tool - T40094- are not yet
marked, mark the removed supports, e.g. with number stamps,
so they can be fitted in the original positions later.
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
Note
ht
rig
py
Co
t.
r
fo
ng
– Remove supports -T40094/3-, -T40094/4- and -T40094/5from base plate (bolted from underneath).
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Caution
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
Seal contact surface between retaining frame and cylinder
ot g
o head
yV
ua
b
d
ran
using silicone adhesive sealant ⇒ Electronic Parts Catalogue
ir se
tee
o
(ETKA) .
h
t
or
u
ac
a
ss
4. Valve gear
125
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Install supports -T40094/9- and -T40094/10- instead at vacant
outer positions.
– Place support -T40094/2- at position “A” and support
-T40094/1- at position “F”.
– First insert inlet camshaft as shown. Ensure that indentation
-arrow- for cylinder head bolt faces »outwards«.
– Position 0.50 mm feeler gauge and push support -T40094/8into inlet camshaft groove.
– Insert exhaust camshaft and lock via groove -arrow- with
-cover T40094/11-.
– Position clamping tool - T40096/1- on exhaust camshaft pul‐
leys.
Caution
The exhaust camshaft tensioning roller has been discontinued
n AG. Volkswagen AG do
es n
wage
⇒ Electronic Parts Catalogue (ETKA) .
o
olks
t gu
ara
nte
eo
ra
c
V
by
– Tension camshaft fitting tool - T40096/1- with knurled wheel
until teeth flanks align. If necessary, use a 13 mm open-ended
spanner to assist.
– Slide exhaust camshaft towards inlet camshaft until teeth en‐
gage.
– Place retaining frame on camshafts.
r
fo
ng
All camshaft bearings must be seated on the camshafts.
agen
lksw
Vo
by
AG.
Rep. gr.15 - Cylinder head, valve gear
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
126
ht
rig
py
Co
t.
•
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
ility
ab
y li
an
pt
ce
ed
In the case of exhaust camshafts with tensioning roller,risensure
ho on the
that the clamping jaw marked with an arrow is seated
t
au
wider gear.
ss
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Position camshaft fitting tool - T40095- as shown, thereby fix‐
ing camshafts in position in retaining frame.
– Remove cover - T40094/11- .
– Pull support - T40094/8- out of inlet camshaft groove.
– Cut off nozzle on tube at front marking (∅ of nozzle approx.
2 mm).
pe
rm
itte
d
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Note
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
ility
ab
y li
an
pt
ce
un
le
– Apply beads of sealant (approx. 2…3 mm wide) -arrows- onto
clean sealing surfaces of cylinder head as illustrated.
Sealant beads must not be thicker than specified, otherwise ex‐
cess sealant could enter the camshaft bearings.
– Install new cap ⇒ Item 14 (page 120) flush on cylinder head.
– Remove camshafts from camshaft fitting tool - T40095- to‐
gether with retaining frame and camshaft fitting tool - T40094- .
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
– Carefully insert camshafts and retaining frame into cylinder
head.
4. Valve gear
127
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– First tighten securing bolts of retaining frame hand-tight in se‐
quence -1….24-.
•
The retaining frame should make contact with the cylinder
head over the complete surface.
– Tighten retaining frame bolts to final torque in the sequence
-1…24-.
– Remove camshaft fitting tool - T40095- and clamping tool T40096/1- .
– Renew camshaft seal ⇒ page 129 .
Note
♦ After installing camshafts wait for approx. 30 minutes before
starting engine. The hydraulic compensation elements must
settle (otherwise valves will strike pistons).
♦ After working on valve gear, carefully crank engine at least 2
revolutions by hand to ensure that no valves make contact on
starting.
– Fit hub on camshaft.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
– Push camshaft pulley onto hub.
Note
The toothed segment -arrow- of the camshaft belt pulley must be
on top.
AG.
Prote
cted
by
Rep. gr.15 - Cylinder head, valve gear
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
128
ht
rig
py
Co
t.
r
fo
ng
– Insert securing bolts -1- by hand without play to camshaft pul‐
ley.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
– Tighten securing bolt -1- of hub. Use counter-hold tool T10051- to do this.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Lock hub with diesel injection pump locking pin - 3359- .
– Install toothed belt and adjust valve timing ⇒ page 107 .
– Install vacuum pump ⇒ page 102 .
– Install cylinder head cover ⇒ page 93 .
– Install fuel filter.
Specified torques
♦ ⇒ “4.1 Assembly overview - valve gear”, page 119
♦ ⇒ “1.2 Assembly overview - cylinder head cover”, page 81
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 105
4.5
Removing and installing camshaft oil seal
Special tools and workshop
equipment required
♦ Fitting tool - 10 - 203♦ Oil seal extractor - 3240♦ Torque wrench - V.A.G
1331♦ Torque wrench - V.A.G
1332♦ Bolt M12 x 1.5 x 65
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Removing
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
– Remove camshaft pulley and hub ⇒ page 123 .
ht
rig
py
Co
t.
agen
lksw
Vo
by
4. Valve gear
do
c
um
en
– Removed toothed belt from camshaft and high-pressure pump
⇒ page 107 .
129
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Insert thrust piece - 3240/1- into camshaft.
– Unscrew inner part of oil seal extractor - 3240- 2 turns (approx.
3 mm) from the outer part and lock in position with the knurled
screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against camshaft
until oil seal is pulled out.
Installing
Installation is carried out in the reverse order; note the following:
Note
The oil seal sealing lip must not be additionally oiled or greased.
– Remove oil residues from crankshaft journal with a clean cloth.
olkswagen AG
en AG. V
does
not
gu
ara
nte
eo
ra
c
– Fit guide sleeve - 3240- onto camshaft as shown in illustration. olkswag
V
by
ed
– Carefully slide oil seal -1- over guide sleeve onto camshaft.
ris
ility
ab
y li
an
pt
ce
tho
au
s
s
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
– Carefully place seal onto camshaft.
– Press in oil seal with press piece of fitting tool - 10 - 203- and
bolt M12 × 1.5 x 65 as far as stop.
– Install camshaft pulley and hub ⇒ page 107 .
– Install toothed belt and adjust the valve timing ⇒ page 107 .
Specified torques
♦ ⇒ “1.2 Assembly overview - cylinder head cover”, page 81
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Rep. gr.15 - Cylinder head, valve gear
ht
rig
py
Co
t.
130
thi
sd
o
cu
m
en
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 105
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
4.6
Checking hydraulic compensation ele‐
ment
Special tools and workshop equipment required
♦ Feeler gauges
Note
♦ The hydraulic compensation elements cannot be repaired.
♦ Irregular valve noise during starting is normal.
Procedure:
– Start engine and run until the radiator fan has switched on
once.
– Increase engine speed to about 2500 rpm for 2 minutes (per‐
form road test if necessary).
– If the hydraulic compensation elements are still noisy, find out
which is the defective compensation element as follows:
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is cam
Turn crankshaft by the bolt for the toothed belt wheel until
r
o
eo
h
ut
of supporting element to be tested is facing upwards.
ra
a
c
s
s
– Remove cylinder head cover ⇒ page 93 .
–
pe
rm
itte
d
un
le
ility
ab
y li
an
pt
ce
– Press roller rocker finger downwards -arrow- to check clear‐
ance between cam and roller rocker finger.
ht
rig
py
Co
t.
agen
lksw
Vo
by
4. Valve gear
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– If a 0.20 mm feeler gauge can be inserted between cam and
roller rocker finger, replace hydraulic compensation element.
131
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
4.7
Renewing valve stem seals
pe
rm
itte
d
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
♦ Valve stem seal puller 3364-
ility
ab
y li
an
pt
ce
♦ 10 mm jointed spanner 3220-
un
le
Special tools and workshop
equipment required
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
♦ Valve stem seal fitting tool 3365-
Prote
cted
by
– Place guide plate - VAS 5161/23- onto cylinder head.
– Secure guide plate on intake manifold side with knurled screw
- VAS 5161/12- and tighten it hand-tight to studs using M6
collarless nuts -1-.
– Screw sealing bolts - VAS 5161/10- into the guide plate.
132
Rep. gr.15 - Cylinder head, valve gear
AG.
– Remove camshafts ⇒ page 123 .
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
– Remove all glow plugs using jointed spanner - 3220- .
⇒ page 405
ht
rig
py
Co
t.
Procedure
do
c
um
en
r
te o
iva
r
rp
fo
g
n
♦ Removal and installation
device for valve cotters VAS 5161 A- with guide
plate - VAS 5161/23- and
spacer ring - VAS
5161/23-1-
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Screw adapter - VAS 5161/11- hand-tight into the relevant
glow plug thread.
– Insert punch - VAS 5161/3- in the guide plate and use a plastic
hammer to knock loose the firmly seated valve cotters.
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
– Push spacer ring - VAS 5161/23-1- onto the assembly car‐
tridge - VAS 5161/8- .
– Connect adapter - VAS 5161/11- to compressed air supply,
using a standard commercially available union and apply pres‐
sure continuously.
•
Minimum pressure: 6 bar
– Attach pressure fork - VAS 5161/2- to ratchet piece and press
assembly cartridge downwards.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
ht
rig
py
Co
t.
– Release pressure fork.
thi
sd
o
cu
m
en
– Move knurled screw backwards and forwards slightly. This
causes the valve cotters to be pressed apart and taken into
the assembly cartridge.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
– Screw attachment fork - VAS 5161/5- with ratchet piece VAS 5161/6- into guide plate .
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
c
o
p
yri
gh
t
.
C
op
yi
– Remove assembly cartridge with spacer ring, valve plate and
valve spring.
agen
lksw
Vo
by
Prote
cted
by
– Pull off valve stem seals using valve stem seal puller - 3364- .
4. Valve gear
133
AG.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Note
A plastic sleeve -A- is included with the new valve stem oil seals.
– Fit plastic sleeve -A- onto valve stem to prevent damage to
new valve stem oil seal -B-.
– Lightly oil sealing lip of valve stem seal.
– Push valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– If necessary, use a plastic head hammer to tap lightly on fitting
tool until valve stem oil seal is fitted to stop.
– Remove plastic sleeve.
– Insert valve spring and valve plate into cylinder head.
– If valve cotters have been removed from assembly cartridge ,
they need to be put into insertion device - VAS 5161/18- first.
Note
Larger diameter of valve cotters face upwards.
AG. Volkswagen AG d
agen
oes
ksw
– Press assembly cartridge onto insertion device from above
Vol
by
and pick up valve cotters.
d
se
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
ri
ho
ut
a
ss
not
gu
ara
nte
eo
ra
c
– Insert assembly cartridge - VAS 5161/8- into guide plate again.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Press pressure fork downwards and pull knurled screw up‐
wards, turning it clockwise and anticlockwise. This action will
install the valve cotters.
– Reduce pressure on pressure fork whilst pulling on knurled
screw.
Installation is carried out in the reverse order; note the following:
– Install glow plugs ⇒ page 405 .
– Install camshafts ⇒ page 123 .
Note
♦ Engine is not to be rotated for approx. 30 minutes after instal‐
least 2 rotations to ensure that none of the valves make con‐
tact when the starter is operated.
AG.
Prote
cted
by
Rep. gr.15 - Cylinder head, valve gear
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
134
ht
rig
py
Co
t.
♦ After working on the valve gear, turn the engine carefully at
do
c
um
en
ling camshafts. The hydraulic compensation elements must
settle (otherwise valves will strike pistons).
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
5
Inlet and exhaust valves
lkswag135
en AG
AG. Vopage
⇒ “5.1 Reworking valve
seats”,
do
agen
w
olks
V
⇒ “5.2 Checking
by valve guides”, page 135
ed
ris
tho dimensions”, page 136
⇒ “5.3 Valve
au
un
le
pe
rm
itte
d
Reworking valve seats
Note
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Valve seats must not be reworked due to the very small toleran‐
ces.
5.2
Checking valve guides
Special tools and workshop equipment required
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
♦ Dial gauge - VAS 6079-
do
c
um
en
r
te o
iva
r
rp
fo
g
n
♦ Universal dial gauge bracket - VW 387-
ht
rig
py
Co
t.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
ss
ility
ab
y li
an
pt
ce
5.1
es n
ot g
ua
ran
tee
or
ac
Test procedure
– Insert new valve in guide. The end of the valve stem must be
flush with the guide. On account of differing stem diameters,
only use inlet valve in inlet guide and exhaust valve in exhaust
guide.
– Determine rock. Wear limit: max. 1.3 mm
– Cylinder head must be renewed if rock exceeds wear limit.
5. Inlet and exhaust valves
135
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
5.3
Valve dimensions
Note
Valves must not be reworked. Only lapping-in is permitted.
mm
mm
mm
∠°
Exhaust valve
26.60
5.940
99.30
45
26.00
5.940
99.10
45
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
r
fo
ng
AG.
Rep. gr.15 - Cylinder head, valve gear
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
136
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
∅a
∅b
c
α
Inlet valve
ht
rig
py
Co
t.
Dimension
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
17 –
Lubrication
1
Sump, oil pump
⇒ “1.1 Assembly overview - sump, oil pump”, page
137
Volkswa
gen AG
does
not
gu
y
b
ara
d
e
nte
risoil pump”, page 146
installing
o
eo
h
t
u
ra
a
c
installing
oil pump, vehicles with balancer
ss
AG.
agen
ksw page 140
⇒ “1.2 Removing and installing oil sump”,
Vol
⇒ “1.3 Removing and
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
⇒ “1.6 Removing and installing oil level and oil temperature send‐
er G266 ”, page 147
⇒ “1.7 Removing and installing dipstick tube”, page 148
1.1
Assembly overview - sump, oil pump
Note
Renew cover in sump every time it is removed ⇒ ETKA (electronic
parts catalogue)
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
⇒ “1.5 Checking engine oil level”, page 147
ility
ab
y li
an
pt
ce
⇒ “1.4 Removing and
shaft module”, page 146
1. Sump, oil pump
137
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
pe
rm
itte
d
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Note
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
3 - Toothed belt for oil pump
❑ Check for damage.
❑ Replace if necessary.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
ility
ab
y li
an
pt
ce
2 - Sealing flange
❑ With seal.
❑ Must seat on dowel
sleeves.
❑ Insert with silicone seal‐
ant ⇒ Electronic Parts
Catalogue (ETKA) .
❑ Do not apply additional
oil or grease the sealing
lip of the oil seal.
❑ Before installing, re‐
move oil residue from
crankshaft journal using
a clean cloth.
❑ Removing and installing
⇒ page 48 .
un
le
1 - Bolt
❑ 15 Nm
♦ Belts which have been in use
longer can sag.
♦ This is not a fault and does not
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
6 - Guide tube
ht
rig
py
Co
t.
5 - Oil dipstick
❑ The oil level must not be above the max. mark!
❑ Markings ⇒ page 147 .
do
c
um
en
4 - Bolt
❑ 10 Nm
r
te o
iva
r
rp
fo
g
n
necessarily mean belt needs re‐
placing.
7 - Clip
8 - Dowel sleeves
9 - O-ring
❑ Renew after removing
10 - Bolt
❑ 15 Nm
11 - Oil pump with pressed-on toothed belt pulley
❑ With 12 bar pressure relief valve
❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
If toothed belt or oil pump have to be removed:
♦ Check oil pump for free movement
♦ It must be possible to turn toothed belt pulley easily
♦ Replace if tight/binding.
12 - Bolt
❑ 15 Nm
138
Rep. gr.17 - Lubrication
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
13 - Suction line
❑ Clean strainer if soiled.
14 - Baffle plate
15 - Bolt
❑ 15 Nm
16 - Bolt
❑ 15 Nm
17 - Oil sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant ⇒ Electronic Parts Catalogue (ETKA) .
Note
Renew cover in sump every time it
is removed ⇒ ETKA (electronic
parts catalogue)
❑ Removing and installing ⇒ page 140 .
18 - Bolt
❑ 15 Nm
21 - Bolt
❑ Only for vehicles compliant with emission standard EU 5.
❑ 10 Nm
22 - Oil level and oil temperature sender - G266❑ Only for vehicles compliant with emission standard EU 5.
❑ Black 3-pin connector
❑ Removing and installing ⇒ page 147 .
23 - Seal
❑ Only for vehicles compliant with emission standard EU 5.
❑ Renew after removing
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
26 - Oil spray jet
❑ For piston cooling.
ht
rig
py
Co
t.
25 - Bolt
❑ Insert without sealant.
❑ 27 Nm
r
fo
ng
24 - Oil level and oil temperature sender - G266- wiring harness
❑ Only for vehicles compliant with emission standard EU 5.
1. Sump, oil pump
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
20 - Oil drain plug
❑ Renew after removing
❑ 30 Nm
un
le
19 - Seal
❑ Renew after removing
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
139
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
1.2
Removing and installing oil sump
Special tools and workshop
equipment required
♦ 10 mm jointed spanner VAS 3185♦ Special wrench, long reach
- T10058♦ Torque wrench (5…50 Nm)
- V.A.G 1331♦ Used oil collection and ex‐
traction unit - V.A.G 1782-
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
♦ Support bracket - 10 - 222 A-
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Special tools and workshop equipment required
Rep. gr.17 - Lubrication
AG.
140
agen
lksw
Vo
by
Flat scraper
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Eye protection
ht
rig
py
Co
t.
Hand drill with plastic brush
do
c
um
en
Silicone sealant ⇒ Electronic Parts Catalogue (ETKA)
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Removing
– Remove underbody guard, if fitted ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody guard .
– Drain coolant ⇒ page 182 .
– Place used oil collection and extraction unit - V.A.G 1782- un‐
der engine and drain engine oil.
Note
♦ Observe environmental regulations for disposal.
♦ The following procedures are for the left side of the vehicle.
This procedure also applies for the right side of the vehicle.
– Remove bolt -1- and pull it out from anti-roll bar -3-.
– Remove bolts -2-.
– Remove anti-roll bar -3- to side.
Vehicles with four-wheel drive:
Note
When removing sump on a vehicle with four-wheel drive, bracket
for final drive must be removed to allow drive shaft to be pulled
downwards slightly. This is necessary to allow the sump to be
taken out later over the shaft.
– Unscrew bolt -arrow- from bracket -1-.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
– Unscrew bolts -arrows- and remove bracket -1- for final drive.
– Pull final drive downwards slightly.
thi
sd
o
cu
m
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Continuation for all vehicles:
1. Sump, oil pump
141
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Position engine with support bracket - 10 - 222 A- as shown
and take up weight of engine in installation position.
Note
The securing bolts for the assembly
wagen AG may only be re‐
. Volksmountings
gen AG with support
do
es n
moved if the engine isolksupported
bracket
- 10-222
swa
ot g
V
y
ua
A- !
db
r
an
tee
or
ac
– Unscrew bolts -3- for coolant pipe -2- at left assembly mount‐
ing and remove coolant pipe -2- from coolant hose -1-.
– Unscrew bolts -3- for engine support -1- on left and right -1-.
do
c
um
en
Caution
•
Nut -2- must not be loosened.
•
If nut -2- is loosened, engine mounting must subsequently
be renewed.
ht
rig
py
Co
t.
agen
lksw
Vo
by
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
♦ Engine mounting connection to engine support may only
be loosened if engine mounting is to be renewed.
AG.
– Unscrew bolts -1- from left engine mounting -A-.
142
Rep. gr.17 - Lubrication
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
e
ris
tho
u
a
ss
un
le
pe
rm
itte
d
– Unscrew bolts -1- from right engine mounting -A-.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Before lifting engine on vehicles with an air conditioner, pull elec‐
trical connection off air condition compressor otherwise it may be
damaged.
– Pull electrical connections off air conditioner compressor.
– Raise engine by 90 - 100 mm with support bracket - 10 - 222
A- and spindle - 10 - 222 A/10- -a-.
– Remove front anti-roll bar with coupling rods ⇒ Rep. gr. 40
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Note
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
Amarok 2011 ➤
common rail) - Edition 04.2013
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
4-cylinder
diesel
engine
(2.0
l
engine,
s
s
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
– Unclip coolant hose -1- from brackets -arrows- on bottom of
radiator and tie coolant hose -1- up slightly.
For vehicles compliant with emission standard EU 5.
– Pull electrical connector -arrow- off oil level and oil tempera‐
ture sender - G266- .
Continuation for all vehicles
– Turn crankshaft until recesses in dual-mass flywheel are visi‐
ble for unscrewing sump bolts.
Note
In vehicles without recesses in dual-mass flywheel, dual-mass
flywheel must be removed ⇒ page 54 .
1. Sump, oil pump
143
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Remove connecting bolts for sump and gearbox.
– Diagonally unscrew bolts of oil sump.
– Loosen sump with light blows of a rubber headed hammer if
necessary.
– Remove sump.
– Remove sealant remaining on crankcase with flat scraper.
WARNING
Wear eye protection.
– Remove sealant residues on oil sump using a rotating brush,
e.g. with a hand drill with a plastic brush attachment.
– Clean sealing surfaces. They must be free of oil and grease.
Installing
Installation is carried out in the reverse order; note the following:
Note
♦ Observe expiry date of sealing compound.
♦ Sump must be installed within 5 minutes of applying silicone
sealing compound.
– Cut off nozzle on tube at front marking (∅ of nozzle approx.
3 mm).
– Apply silicone sealant to clean sealing surface of sump as
shown. Sealant bead must be:
AG. Volkswagen A
G do
es n
ot g
ua
ran
tee
or
ac
ility
ab
y li
an
pt
ce
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
♦ Run bead along inner
agen
ksw
Vol
y
db
ise
or bolt holes -arrows-.
side thof
au
ss
Caution
Danger of blocking lubrication system with excess sealant.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Rep. gr.17 - Lubrication
do
c
um
en
144
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
♦ Do not apply sealant bead thicker than specified.
ht
rig
py
Co
t.
♦ 2…3 mm thick.
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
•
ility
ab
y li
an
pt
ce
– Apply bead of sealant onto
illustrated.
AG. Volkswagen AG d
agen
oes
ksw
not
l
Amarok
2011 ➤
o
V
gu
y
b
ara04.2013
d
4-cylinder diesel engine
(2.0
l
engine,
common
rail)
Edition
e
nte
s
ri
eo
tho
u
ra
a
c
s
clean sealing surface
of
sump
as
s
Thickness of sealant bead: 2…3 mm.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Note
♦ Take particular care when applying sealant bead at front and
rear of sealing flange -arrows-.
♦ Oil sump must be installed within 5 minutes after applying
sealant.
♦ When installing sump with engine removed, ensure that sump
is flush with crankcase at flywheel end.
AG.
– Secure anti-roll bar to subframe. Use new bolts. Tighten bolts
when vehicle is standing on its wheels in an unloaded condi‐
tion or when vehicle is raised and wheels are also in the empty
weight position ⇒ front suspension; Rep. gr. 40 .
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
– Tighten bolts between sump and gearbox.
ht
rig
py
Co
t.
– Tighten sump bolts.
thi
sd
o
cu
m
en
– Place oil sump in position and slightly tighten the sump--togearbox connecting bolts and all the oil sump bolts. Ensure
that sump is flush against intermediate plate and gearbox
flange.
Prote
cted
by
Note
♦ Renew cover in sump every time it is removed ⇒ ETKA (elec‐
tronic parts catalogue)
♦ Let sealing compound dry for approx. 30 minutes after instal‐
ling oil sump. Only then fill with engine oil.
– Install bracket on vehicles with four-wheel drive
– Carefully guide engine into engine mounting with support
bracket - 10 - 222 A- and secure engine to engine mounting
⇒ page 31 .
Specified torques
♦ ⇒ “1.1 Assembly overview - sump, oil pump”, page 137
Component
Specified torque
Anti-roll bar to coupling rod
Bolts between sump and gear‐
box.
110 Nm
40 Nm
1. Sump, oil pump
145
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
1.3
Removing and installing oil pump
Removing
– Remove sump ⇒ page 140 .
– Unscrew bolts -arrows- for oil pump -1- and baffle plate -2-.
– Remove baffle plate.
– Detach oil pump -1- from toothed belt.
Installing
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Renew O-ring.
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
Note
ility
ab
y li
an
pt
ce
Installation is carried out in the reverse order; note
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss following:
the
– Insert new dowel sleeves when oil pump has no dowel sleeves
-arrows- for centring oil pump.
– Check oil pump for ease of movement, turn toothed belt pulley
with one finger for this.
Note
♦ Renew sluggish oil pump.
♦ Renew damaged toothed belt.
Prote
cted
by
– Replenish engine oil and check oil level ⇒ page 147 .
Specified torques
♦ ⇒ “1.1 Assembly overview - sump, oil pump”, page 137
1.4
Removing and installing oil pump, vehi‐
cles with balancer shaft module
Removing
– Remove sump ⇒ page 140 .
Caution
Bolt on intermediate gear wheel must not be loosened.
146
Rep. gr.17 - Lubrication
AG.
– Install sump ⇒ page 140 .
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
– Fit oil pump with toothed belt pulley into toothed belt and tight‐
en along with baffle.
ht
rig
py
Co
t.
– Check toothed belt for oil pump.
thi
sd
o
cu
m
en
♦ The toothed belt can sag after long use, this is not a fault.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Remove circlip -1- with circlip pliers.
– Use a commercially available magnet to pull drive shaft -2- out
of oil pump -arrow-.
– Unscrew bolt -4- and detach suction line from oil pump.
– Remove bolts -3- and -5- and remove oil pump.
Installing
Installation is carried out in the reverse order; note the following:
Note
♦ Renew O-ring.
♦ Renew damaged or over-tensioned circlip.
♦ Circlip must lie in base of groove.
– Ensure both dowel sleeves are in place before installing oil
pump.
– Install sump ⇒ page 140 .
Specified torques
♦ ⇒ “1.1 Assembly
Checking engine oil level
Oil capacities:
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
With oil filter change: 7.0 l
Without oil filter change: 6.7 l
Engine oil specifications:
⇒ Maintenance ; Booklet 11
Markings on oil dipstick
Note
The oil level may be in area -d- due to the infiltration of fuel in the
engine oil as a result of unfavourable driving conditions after fill‐
ing. This is a perfectly normal and self-regulating characteristic.
It is not necessary to adjust the engine oil level.
1 - Min. mark
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
a - Oil level in min. mark area: replenish engine oil!
ht
rig
py
Co
t.
2 - Max. mark
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
1.5
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise - sump, oil pump”, page 137
r
overview
o
eo
h
t
u
ra
a
c
s
s
b - Oil level in middle range: can be topped-up with engine oil.
AG.
Prote
cted
by
c - Oil level in max. mark area: Do not replenish engine oil!
d - The oil level may be in this area as a result of particular driving
conditions.
1.6
Removing and installing oil level and oil
temperature sender - G266-
Removing
– Drain off engine oil.
1. Sump, oil pump
147
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
AG. Volkswagen AG d
agen
oes
ksw
– Disconnect connector
Vol-3-.
pe
rm
itte
d
Installation is carried out in the reverse order; note the following:
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– Replenish engine oil and check oil level ⇒ page 147 .
Specified torques
♦ ⇒ “1.1 Assembly overview - sump, oil pump”, page 137
Removing and installing dipstick tube
Removing
Observe general notes on the lubrication system ⇒ page 7
ht
rig
py
Co
t.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Observe rules for cleanliness when working on charge air system
⇒ page 8
agen
lksw
Vo
by
– Release and pull off connector -1- for intake air temperature
sender - G42- together with charge air pressure sender - G31-1-.
AG.
– Remove charge air pipe. Loosen clip -arrow- and pull hose
connection with charge air pipe -1- off throttle valve module J338- -2-.
148
Rep. gr.17 - Lubrication
do
c
um
en
r
te o
iva
r
rp
fo
g
n
1.7
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
– Renew self-locking bolts -1- and seal -2-.
ility
ab
y li
an
pt
ce
Installing
oil level and oil
not
gu
ara
nte
temperature
eo
ra
c
un
le
–
y
db
ise and remove
Unscrew boltshor-1t
sender - G266-item 4-.
au
ss
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Loosen clip -1- and pull charge air hose off charge air pipe.
Then remove bolt -2- and remove pipe -arrow-.
– Loosen lower attachment -arrow- for dipstick tube. Unclip wir‐
ing harness retainer from engine speed sender - G28- on tube
-1-.
– Remove nut -2-. Move wiring harness retainer aside. Then re‐
move bolt -1- and remove dipstick tube -arrow- .upwards.
Volkswag
Installing
Specified torques
ht
rig
py
Co
t.
r
fo
ng
♦ ⇒ “1.1 Assembly overview - sump, oil pump”, page 137
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Always renew O-ring on dipstick tube every time tube is removed.
ility
ab
y li
an
pt
ce
Note
the
en AG
does
not
gu
ara
nte
following:
eo
ra
c
un
le
Installation is carried out in
AG
agen
ksw
l
o
yV
db
ise
r
the hreverse
order; note
o
ut
a
ss
1. Sump, oil pump
149
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2
Oil filter, oil pressure switch
⇒ “2.1 Assembly overview - oil filter housing with engine oil cool‐
er”, page 150
⇒ “2.2 Removing and installing oil filter housing with engine oil
cooler”, page 151
⇒ “2.3 Removing and installing oil pressure switch F1 ”,
page 154
⇒ “2.4 Checking oil pressure switch F1 ”, page 156
⇒ “2.5 Checking oil pressure”, page 157
⇒ “2.6 Measure oil consumption”, page 157
2.1
Assembly overview - oil filter
G. Volkswagen AG d
n Ahousing
oes
wage
s
k
not
l
o
with engine oil cooler
gu
yV
b
ar
d
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
WARNING
an
tee
or
ac
e
ris
tho
u
a
ss
Do not lubricate rubber seals (11 and 14) with oil. Oil would
make the coolant seals swell up.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
1 - O-ring
❑ Renew after removing
2 - Cap
❑ 25 Nm
3 - O-ring
❑ Renew after removing
4 - O-ring
❑ Renew after removing
Rep. gr.17 - Lubrication
Prote
cted
by
150
AG.
9 - Engine oil cooler
❑ Observe general notes
on the lubrication sys‐
tem ⇒ page 7
❑ Ensure clearance to ad‐
jacent components.
❑ Coolant hose schematic
diagram ⇒ page 175 .
❑ Checking engine oil
cooler for leaks
⇒ page 159
❑ Removing and installing
engine oil cooler
agen
lksw
Vo
by
8 - Spreader clip
c
o
p
yri
gh
t
.
C
op
yi
7 - Bolt
❑ 10 Nm
ht
rig
py
Co
t.
6 - Guide tube
❑ Renew O-ring.
do
c
um
en
5 - Oil filter element
❑ Observe general notes
on the lubrication sys‐
tem ⇒ page 7
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
⇒ page 151 .
10 - Bolt
❑ 11 Nm
11 - Rubber seals
❑ Renew after removing
❑ May not be lubricated with oil
❑ Fit into lugs on engine oil cooler.
12 - Bolt
❑ Renew after removing
❑ Specified torques and installation sequence ⇒ page 151 .
13 - Oil filter bracket
❑ Ensure clearance to adjacent components.
❑ Removing and installing oil filter bracket ⇒ page 151 .
14 - Rubber seals
❑ Renew after removing
❑ May not be lubricated with oil
❑ Fit into lugs on oil filter bracket.
Oil filter bracket - specified torques and installation sequence
Note
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
s
i
r
First tighten upper left andholower right bolts.
eo
ut
ra
a
c
s
Screw in bolts hand-tight.
s
–
– Tighten bolts in 2 stages:
Stage
Bolts
Specified torque/turning further angle
-arrows-arrows-
in diagonal sequence, 14 Nm
turn 180° further using diagonal se‐
quence
2.2
Removing and installing oil filter housing
with engine oil cooler
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
1.
2.
ility
ab
y li
an
pt
ce
–
WARNING
Do not lubricate rubber seals (8 and 11) with oil. Oil would
make the coolant seals swell up.
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
Renew bolts for oil filter bracket.
ht
rig
py
Co
t.
2. Oil filter, oil pressure switch
151
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Special tools and workshop
equipment required
♦ Used oil collection and ex‐
traction unit - V.A.G 1782♦ Drip tray for workshop hoist
- VAS 6208♦ Hose clip pliers - VAS
6362-
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Removing
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
♦ Removal lever - 80 - 200-
– Remove underbody guard, if fitted ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody guard .
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Rep. gr.17 - Lubrication
ht
rig
py
Co
t.
152
do
c
um
en
r
te o
iva
r
rp
fo
g
n
– Drain coolant ⇒ page 182 .
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Remove oil filter element.
pe
rm
itte
d
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
– Loosen screw-type clip -2- and pull charge air pipe -1- off from
throttle valve module - J338- with throttle valve potentiometer
- G69- and intake manifold flap motor - V157- .
ility
ab
y li
an
pt
ce
un
le
Observe instructions for hose connections with screw-type clips
⇒ page 11 .
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
– Unscrew securing bolt -1- for charge air pipe.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
– Unscrew securing bolt from charge air pipe bracket -2- on
coolant pipe -1-.
2. Oil filter, oil pressure switch
153
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Pull oil dipstick out of guide tube -1- a little and undo bolt -2-.
– Press off expanding clip -3- using removal lever - 80 - 200- .
– Pull oil dipstick guide tube off cylinder block upwards and push
to side.
– Place drip tray for workshop crane - VAS 6208- under point of
separation.
– Remove coolant hose, loosen hose clip -1- for this.
– Place used oil collection and extraction unit - V.A.G 1782- un‐
der engine.
– Unscrew bolts -arrows- and remove oil filter bracket with en‐
gine oil cooler.
Installing
Installation is carried out in the reverse order; note the following:
Note
– Filling with coolant ⇒ page 182
♦ ⇒ “2.1 Assembly overview - oil filter housing with engine oil
cooler”, page 150
2.3
Removing and installing oil pressure
switch - F1-
AG.
Prote
cted
by
Rep. gr.17 - Lubrication
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
154
ht
rig
py
Co
t.
r
fo
ng
Special tools and workshop equipment required
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
Specified torques
ility
ab
y li
an
pt
ce
grease when installing.
un
le
♦
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
♦
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
Renew gaskets, seals and O-rings.
ise
r
o
eo
h
t
u
ra
a free of oil and
Hose unions and air intake pipes/hoses mustssbe
c
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Torque wrench (5…50 Nm) - V.A.G 1331-
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Removing
– Unscrew securing bolt -1- from right engine mounting -A- and
remove engine mounting.
– Unclip connector -2- on oil pressure switch - F1- .
– Unscrew oil pressure switch - F1- -B- from cylinder head using
articulated wrench, 24 mm - T40175- .
Collect escaping engine oil with cloths.
ht
rig
py
Co
t.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Installing
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Note
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
♦ Jointed wrench 24 mm - T40175-
Installation is carried out in the reverse order; note the following:
AG.
Specified torques
agen
lksw
Vo
by
– Tighten oil pressure switch - F1- .
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 78
2. Oil filter, oil pressure switch
155
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2.4
Checking oil pressure switch - F1-
Special tools and workshop
equipment required
♦ Oil pressure tester - V.A.G
1342♦ Voltage tester - V.A.G
1527/B♦ Auxiliary measuring set V.A.G 1594/C-
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
r
te o
iva
r
rp
fo
g
n
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
– Pull connector off oil pressure switch - F1- .
156
Rep. gr.17 - Lubrication
AG.
Engine oil temperature at least 80 °C (radiator fan must have
run once)
agen
lksw
Vo
by
•
ht
rig
py
Co
t.
Oil level OK, checking ⇒ page 147
do
c
um
en
•
Test procedure
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Test prerequisites
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
♦ Current flow diagram
⇒ Current flow diagrams,
Electrical fault finding and
Fitting locations
Amarok 2011 ➤
4-cylinder diesel engine
(2.0
l
engine,
common
rail)
Edition 04.2013
k
s
l
w
o
agen
AG. V
switch .
ility
ab
y li
an
pt
ce
–
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
–
AG do
n
es n
wage
ot g
olks
V
yand screw into oil pres‐
ua
Remove oil pressure switch - F1- -2b
ran
ed
s
i
tee
r
sure tester - V.A.G 1342- .
o
h
t
or
u
ac
a
Screw tester into oil filter bracket
in place of oil pressure
ss
– Connect brown wire -1- of tester to earth (-).
•
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
– Connect voltage tester - V.A.G 1527 B- to battery positive (+)
and oil pressure switch using cables from auxiliary test set V.A.G 1594 C- .
LED must not light up.
If the LED lights up:
– Replace oil pressure switch - F1If LED does not light up:
– Start engine and increase revolutions slowly.
From 0.30…0.60 bar the LED must light up, otherwise renew
oil pressure switch - F1- .
Checking oil pressure
Prerequisite
Oil pressure tester - V.A.G 1342- is connected ⇒ page 156 .
AG.
Prote
cted
by
– Increase engine speed further.
•
Oil pressure at idling speed: at least 0.6 bar (vehicles compli‐
ant with EU 4 standard: 1.2 - 2.1 bar).
•
Oil pressure at 2,000 rpm: at least 1.0 bar (vehicles compliant
with EU 4 standard: 1.6 - 2.1 bar).
•
Oil pressure at 3,700 rpm in the case of vehicles compliant
with EU 4 standard: 3.0 - 4.0 bar.
•
At higher engine speeds, the oil pressure must not exceed 5.0
bar.
agen
lksw
Vo
by
Test procedure
c
o
p
yri
gh
t
.
C
op
yi
•
thi
sd
o
cu
m
en
2.5
ht
rig
py
Co
t.
•
Note
In the case of vehicles compliant with the EU 4 standard, the oil
pressure at 2,000 rpm can be between 3.0 and 4.0 bar during the
first 1000 km.
If specification is not attained:
– Renew oil pump if necessary ⇒ page 146 .
Note
Mechanical damage, e.g. to bearings, could also be the cause for
oil pressure being too low.
2.6
Measure oil consumption
Special tools and workshop equipment required
♦ Vehicle diagnostic tester
Procedure
– Pull handbrake on.
2. Oil filter, oil pressure switch
157
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Manual gearbox: gear stick in neutral.
– Automatic gearbox: move selector lever to position “N”.
– Connect ⇒ Vehicle diagnostic tester.
– Switch ignition on.
olkswagen AG
en AG. V
nte
eo
ra
c
ris
ho
ut
a
ss
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Rep. gr.17 - Lubrication
ht
rig
py
Co
t.
158
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
does
ag
– Carry out program oOil
using
ksw consumption measurement
not
V l
gu
y
b
ara
⇒ Vehicle diagnostic
tester
and
follow
instructions.
d
e
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
3
ility
ab
y li
an
pt
ce
4-cylinder
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
Amarok
e o2011 ➤
h
t
u
ra
a
c
diesel
engine
(2.0
l
engine,
common
rail)
Edition
04.2013
s
s
Engine oil cooler
3.1
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
⇒ “3.1 Checking engine oil cooler for leaks”, page 159
Checking engine oil cooler for leaks
Special tools and workshop
equipment required
♦ Refractometer - T10007 A-
♦ Hose clamps up to 25 mm 3094-
agen
lksw
Vo
by
AG.
Prote
cted
by
♦ Drip tray - V.A.G 1306- or
drip tray - VAS 6208-
c
o
p
yri
gh
t.
C
op
yi
♦ Spring-type clip pliers VAS 5024 A-
thi
sd
o
cu
m
en
♦ Adapter for cooling system
tester - V.A.G 1274/8-
ht
rig
py
Co
t.
♦ Cooling system tester V.A.G 1274-
3. Engine oil cooler
159
. Volkswagen AG
gen AG
d
oes
wa
not
Amarok 2011 ➤
olks
gu
yV
b
ara
d
4-cylinder diesel engine (2.0
l
engine,
common
rail)
Edition
04.2013
e
n
is
•
Engine cold
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Test procedure
– Remove underbody guard, if fitted ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody guard .
– Drain coolant ⇒ page 182 .
– Loosen hose clip on engine oil cooler with spring-type clip pli‐
ers - VAS 5024- .
– Remove engine oil cooler with housing ⇒ page 151 .
Note
♦ Collect escaping coolant with drip tray - VAS 6208- .
♦ Collect leaking engine oil with an absorbent cleaning cloth, if
♦ Do not damage engine oil cooler housing when securing with
agen
lksw
Vo
by
AG.
Checking when removed
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
screw clamp.
– Secure housing with the old gasket on a suitable, flat, clean
surface using a suitable screw clamp -4-.
– Fit plug -2- to venting connection of expansion tank -1-.
– Fit coolant hose -3- to engine oil cooler -5- and to expansion
tank -1-.
– Fill expansion tank up to “max.” mark.
– Fit cooling system tester - V.A.G 1274- with adapter for cooling
system tester - V.A.G 1274/8- on coolant expansion tank-1-.
– Using hand pump on tester, build up a pressure of approx. 1.6
bar.
– Observe pressure drop on pressure gauge. A pressure drop
within 10 minutes is not permitted.
If pressure drops:
– Renew engine oil cooler ⇒ page 151 .
Install in reverse order. In the process, note the following:
– Renew seal for housing.
– Install underbody guard, if fitted previously ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody guard .
– Check coolant level and, if necessary, replenish
⇒ page 182 .
– Check engine oil level and, if necessary, replenish
⇒ page 147 .
160
Rep. gr.17 - Lubrication
ht
rig
py
Co
t.
necessary.
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Prerequisites:
ility
ab
y li
an
pt
ce
♦ Torque wrench - V.A.G
tee
or
ac
r
ho
ut
a
1331ss
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Balancer shaft module
⇒ “4.1 Assembly overview - balancer shaft
⇒ “4.3 Installing a new balancer shaft module”, page 165
⇒ “4.4 Installing a previously used balancer shaft module again”,
page 168
3 - Suction hose
❑ Clean strainer if soiled.
4 - Bolt
❑ 10 Nm
5 - O-ring
❑ Renew after removing
6 - Oil pump
❑ Before installing, check
that both dowel sleeves
for centring oil pump on
balancer shaft module
are fitted.
AG.
2 - Bolt
❑ 10 Nm
agen
lksw
Vo
by
1 - Oil sump
❑ Tightening sequence
⇒ page 163 .
❑ Removing and installing
⇒ page 140 .
r
fo
ng
Assembly overview - balancer shaft module
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
4.1
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
ility
ab
y li
an
pt
ce
⇒ “4.2 Removing balancer shaft module”, page 163
ht
rig
py
Co
t.
4
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
module”,
page 161
a
c
s
s
7 - Drive shaft for oil pump
8 - Circlip
❑ Must lie in base of
groove.
❑ Renew damaged or
over-tensioned circlip.
9 - Spur gear for balancer shaft
10 - Bolt
❑ Renew after removing
❑ 20 Nm + 90°
11 - Hub
❑ Renew after removing
❑ For intermediate gear wheel.
12 - Bolt
❑ Renew after removing
❑ 90 Nm + 90°
13 - Thrust washer
❑ Renew after removing
❑ For intermediate gear wheel.
❑ Note installation position ⇒ page 163 .
4. Balancer shaft module
161
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
14 - Intermediate gear wheel
❑ Renew after removing
❑ The new intermediate gear wheel has coating which wears down until the correct tooth backlash is at‐
tained.
Caution
When installing the inter‐
mediate gear wheel, en‐
sure that the thrust
washer is seated cor‐
rectly ⇒ page 163 .
❑ Installation position: Part number must be visible.
❑ Installing ⇒ page 165 .
15 - Thrust washer
❑ Renew after removing
❑ For intermediate gear wheel.
❑ Note installation position ⇒ page 163 .
❑ If necessary, attach to housing with grease when installing intermediate gear wheel.
16 - Spur gear for crankshaft
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
17 - Balancer shaft module
AG. Volkswagen AG d
❑ Removing ⇒ page 163
agen
oes
ksw
not
l
o
gu
❑ Installing new balancer shaft module
y V ⇒ page 165 .
b
ara
d
e
nte
s
i
r
❑ Reinstalling previously run balancer
shaft
module
⇒
page
168
.
o
eo
h
ut
ra
a
c module on cylinder block
❑ Before installing, check that
the
two
dowel
sleeves
for
centring
balancer
shaft
s
s
are fitted.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
18 - Bolt
❑ Renew after removing
❑ Note tightening sequence: installing new balancer shaft module ⇒ page 165 , reinstalling previously run
balancer shaft module ⇒ page 168 .
❑ M7 = 13 Nm + 90°
❑ M8 = 20 Nm + 90°
19 - Oil extraction pipe
23 - Bolt
❑ Tighten in stages and in diagonal sequence.
❑ Initial tightening torque: 5 Nm
❑ 15 Nm
25 - Oil drain plug
❑ Renew after removing
❑ With seal.
❑ 30 Nm
162
Rep. gr.17 - Lubrication
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
24 - Seal
❑ Permanently attached to drain plug.
thi
sd
o
cu
m
en
22 - Bolt
❑ 45 Nm
agen
lksw
Vo
by
21 - Bolt
❑ 40 Nm
ht
rig
py
Co
t.
20 - Bolt
❑ 10 Nm
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Oil spray jet and pressure relief valve
1-
Bolt with pressure relief valve, 27 Nm
2-
Oil spray jet (for cooling of pistons)
Thrust washer installation position
Caution
When installing intermediate gear wheel, make sure that thrust
washer -A- does not slip out of balancer shaft module inden‐
tations -arrows- and subsequently become jammed. If neces‐
sary, fix in place with grease on balancer shaft module.
Sump - tightening sequence
–
Initially tighten bolts -1 … 20- diagonally.
2.
Tighten bolts -arrows- securing sump to gearbox.
3.
Tighten bolts -1 … 20- diagonally in stages.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
4.2
ility
ab
y li
an
pt
ce
1.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
–
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
Renew bolts for oil sump.
b
d
ran
ir se
tee
o
h
t
or
Tighten bolts in diagonal sequence
in
3
stages
as
follows:
u
ac
a
ss
Removing balancer shaft module
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-
do
c
um
en
4. Balancer shaft module
163
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Crankshaft stop - T10050- for engines with round crankshaft
toothed belt pulley
Removing
– Pull oil dipstick out.
– Remove sump ⇒ page 140 .
–
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
The markings on the crankshaft toothed belt pulley -2- and the
crankshaft stop - T10050- -1- must align. At the same time, the
pin of the crankshaft stop - T10050- must engage in the drilling in
the sealing flange.
ility
ab
y li
an
pt
ce
Note
– Unscrew bolts in sequence -6 … 1- and remove balancer shaft
module together with oil pump.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Rep. gr.17 - Lubrication
ht
rig
py
Co
t.
164
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
–
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
Remove vibration damper ⇒ page
by 44 .
ara
d
e
nte
is
r
o
eo
h
Rotate crankshaft to TDCutand lock in position with crankshaft
ra
a
c
s
stop - T10050- .
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
4.3
Installing a new balancer shaft module
Special tools and workshop
equipment required
♦ Bits - T10099♦ Locking device - T10255-
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
ht
rig
py
Co
t.
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
♦ 14 mm tool insert - T10393-
4. Balancer shaft module
165
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - EditionA04.2013
G. Volkswagen
Note
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
♦ The spur gear drive of the balancer shaft module must be in‐
AG do
es n
ot g
ua
ran
tee
or
ac
ility
ab
y li
an
pt
ce
n
wage
olks
V
by
ed
ris
o
th
au
ss
stalled with correct tooth backlash.
♦ A coating is applied to the new intermediate gear wheel to set
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
the correct tooth backlash.
♦ Intermediate gear wheels that have a white point are partly
coated around the circumference. Intermediate gear wheels
without a white spot are fully coated around the circumference
♦ The coating is quickly worn away, as a result of which the tooth
backlash is set.
♦ For this reason a new balancer shaft module must always be
installed with a new intermediate gear wheel with special coat‐
ing.
♦ A white spot is positioned only on partly coated intermediate
gear wheel to ensure correct installation position.
♦ For intermediate gear wheels with coating around the com‐
♦ Bolts that are firmly tightened at a specified angle must be
c
o
p
yri
gh
t
.
C
op
yi
Crankshaft locked in position with crankshaft stop - T10050- .
Prote
cted
by
The threaded connection of the intermediate gear wheel must
be loosened to position the balancer shaft module. When doing
this, do not loosen the bolt fully to prevent that the thrust wash‐
er does not slip behind the intermediate gear wheel. Thrust
washer installation position ⇒ page 163
Note
For illustration purposes the following procedure is described with
sealing flange removed.
– Before positioning balancer shaft module on cylinder block,
loosen bolt -1- for intermediate gear wheel approx. 45°.
– Check to see whether both dowel sleeves are in place to cor‐
rectly position balancer shaft module on cylinder block.
– Place balancer shaft module on cylinder block.
Note
Take care not to damage coating on intermediate gear wheel.
166
Rep. gr.17 - Lubrication
AG.
Caution
agen
lksw
Vo
by
•
ht
rig
py
Co
t.
renewed.
thi
sd
o
cu
m
en
plete circumference the installation position is not relevant.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Fit bolts in sequence -1 … 6- and hand-tighten at first.
– Tighten bolts of balancer shaft module as follows:
2.
3.
5.
t gu
ara
nte
eo
ra
c
V
by
d
Tighten bolts -3- and -5- tori13
se Nm.
tho
u
Turn bolts -3- and -5- s90°
s a further with rigid spanner.
Tighten bolts -1 … 2-, -4- and -6- to 20 Nm.
Turn bolts -1 … 2-, -4- and -6- 90° further with rigid spanner.
ility
ab
y li
an
pt
ce
4.
n AG. Volkswagen AG do
age…
es n
w-1
Initially tighten bolts in the sequence
6- to 6 Nm.
o
olks
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
– Lock balancer shaft with locking device - T10255- . To do this,
turn balancer shaft if necessary.
Locking tool pin must engage in groove in balancer shaft when
doing this.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
•
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
1.
c
o
p
yri
gh
t.
C
op
yi
– Carefully fit gear wheel of balancer shaft onto balancer shaft.
While doing this, press intermediate wheel to one side slightly.
Note
♦ Ensure threaded holes in balancer shaft are central within
elongated holes of balancer shaft gear wheel.
♦ If elongated holes in balancer shaft gear wheel cannot be
aligned with the threaded holes, the balancer shaft gear wheel
must be turned further by a corresponding number of teeth and
must be mounted again.
– Securely tighten balancer shaft gear wheel -arrows-.
– Remove locking tool - T10255- .
4. Balancer shaft module
167
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
The following 3 procedures must be performed simultaneously
(2nd mechanic required):
– Press intermediate gear wheel -3- forcefully (with assistance
of a wooden rod if necessary) in -direction of arrow- into teeth
of drive gear wheel -2- and balancer shaft gear wheel -1(meshing together).
– When doing so, turn the balancer shaft gear wheel -1- slightly
in an anticlockwise direction.
– Firmly tighten bolt for intermediate gear wheel using bit T10099- and 14 mm tool insert - T10393⇒ Item 13 (page 161) .
– Remove crankshaft stop - T10050- .
Note
No backlash may be perceptible after installing intermediate gear agen AG. Volkswagen AG do
es n
w
wheel. This can be checked by hand using light force.
ot g
olks
yV
ua
ran
tee
un
le
pe
rm
itte
d
– Install sump ⇒ page 140 .
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Specified torques
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– Install belt pulley/vibration damper (replace securing bolts)
⇒ page 44
– Install poly V-belt ⇒ page 40 .
or
ac
ility
ab
y li
an
pt
ce
b
ed
ris
o
h
t In the proc‐
Further installation is carried out in the reverse order.
au
ess, note the following:
ss
♦ ⇒ “1.1 Assembly overview - sump, oil pump”, page 137
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 105
Installing a previously used balancer
shaft module again
Prote
cted
by
♦ If the previously used balancer shaft module is to be reinstalled
and neither has the drive gear wheel on crankshaft been re‐
newed nor has the crankshaft been removed, proceed as
follows. The intermediate gear wheel must also not have been
loosened.
♦ Renew bolts tightened through an additional specified angle.
168
Rep. gr.17 - Lubrication
AG.
c
o
p
yri
gh
t.
C
op
yi
Note
agen
lksw
Vo
by
If the bolt for the intermediate wheel has been removed, a new
intermediate wheel with coating must be installed and the hub
⇒ Item 11 (page 161) including bolt ⇒ Item 12 (page 161) and
thrust washer must be renewed. This also applies to replace‐
ment of the drive gear wheel on the crankshaft and to removal
of the crankshaft. Otherwise, the tooth backlash will be incor‐
rect. Procedure when installing ⇒ page 165 .
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Caution
ht
rig
py
Co
t.
4.4
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Lock balancer shaft with locking device - T10255- . To do this,
turn balancer shaft if necessary.
•
Locking tool pin must engage in groove in balancer shaft when
doing this.
– Check to see whether both dowel sleeves are in place to cor‐
rectly position balancer shaft module on cylinder block.
– Place balancer shaft module on cylinder block.
•
The intermediate gear wheel must mesh in the crankshaft
drive gear wheel when the balancer shaft is locked.
•
The intermediate gear wheel must have a slight tooth back‐
lash.
– Fit bolts in sequence -1 … 6- and hand-tighten at first.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
… 6- to
is 6 Nm.
r
o
eo
h
ut
ra
a
c
s
s
– Tighten bolts of balancer shaft module as follows:
Tighten bolts -3- and -5- to 13 Nm.
3.
Turn bolts -3- and -5- 90° further with rigid spanner.
4.
Tighten bolts -1 … 2-, -4- and -6- to 20 Nm.
5.
Turn bolts -1 … 2-, -4- and -8- 90° further with rigid spanner.
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
2.
– Remove crankshaft stop - T10050- .
Further installation is carried out in the reverse order. In the proc‐
ess, note the following:
– Install sump ⇒ page 140 .
– Install belt pulley/vibration damper (replace securing bolts)
⇒ page 44
Specified torques
♦ ⇒ “1.1 Assembly overview - sump, oil pump”, page 137
ht
rig
py
Co
t.
r
fo
ng
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 105
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
Initially tighten bolts in the sequence -1
ility
ab
y li
an
pt
ce
1.
agen
lksw
Vo
by
4. Balancer shaft module
169
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
5
Oil circuit
⇒ “5.1 Removing and installing oil supply line to turbocharger,
120 kW and 132 kW engines”, page 170
⇒ “5.2 Removing and installing oil pressure line to turbocharger 90 kW and 103 kW engine”, page 172
5.1
Removing and installing oil supply line
to turbocharger, 120 kW and 132 kW
engines
Special tools and workshop equipment required
♦ Support bracket - 10 - 222 A-
– Position engine with support bracket - 10o-lks222
A- as shown
wagen AG
.V
and take up weight of engine in
installation
position.
gen AG
does
a
w
s
The securing bolts for the assembly mountings may only be re‐
moved if the engine is supported with support bracket - 10-222
A- !
ility
ab
y li
an
pt
ce
ss
not
gu
ara
nte
eo
ra
c
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Removing
– Remove air filter housing ⇒ page 370 .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing starter .
– Remove right engine support ⇒ page 31 .
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Rep. gr.17 - Lubrication
ht
rig
py
Co
t.
170
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Note
olk
yV
db
e
ris
tho
au
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unbolt bracket -2- for oil supply line -1- from turbocharger.
ility
ab
y li
an
pt
ce
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
– Loosen banjo bolt -2- for oil supply line on lower turbocharger
-1-.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
un
le
– Loosen
-1-.
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
Vo oil supply line on upper turbocharger
yfor
ua
banjo bolt -2b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
– Unscrew bolt -2- for oil supply line bracket -1- through opening
on assembly mounting -3-.
5. Oil circuit
171
AG.
Prote
cted
by
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unscrew banjo bolt -2- for oil supply line -1-.
. Volkswagen AG
– Collect escaping oil with a cloth. kswagen AG
– Completely
Installing
does
not
gu
ara
nte
eo
ra
c
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Note
pe
rm
itte
d
un
le
Installation is carried out in the reverse order; note the following:
ility
ab
y li
an
pt
ce
ol
yV
d b line.
remove oil supply
e
ris
ho
ut
a
ss
Procedure must be adhered to, this ensures that the oil supply
line is installed stress-free.
– Renew seals, gaskets and self-locking nuts.
– Fit new double seal -2- onto the respective line connection
-1- and secure by screwing in the corresponding banjo bolt
-3-.
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Removing and
installing starter .
– Install charge air pipe ⇒ page 250 .
– Install air filter housing ⇒ page 368 .
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
♦ ⇒ “2.1 Removing and installing assembly mountings”,
page 31
♦ ⇒ “1.1 Assembly overview - charge air system”, page 250
AG.
♦ ⇒ “7.1 Assembly overview - air filter”, page 368
♦ ⇒ “2.1 Assembly overview - turbocharger, 120 kW and 132 kW
engines”, page 260
5.2
Removing and installing oil pressure line
to turbocharger - 90 kW and 103 kW en‐
gine
Special tools and workshop equipment required
♦ Support bracket - 10 - 222 A-
172
Rep. gr.17 - Lubrication
ht
rig
py
Co
t.
Specified torques
do
c
um
en
r
te o
iva
r
rp
fo
g
n
– Install right engine support ⇒ page 31 .
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Position engine with support bracket - 10 - 222 A- as shown
and take up weight of engine in installation position.
Note
The securing bolts for the assembly mountings may only be re‐
moved if the engine is supported with support bracket - 10-222
A- !
Removing
– Remove air filter housing ⇒ page 370 .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing starter .
– Remove right engine support ⇒ page 31 .
– Remove securing bolt -2-.
– Remove banjo bolts -1 and 3-.
– Collect escaping oil with a cloth.
Installing
ility
ab
y li
an
pt
ce
– Collect escaping oil with a cloth.
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
– Remove bolts -1- and remove oil pressure
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ra
line. aut
c
s
s
Note
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Installation is carried out in the reverse order; note the following:
Procedure must be adhered to, this ensures that the oil pressure
line is installed stress-free.
– Renew seals, gaskets and self-locking nuts.
thi
sd
o
cu
m
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
5. Oil circuit
173
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Fit new seals -2- onto the respective line connection -3- and
secure by screwing in the corresponding banjo bolt -1-.
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Removing and
installing starter .
– Install right engine support ⇒ page 31 .
– Install charge air pipe ⇒ page 250 .
– Install air filter housing ⇒ page 368 .
Specified torques
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
♦ ⇒ “2.1 Removing and installing assembly mountings”,
page 31
♦ ⇒ “1.1 Assembly overview - charge air system”, page 250
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
♦ ⇒ “7.1 Assembly overview - air filter”, page 368
♦ ⇒ “2.2 Assembly overview - turbocharger, 90 kW and 103 kW
engines”, page 264
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Rep. gr.17 - Lubrication
thi
sd
o
cu
m
en
174
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
19 –
Cooling
1
Cooling system, coolant
⇒ “1.1 Coolant hose schematic diagram”, page 175
⇒ “1.2 Assembly overview - coolant hoses”, page 178
⇒ “1.3 Checking cooling system for leaks”, page 180
⇒ “1.4 Draining and filling coolant”, page 182
1.1
Coolant hose schematic diagram
1.1.1
Coolant hose schematic diagram for vehicles with supplementary heater,
engine codes CDCA and CDBA
1 - Expansion tank
2 - Heat exchanger for heater
unit
3 - Union on rear of cylinder
head
❑ With coolant tempera‐
ture sender - G624 - Cylinder head
5 - Engine oil cooler
9 - Radiator
❑ Renew coolant after re‐
placing.
❑ Removing and installing
⇒ page 204 .
10 - Coolant pump
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
8 - Auxiliary heater
❑ Depending on equip‐
ment.
ility
ab
y li
an
pt
ce
7 - Circulation pump - V55❑ Assembly overview
⇒ page 189 .
❑ Removing and installing
⇒ page 200 .
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
6 - 4/2-way valve
❑ With thermostat.
❑ Can only be renewed
complete.
❑ Removing and installing
⇒ page 191 .
do
c
um
en
11 - Continued coolant circula‐
tion pump - V51❑ Removing and installing ⇒ page 198 .
ht
rig
py
Co
t.
agen
lksw
Vo
by
1. Cooling system, coolant
175
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
12 - Continued coolant circulation pump - V5113 - Radiator outlet coolant temperature sender - G8314 - Exhaust gas recirculation cooler
❑ Removing and installing ⇒ page 392 .
15 - Thermostat (Y-piece)
Coolant hose schematic diagram, vehicles with auxiliary heater, engine co‐
des CSHA and CNEA (emission standards EU 4 and EU 5)
7 - Circulation pump - V558 - Coolant pump
9 - Auxiliary heater
❑ Depending on equip‐
ment.
10 - 2-way valve for coolant
shut-off valve - N14711 - Radiator
❑ Renew coolant after re‐
placing
12 - Exhaust gas recirculation
cooler changeover valve N34513 - Continued coolant circula‐
tion pump - V5114 - Radiator outlet coolant
temperature sender - G8315 - Exhaust gas recirculation cooler
16 - Thermostat (Y-piece)
17 - Coolant temperature sender - G62-
Rep. gr.19 - Cooling
thi
sd
o
cu
m
en
6 - 4/2-way valve
❑ With thermostat.
❑ Can only be renewed
complete.
AG.
5 - Engine oil cooler
agen
lksw
Vo
by
4 - Cylinder head
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
3 - Union on rear of cylinder
head
❑ With coolant tempera‐
ture sender - G62-
ht
rig
py
Co
t.
2 - Heat exchanger for heater
unit
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
1 - Expansion tank
176
ility
ab
y li
an
pt
ce
1.1.2
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
16 - Coolant temperature sender - G62-
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
1.1.3
Coolant hose schematic diagram, vehicles with auxiliary heater, engine co‐
des CDBA and CNFA (emission standards EU 3, EU 4 and EU 5)
1 - Expansion tank
2 - Heat exchanger for heater
unit
3 - Union on rear of cylinder
head
❑ With coolant tempera‐
ture sender - G624 - Cylinder head
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise- V55Circulation pump
r
o
eo
h
t
u
ra
a
c
s
4/2-way valve
s
5 - Engine oil cooler
6-
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
7-
❑ With thermostat.
❑ Can only be renewed
complete.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
8 - Coolant pump
9 - Auxiliary heater
❑ Depending on equip‐
ment.
10 - 2-way valve for coolant
shut-off valve - N14711 - Radiator
❑ Renew coolant after re‐
placing
12 - Exhaust gas recirculation
cooler
do
c
um
en
1. Cooling system, coolant
177
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Assembly overview - coolant hoses
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
2 - Spring-type clip
❑ Hose clip pliers - VAS
6340- or hose clip pliers
- VAS 6362- are recom‐
mended for installation
of spring-type clips.
Prote
cted
by
8 - Coolant pipe
9 - Coolant line
❑ Coolant hose schematic
diagram ⇒ page 175 .
10 - Bolt
❑ 9 Nm
11 - Ball thermostat (4/2-way valve)
❑ Thermostat is installed in valve.
❑ Renew completely.
❑ Removing and installing ⇒ page 191 .
12 - O-ring
❑ Renew if damaged or leaking.
13 - Coolant pipe
14 - Coolant pipe
15 - Coolant line
❑ Coolant hose schematic diagram ⇒ page 175 .
16 - Coolant line
❑ Coolant hose schematic diagram ⇒ page 175 .
❑ Secured to top of radiator.
178
Rep. gr.19 - Cooling
AG.
7 - Y-thermostat
agen
lksw
Vo
by
6 - Connection
❑ Removing and installing
with coolant tempera‐
ture sender - G62⇒ page 196
c
o
p
yri
gh
t
.
C
op
yi
5 - T piece
❑ To heat exchanger
ht
rig
py
Co
t.
4 - Retaining clip
r
fo
ng
3 - Coolant line
❑ Coolant hose schematic
diagram ⇒ page 175 .
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
1 - Expansion tank
❑ Checking cooling sys‐
tem for leaks with cool‐
ing system tester V.A.G 1274- and adapt‐
er - V.A.G 1274/8⇒ page 180 .
❑ With coolant tempera‐
ture display sender G32- .
un
le
1.2
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
17 - Upper coolant hose
❑ Coolant hose schematic diagram ⇒ page 175 .
18 - Coolant hose
❑ Coolant hose schematic diagram ⇒ page 175 .
19 - Radiator
❑ Renew coolant after replacing
❑ Removing and installing ⇒ page 204 .
20 - Coolant hose at bottom with T piece
❑ Coolant hose schematic diagram ⇒ page 175 .
21 - Engine oil cooler
22 - Continued coolant circulation pump - V51❑ Removing and installing ⇒ page 198 .
23 - Retaining clip
24 - Radiator outlet coolant temperature sender - G83❑ Removing and installing ⇒ page 197 .
25 - Coolant line
❑ Coolant hose schematic diagram ⇒ page 175 .
26 - Exhaust gas recirculation cooler
❑ Removing and installing ⇒ page 392 .
27 - Bracket
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
28 - Coolant line
❑ Coolant hose schematic diagram ⇒ page 175 .
1. Cooling system, coolant
179
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
AG. Volkswagen AG d
agen (2.0 l engine,
oes
4-cylinder diesel
engine
common
rail) - Edition 04.2013
ksw
not
l
o
V
Checking cooling system for leaks
ility
ab
y li
an
pt
ce
ss
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
1.3
gu
ara
nte
eo
ra
c
by
ed
ris
o
th
au
Special tools and workshop
equipment required
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
♦ Cooling system tester V.A.G 1274 B♦ Adapter for cooling system
tester - V.A.G 1274/8♦ Adapter for cooling system
tester - V.A.G 1274/9-
do
c
um
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Test prerequisite
•
Engine is at operating temperature
•
Perform leakage test of cooling system using cooling system
tester - V.A.G 1274- and adapters adapter - V.A.G 1274/8- and
adapter - V.A.G 1274/9- .
Test sequence:
WARNING
Hot steam may escape when expansion tank is opened. Place
cloth over cap and open with caution.
– Open filler cap on coolant expansion tank.
– Screw adapter for cooling system tester - V.A.G 1274/8- into
coolant expansion tank.
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/8- .
180
Rep. gr.19 - Cooling
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Join connection piece - V.A.G 1274 B/1- to cooling system
tester - V.A.G 1274 B- using connecting hose supplied.
– Using hand pump on tester, build up a pressure of approx. 1.0
bar.
DANGER!
Risk of scalding! Before the cooling system tester - V.A.G 1274
B- is disconnected from the connecting hose or the connector
- V.A.G 1274 B/1- , reduction of the pressure is essential. To
do this, press pressure relief valve on cooling system tester V.A.G 1274 B- until pressure gauge displays value of »0«.
If pressure drops:
– Find leaks and rectify.
Check pressure relief valve in filler cap
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
– Screw cap into adapter for cooling system
1274/9- .
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
tester
s - V.A.G
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/9- .
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
– Join connection piece - V.A.G 1274 B/1- to cooling system
tester - V.A.G 1274 B- using connecting hose supplied.
– Using hand pump on cooling system tester, build up a pres‐
sure of approx. 1.6 bar.
The pressure relief valve must not open.
If the pressure relief valve opens prematurely:
– Renew cap.
– Increase pressure to over 1.6 bar.
The pressure relief valve must open.
If the pressure relief valve does not open:
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
1. Cooling system, coolant
thi
sd
o
cu
m
en
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
– Renew cap.
181
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
1.4
Draining and filling coolant
Special tools and workshop
equipment required
♦ Refractometer - T10007 A♦ Drip tray for workshop hoist
- VAS 6208♦ Hose clip pliers - VAS
6340♦ Cooling system charge unit
- VAS 6096♦ Adapter for cooling system
tester - V.A.G 1274/8-
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
WARNING
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Draining
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
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.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Rep. gr.19 - Cooling
thi
sd
o
cu
m
en
182
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
AG. Volkswagen AG d
oes
not
o
gu
yV
b
ara
d
e
Remove underbody
guard, if fitted ⇒ General body repairs,
nte
ris
o
eo
h gr. 66 ; Underbody guard .
exterior; Rep.
t
u
ra
a
c
ss
agen tank -1-.
– Open cap -2- on expansion
lksw
ility
ab
y li
an
pt
ce
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
–
– Remove spring-type clip -2- and pull lower coolant hose -1- off
radiator -3-.
Note
Observe environmental regulations for disposal.
Filling
ht
rig
py
Co
t.
r
fo
ng
Caution
c
o
p
yri
gh
t
.
C
op
yi
Only distilled water may be used for mixing with coolant addi‐
tives. The use of distilled water ensures optimum protection
against corrosion.
1. Cooling system, coolant
183
agen
lksw
Vo
by
AG.
Prote
cted
by
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Note
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic Parts Catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the engine.
♦ The correct coolant solution ratio helps prevent damage due
to freezing and corrosion as well as scaling. Moreover, the
boiling temperature is raised. Therefore, the cooling system
. Volkswagen AG
n AG
must be filled all year round with coolant
additive.
doe
wage
s no
t gu
ara
nte
s
i
r
gine reliability under heavy
eo
ho loads, particularly in countries with
t
u
ra
tropical climates. s a
c
s
ks
Vol
by
♦ Because of its higher boiling
ed point, the coolant improves en‐
♦ The coolant concentration must not be reduced by adding wa‐
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
ter even in warmer seasons and in warmer countries. The
coolant additive concentration must be at least 40 %.
♦ If a stronger anti-freeze mixture is necessary due to harsher
weather conditions, the coolant additive content can be in‐
creased. But only to 60 %, or the antifreeze protection will be
reduced again and the cooling effect will be impaired.
♦ ONLY refractometer - T10007 A- may be used for determining
current anti-freeze density.
♦ Read anti-freeze figures from respective scale for type of anti-
freeze added.
♦ Do not reuse old coolant.
Recommended mixture ratios:
Frost protection Coolant additive Coolant ad‐ Distilled wa‐
to
portion
ditive 3)
ter3)
5.0 l
6.25 l
7.5 l
6.25 l
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
40 %
50 %
3) The quantity of coolant can vary depending upon vehicle equipment.
AG.
Prote
cted
by
Procedure:
– Unscrew cap -2- from expansion tank -1-.
– Pull off coolant hose -3- on expansion tank -1-.
– Fill expansion tank -1- to capacity and reconnect coolant hose
-3-.
– Seal expansion tank -1- with cap -2-.
– Install underbody guard, if fitted previously ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody guard .
– Start engine and keep engine speed at approx. 2000 rpm until
radiator fan starts up.
184
Rep. gr.19 - Cooling
ht
rig
py
Co
t.
-25 °C
-36 °C
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
countries with Arctic climates, down to about -36 °C).
ility
ab
y li
an
pt
ce
♦ Frost protection must be guaranteed down to about -25 °C (in
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– 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.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
thi
sd
o
cu
m
en
1. Cooling system, coolant
185
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Rep. gr.19 - Cooling
ht
rig
py
Co
t.
186
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2
Coolant pump, regulation of cooling
system
⇒ “2.1 Assembly overview - coolant pump/ball thermostat (4/2way valve)”, page 187
⇒ “2.2 Assembly overview - Continued coolant circulation pump
V51 ”, page 188
⇒ “2.3 Assembly overview - circulation pump V55 ”, page 189
⇒ “2.4 Removing and installing coolant pump”, page 190
⇒ “2.5 Removing and installing 4/2-way valve with thermostat”,
page 191
⇒ “2.6 Removing and installing coolant temperature sender G62
”, page 196
⇒ “2.7 Removing and installing coolant temperature sender at ra‐
diator outlet G83 ”, page 197
⇒ “2.8 Removing and installing continued coolant circulation
pump V51 ”, page 198
⇒ “2.9 Removing and installing Y-thermostat”, page 199
⇒ “2.10 Removing and installing recirculation pump V55 ”,
page 200
2.1
Assembly overview - coolant pump/ball thermostat (4/2-way valve)
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a removing
after
c
s
s
1 - Cylinder block
ility
ab
y li
an
pt
ce
un
le
2 - O-ring
❑ Renew
4 - Ball thermostat (4/2-way
valve)
❑ Removing and installing
⇒ page 191 .
5 - O-ring
❑ Renew after removing
6 - Coolant pump
❑ Removing and installing
⇒ page 190 .
7 - Bolt
❑ 15 Nm
8 - Oil sump
ht
rig
py
Co
t.
r
fo
ng
9 - Bolt
❑ 15 Nm
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
3 - Bolt
❑ 15 Nm
2. Coolant pump, regulation of cooling system
187
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2.2
Assembly overview - Continued coolant circulation pump - V51-
1 - Coolant hose
❑ Return flow to exhaust
gas recirculation cooler
2 - Spring-type clip
3 - Bolt
❑ 4.5 Nm
4 - Bolt
❑ 1.2 Nm
5 - Bracket
❑ For continued coolant
circulation pump - V51- .
AG. Volkswagen AG d
❑ For continued coolant
agen
oes
ksw
not
l
o
V
circulation pump - V51gu
by
ara
d
wiring harness. rise
nte
tho
eo
ra
c
pe
rm
itte
d
un
le
ility
ab
y li
an
pt
ce
au circula‐
6 - Continued coolant
ss
tion pump - V51❑ Removing and installing
⇒ page 198 .
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Rep. gr.19 - Cooling
ht
rig
py
Co
t.
188
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
7 - Coolant hose
❑ Feed line from radiator
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2.3
Assembly overview - circulation pump - V55-
1 - Bracket
❑ Secured on left wheel
housing
2 - Bolt
❑ 8 Nm
3 - Rubber bush
4 - Circulation pump - V55❑ Removing and installing
⇒ page 200 .
5 - Spring-type clip
6 - Coolant hose
❑ To heater cooler.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
r
fo
ng
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
2. Coolant pump, regulation of cooling system
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
7 - Coolant hose
❑ From cylinder head
189
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2.4
Removing and installing coolant pump
Special tools and workshop
equipment required
♦ Refractometer - T10007 A♦ Drip tray for workshop hoist
- VAS 6208-
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
– Drain coolant ⇒ page 182 .
– Remove toothed belt ⇒ page 107 .
– Unscrew securing bolts -1- of coolant pump -2- and carefully
remove coolant pump.
Installing
Installation is carried out in the reverse order; note the following:
•
Always renew gaskets, seals and O-rings.
190
Rep. gr.19 - Cooling
AG.
– Remove underbody guard, if fitted ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody guard .
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Removing
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
♦ Spring-type clip pliers VAS 6362-
ht
rig
py
Co
t.
♦ Torque wrench - V.A.G
1331-
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
Insert coolant pump -2- into cylinder block and tighten
securing
ise
r
o
eo
h
t
bolts -1-.
u
ra
a
c
s
s
– Moisten new O-ring -3- with coolant.
ility
ab
y li
an
pt
ce
Note
Coolant pump sealing plug faces downwards.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
–
– Install toothed belt ⇒ page 107 .
– Replenish coolant ⇒ page 182 .
– Install underbody guard, if fitted previously ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody guard .
Specified torques
♦ ⇒ “2.1 Assembly overview - coolant pump/ball thermostat (4/2way valve)”, page 187
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 105
Removing and installing 4/2-way valve with thermostat
agen
lksw
Vo
by
AG.
Prote
cted
by
♦ Torque wrench (5…50 Nm)
- V.A.G 1331-
c
o
p
yri
gh
t.
C
op
yi
♦ Refractometer - T10007 A-
ht
rig
py
Co
t.
Special tools and workshop
equipment required
thi
sd
o
cu
m
en
2.5
♦ Hose clip pliers - VAS
6340-
2. Coolant pump, regulation of cooling system
191
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Special tools and workshop equipment required
♦ Support bracket - 10 - 222 A-
Removing
– Remove underbody guard, if fitted ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody guard .
Note
Thermostat is located within the 4/2-way valve and cannot be re‐
placed individually.
– Position engine with support bracket - 10 - 222 A- as shown
and take up weight of engine in installation position.
olksw
agen AG
AG. V
– Disconnect battery ⇒ Electrical
Rep.
gr. do27
gensystem;
es .
swa
not
gu
ara
nte
eo
ra
c
ility
ab
y li
an
pt
ce
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
– Unscrew securing bolts -3- for coolant pipe -2-.
– Remove coolant hose -1- at 4/2-way valve and lay aside.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Rep. gr.19 - Cooling
ht
rig
py
Co
t.
192
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
– Drain
olk
yV
d b182 .
coolant ⇒ page
e
ris
ho
ut
a
ss
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unscrew bolts -3- for left engine support -1-.
Caution
•
Nut -2- must not be loosened.
•
If nut -2- is loosened, engine mounting must subsequently
be renewed.
♦ Engine mounting connection to engine support may only
be loosened if engine mounting is to be renewed.
– Unscrew bolts -1- from left engine mounting -A-.
Note
Coolant pipe is still installed in illustration!
– Loosen screw-type clip -2- and pull charge air pipe -1- off from
throttle valve module - J338- with throttle valve potentiometer
- G69- and intake manifold flap motor - V157- .
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
– Unscrew securing bolt -1- for charge air pipe.
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
2. Coolant pump, regulation of cooling system
193
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unscrew securing bolt from charge air pipe bracket -2- on
coolant pipe -1-.
– Remove throttle valve module - J338- with throttle valve po‐
tentiometer - G69- and intake manifold flap motor - V157⇒ page 357 .
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐
ing and installing alternator .
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Loosen clamp for coolant pipe -4- and pull coolant pipe -4- out
at union -2-.
– Unscrew securing bolt -3- for coolant pipe bracket.
194
Rep. gr.19 - Cooling
AG.
– Loosen clamp for coolant hose -1- and pull off coolant hose
-1-.
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
– Remove oil filter bracket ⇒ page 151 .
do
c
um
en
– Remove coolant hoses -1- at coolant pipe branch-off -2-.
ht
rig
py
Co
t.
– Detach connector -1- for Hall sender - G40- .
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Pull heat shield -2- up slightly from coolant hose -1-.
– Loosen clamp -3- and pull coolant hose -1- off.
– Unscrew bolts -3- for coolant pipes -4- at cylinder block.
Note
b
ed
ris
o
th
au
ss
ara
nte
e
or
ac
– Pull coolant hoses off unions -A and C-.
– Pull coolant pipe out of connection -B-.
– Unscrew securing bolts -3- for 4/2-way valve -2-.
– Pull valve out of cylinder block and then to the left to separate
connection -C- from coolant pipe.
Installing
Installation is carried out in the reverse order; note the following:
Note
ht
rig
py
Co
t.
r
fo
ng
Renew gaskets and seals.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
. Volkswagen AG 4/2-way valve
Separate all electrical cableswarequired
gen AG to remove
does
s
k
not
l
o
and lay aside.
gu
yV
2. Coolant pump, regulation of cooling system
195
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– First position 4/2-way valve with connection -B- on coolant
pipe.
– Install 4/2-way valve.
– Screw in and tighten securing bolts -3-.
– Connect coolant hoses as follows:
♦ -A-: Bypass line to cylinder head
♦ -C-: Radiator return line
–
– Install underbody guard, if fitted previously ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody guard .
Specified torques
♦ ⇒ “2.1 Assembly overview - coolant pump/ball thermostat (4/2way valve)”, page 187
♦ ⇒ “5.1 Assembly overview - intake manifold”, page 354
2.6
Removing and installing coolant temper‐
ature sender - G62-
Special tools and workshop equipment required
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Removing
– Briefly open filler cap for coolant expansion tank in order to
reduce pressure in cooling system.
– Remove underbody guard, if fitted ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody guard .
– Drain coolant ⇒ page 182 .
Note
Place several cloths under the screw connection to absorb es‐
caping coolant.
196
Rep. gr.19 - Cooling
ht
rig
py
Co
t.
r
fo
ng
♦ Hose clip pliers - VAS 6362-
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
– Install alternator ⇒ Starter, current supply, CCS; Rep. gr. 27 ;
Removing and installing alternator .
ility
ab
y li
an
pt
ce
un
le
–
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
Fill cooling system ⇒ page d182
by .
ara
e
nte
is
r
o
eo
h
Install throttle valve module
- J338- with throttle valve poten‐
ut
ra
a
c
tiometer - G69- andssintake manifold flap motor - V157-
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Disconnect connector -2- at coolant temperature sender G62- -1-.
Note
Components for coolant temperature sender - G62- are difficult
to see. A small hand-held mirror is required to unscrew and insert
coolant temperature sender - G62- .
– Pull off retaining clip and pull coolant temperature sender G62- -1- out of union -3-.
Installing
Installation is carried out in the reverse order; note the following:
– Install coolant temperature sender - G62- with new O-ring on‐
ly.
– Replenish coolant ⇒ page 182 .
– Install underbody guard, if fitted previously ⇒ General body
. Volkswagen AG
gen AG
does
repairs, exterior; Rep. gr. 66 ; Underbody guard .
swa
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
Removing and installing coolant temper‐
ature sender at radiator outlet - G83-
not
gu
ara
nte
eo
ra
c
Special tools and workshop equipment required
♦ Hose clamps up to 25 mm - 3094-
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
thi
sd
o
cu
m
en
agen
lksw
Vo
by
AG.
Prote
cted
by
♦ Hose clip pliers - VAS 6362-
ht
rig
py
Co
t.
2.7
k
Vol
by
d
e
ris
tho
u
a
ss
c
o
p
yri
gh
t.
C
op
yi
Removing
– Briefly open filler cap for coolant expansion tank in order to
reduce pressure in cooling system.
– Place several cloths under the screw connection to absorb
escaping coolant.
2. Coolant pump, regulation of cooling system
197
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Detach connector -2- from radiator outlet coolant temperature
sender - G83- .-1-.
– Pinch off coolant hoses with hose clamps, up to 25 mm dia. 3094- .
– Pull off retaining clip -3- and pull radiator outlet coolant tem‐
perature sender - G83- out of union.
Installing
Installation is carried out in the reverse order; note the following:
– Check coolant level ⇒ page 182 .
n AG. Volkswagen A
G do
age
es n
Removing and installing continued
coolant circulation
pump - V51ksw
ot g
Vol
ua
ran
tee
pe
rm
itte
d
♦ Hose clamps up to 25 mm 3094-
by
ed
ris
o
th
au
ss
or
ac
ility
ab
y li
an
pt
ce
Special tools and workshop
equipment required
un
le
2.8
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
♦ Torque wrench (5…50 Nm)
- V.A.G 1331-
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Rep. gr.19 - Cooling
ht
rig
py
Co
t.
198
do
c
um
en
r
te o
iva
r
rp
fo
g
n
♦ Hose clip pliers - VAS
6362-
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Removing
– Remove underbody guard, if fitted ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody guard .
– Pinch off coolant hoses -1 and 4- with hose clamps, up to 25
mm dia. - 3094- .
– Remove coolant hoses -1 and 4- from continued coolant cir‐
culation pump - V51- . To do this, loosen spring-type clips.
– Collect escaping coolant with a cloth.
– Unscrew bolts -2- and remove continued coolant circulation
pump - V51- .
– Loosen clip -2- for wiring harness -1- at bracket -3-.
– Disconnect connector -4- at continued circulation coolant
pump - V51- .
Installing
Installation is carried out in the reverse order; note the following:
– Install continued coolant circulation pump - V51- -3- and se‐
cure with bolts -2-.
– Tighten bolts -2-.
. Volkswagen AG
– Secure coolant hoses -1 and 4- to continued
gen AG coolant circula‐
does
swa
k
not
l
o
tion pump - V51- -3- using spring-type
clips.
gu
yV
b
ed
ris circulation coolant pump - V51– Clip connector onto continued
ho
ut to bracket.
and secure wiring harness
a
s
ara
nte
e
– Install underbody guard, if fitted previously ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody guard .
pe
rm
itte
d
un
le
or
ac
ility
ab
y li
an
pt
ce
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– Check coolant level ⇒ page 182 .
Specified torques
♦ ⇒ “2.2 Assembly overview - Continued coolant circulation
pump V51 ”, page 188
2.9
Removing and installing Y-thermostat
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
Special tools and workshop equipment required
agen
lksw
Vo
by
2. Coolant pump, regulation of cooling system
199
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Hose clamps up to 25 mm - 3094-
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Removing
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
♦ Hose clip pliers - VAS 6340-
– Briefly open filler cap for coolant expansion tank in order to
reduce pressure in cooling system.
– Remove underbody guard, if fitted ⇒ Rep. gr. 66 .
– Detach coolant hoses with clamps up to 25 mm - 3094- .
– Open retainer -4-.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Installing
Installation is carried out in the reverse order; note the following:
Removing and installing recirculation
pump - V55-
Special tools and workshop equipment required
200
AG.
2.10
Rep. gr.19 - Cooling
agen
lksw
Vo
by
– Check coolant level ⇒ page 182 .
ht
rig
py
Co
t.
– Disconnect coolant hoses -2-, -3- and -6- from Y-thermostat.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
– Remove spring-type clip -1- with hose clip pliers - VAS 6340- .
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Hose clamps up to 25 mm - 3094-
♦ Hose clip pliers - VAS 6362-
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Briefly open filler cap for coolant expansion tank in order to
reduce pressure in cooling system.
– Place several cloths under circulation pump - V55- to absorb
escaping coolant.
– Separate connector -2- at circulation pump - V55- -1-.
– Pinch off coolant hoses -3- with hose clamps, up to 25 mm dia.
- 3094- at union.
– Release clamps with hose clip pliers - VAS 6362- .
– Unscrew bolt -4- and remove circulation pump - V55- -1- with
bracket.
Installing
Installation is carried out in the reverse order; note the following:
– Check coolant level ⇒ page 182 .
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Removing
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
ht
rig
py
Co
t.
2. Coolant pump, regulation of cooling system
201
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
3
Radiator, radiator fan
⇒ “3.1 Assembly overview - radiator/ radiator fan V7 ”,
page 202
⇒ “3.2 Assembly overview - radiator cowl and radiator fan V7 ”,
page 204
⇒ “3.3 Removing and installing radiator”, page 204
⇒ “3.4 Removing and installing radiator cowl with radiator fan V7
”, page 207
3.1
Assembly overview - radiator/ radiator fan - V7-
1 - Radiator upper mounting
2 - Radiator
❑ Renew coolant after re‐
placing
❑ Removing and installing
⇒ page 204 .
3 - Charge air cooler
pe
rm
itte
d
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
r
te o
iva
r
rp
fo
g
n
Prote
cted
by
12 - Bolt
❑ 4 Nm
13 - Breather line
❑ Coolant hose schematic diagram ⇒ page 175 .
❑ Secured to top of radiator.
202
Rep. gr.19 - Cooling
AG.
11 - Radiator cowl with radiator fan - V7❑ Removing and installing ⇒ page 207 .
agen
lksw
Vo
by
10 - Bolt
❑ 5 Nm
do
c
um
en
9 - Expansion tank
❑ Checking cooling sys‐
tem for leaks with cool‐
ing system tester V.A.G 1274- and adapt‐
er - V.A.G 1274/8⇒ page 180 .
❑ With coolant tempera‐
ture display sender G32- .
c
o
p
yri
gh
t
.
C
op
yi
8 - Bolt
❑ 5 Nm
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
7 - Connector
ility
ab
y li
an
pt
ce
6 - Cap
❑ Check using cooling
system tester - V.A.G
1274- and adapter for
cooling system tester V.A.G 1274/9- .
❑ Test pressure 1.4…1.6
bar
un
le
5 - Condenser
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
ht
rig
py
Co
t.
4 - Upper cowling
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
14 - Spring-type clip
❑ Hose clip pliers - VAS 6340- or hose clip pliers - VAS 6362- are recommended for installation of springtype clips.
15 - Bolt
❑ 1.2 Nm
16 - Bracket
❑ For continued coolant circulation pump - V51- .
17 - Bolt
❑ 4.5 Nm
18 - Continued coolant circulation pump - V5119 - Coolant hose
❑ Coolant hose schematic diagram ⇒ page 175 .
20 - Bracket
21 - Radiator outlet coolant temperature sender - G83❑ Coolant hose schematic diagram ⇒ page 175 .
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
agen
lksw
Vo
by
AG.
3. Radiator, radiator fan
thi
sd
o
cu
m
en
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
24 - Radiator lower mounting
ility
ab
y li
an
pt
ce
23 - Spring-type clip
ht
rig
py
Co
t.
22 - Bracket
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
203
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
3.2
Assembly overview - radiator cowl and radiator fan - V7-
1 - Radiator
2 - Radiator fan
3 - Bolt
❑ 5 Nm
4 - Bolt
❑ 5 Nm
5 - Locking lug
❑ Must be engaged in ra‐
diator.
6 - Radiator cowl
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Removing and installing radiator
Special tools and workshop equipment required
AG.
Rep. gr.19 - Cooling
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
204
ht
rig
py
Co
t.
♦ Socket set 1/4", 22-piece - VAS 5528-
thi
sd
o
cu
m
en
3.3
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Removing
– Remove bolts -2- for securing radiator to lock carrier -1-.
– Remove lock carrier ⇒ General body repairs, exterior; Rep.
gr. 66 ; Lock carrier .
– Drain coolant ⇒ page 182 .
– Remove radiator cowl ⇒ page 207 .
Observe instructions for hose connections with screw-type clips
⇒ page 11 .
– If fresh air supply system is present, partially remove
⇒ page 116 .
– Remove coolant hose -1- at radiator -3- and remove connect‐
ing hose -2-.
– Remove right connecting hose leading to turbocharger from
chair air cooler and place to one side.
– Remove air duct mounting ⇒ Item 23 (page 369) .
– Unclip left radiator fastening -2- at condenser -3-.
– Unclip right radiator fastening as well and pull condenser -3off radiator -1-.
Caution
•
– Do not bend or stretch the refrigerant lines excessively.
– Carefully remove radiator upwards together with charge air
cooler. When doing so, take the radiator -2- past the refrigerant
lines.
Note
♦ If the radiator -1- is to be replaced, undo bolts of charge air
cooler and remove it from radiator.
♦ Undo and remove bolt -2- on right and left (not shown in illus‐
tration) at radiator.
Installing
ht
rig
py
Co
t.
r
fo
ng
Installation is carried out in the reverse order; note the following:
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
– Support condenser, e.g. with cable ties.
ility
ab
y li
an
pt
ce
un
le
•
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
Vo
y
ua
b
Do not bend oredstretch the refrigerant lines excessively.
ran
ir s
te
o
h
t
During further
removal work, make sure that the refriger‐e or a
u
a
c
ant linesssare not bent or stretched excessively.
3. Radiator, radiator fan
205
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Note
Before installing radiator, check that radiator mountings -1- are
correctly seated on front part of car -2- and, if necessary, reposi‐
tion:
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
– Insert top radiator mountings -1- on right and left into the
mounting on radiator -2- appropriately.
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.
Prote
cted
by
Rep. gr.19 - Cooling
AG.
206
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
Caution
ht
rig
py
Co
t.
r
fo
ng
– When installing the radiator, make sure that the catches -1- of
the radiator mounting on the left and right at the top have en‐
gaged completely in the lock carrier.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
– Insert radiator mounting into lock carrier -2- at bottom -1-, do‐
ing so transversely to the direction of travel, and then turn it
90".
Amarok 2011 ➤
kswagen AG
AG. Volengine
ndiesel
e
4-cylinder
(2.0
l
engine,
common
rail)
Edition 04.2013
g
d
a
o
e
w
left and right so that it
Caution
•
Do not bend or stretch the refrigerant lines excessively.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
– Install radiator cowl ⇒ page 207 .
– Filling with coolant ⇒ page 182
– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
50 ; Lock carrier .
Specified torques
♦ ⇒ “3.1 Assembly overview - radiator/ radiator fan V7 ”,
page 202
♦ ⇒ “3.2 Assembly overview - radiator cowl and radiator fan V7
”, page 204
c
o
p
yri
gh
t.
C
op
yi
Removing
Removing and installing radiator cowl
with radiator fan - V7-
– Remove underbody guard, if fitted ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody guard .
agen
lksw
Vo
by
AG.
Prote
cted
by
– Unclip coolant hose -1- from brackets -2-.
ht
rig
py
Co
t.
3.4
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
–
s no
t gu
a
en‐ rante
eo
ra
c
ility
ab
y li
an
pt
ce
ks
Vol
by
d
e -1- on
Fit condenser -3- on radiator
ris
tho
gages securely in theaucatches
-2-.
ss
– Unscrew securing bolts -3- for radiator cowl -4-.
– Disconnect connector -1- from radiator cowl -2-.
3. Radiator, radiator fan
207
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unscrew securing bolts -1- for radiator cowl -3-.
– Completely unclip bleeder hose -5- from radiator cowl -3-, and
lay it to one side.
– Unclip and unscrew coolant hose -4- with radiator outlet cool‐
ant temperature sender - G83- and continued coolant circula‐
tion pump - V51- -3- from radiator cowl.
– Unscrew bolts -2- and remove continued coolant circulation
pump - V51- with hoses.
– Loosen clip -2- for wiring harness -1- at bracket -3-.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
ility
ab
y li
an
pt
ce
un
le
– Disconnect connector -4- at continued circulation coolant
pump - V51- .
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
agen
lksw
Vo
by
AG.
Rep. gr.19 - Cooling
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
208
ht
rig
py
Co
t.
r
fo
ng
– Remove radiator cowl upwards, together with radiator fan.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
– 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.
Amarok 2011 ➤
engine, common rail) - Edition 04.2013
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
Volkswagen A
AG.4-cylinder
diesel
G do engine (2.0 l
agen
es n
ksw
l
ot g
o
V
y
ua
b
d -arrows- and remove radiator fan -1-.
ran
e
– Unscrew bolts
tee
ris
o
h
t
or
u
ac
a
Installing s
s
Installation is carried out in the reverse order; note the following:
– Install underbody guard, if fitted previously ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody guard .
♦ ⇒ “3.2 Assembly overview - radiator cowl and radiator fan V7
”, page 204
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Specified torques
do
c
um
en
3. Radiator, radiator fan
209
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
20 –
Fuel supply system
1
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Procedure when filling with incorrect
fuel
un
le
pe
rm
itte
d
ility
ab
y li
an
pt
ce
⇒ “1.1 Procedure when filling with incorrect fuel”, page 210
⇒ “1.2 Engine is not running”, page 210
Procedure when filling with incorrect fuel
Caution
Irreparable damage to high-pressure components, especially
the high-pressure pump, due to lack of lubrication though die‐
sel can occur when filling fuel tank with incorrect fuel. Damage
due to seizure and metal particles can be expected. These
metal particles will probably cause further damage to pressure
regulating valves and injectors.
ht
rig
py
Co
t.
♦ 1. 1st case: filling with incorrect fuel was detected BEFORE
starting the engine and the engine was NOT started
⇒ page 210 .
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
♦ 2. 2nd case: filling with incorrect fuel was detected AFTER
starting the engine. Impurities or incorrect type of fuel has en‐
tered the fuel system and has reached the high-pressure
system ⇒ page 211 .
Special tools and workshop equipment required
♦ Fuel extractor - VAS 5190-
♦ Hose - VAS 6550/1♦ Vehicle diagnostic tester
Procedure
– Do not switch ignition on.
– Raise vehicle.
210
Rep. gr.20 - Fuel supply system
AG.
Engine is not running
agen
lksw
Vo
by
1.2
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Here are the solutions for two different cases of filling with incor‐
rect fuel:
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
1.1
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
⇒ “1.3 Engine is running”, page 211
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Thoroughly clean area around filler neck -1- on fuel tank -4-.
– Loosen clamp -2- for connecting hose -1- of filler neck on fuel
tank -4- and pull connecting hose off.
– Extract fuel with fuel extractor - VAS 5190- via the opening.
– Re-attach connecting hose -1- of filler neck to fuel tank, using
n AG. Volkswagen AG do
clamp -2-.
es
wage
not
gu
ara
nte
eo
ra
c
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
ss
ks
Vol
by
d
e
ris
ho
t
au
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
– Press the circlip to release the fuel line and then detach the
fuel supply line -3-.
– Connect pressure gauge pipe -VAS 6550/1- to the fuel supply
line -3-.
– Guide open end of line into a suitable container.
– Connect ⇒ Vehicle diagnostic tester and carry out “Check
electric fuel pump(s)”.
Note
Fuel pump is now activated for 30 seconds.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
– Reconnect fuel supply line.
1.3
AG.
– Perform road test.
agen
lksw
Vo
by
– Fill fuel tank completely with diesel fuel.
ht
rig
py
Co
t.
– Fill fuel tank with 5 litres of diesel fuel. Then, carry out “Guided
Fault Finding, Checking electrical fuel pump(s)” again to emp‐
ty the tank.
thi
sd
o
cu
m
en
– Repeat this procedure until fuel tank is completely empty.
Engine is running
Special tools and workshop equipment required
♦ Fuel extractor - VAS 5190-
♦ Hose - VAS 6550/1♦ Vehicle diagnostic tester
Procedure
– Do not switch ignition on.
– Raise vehicle.
1. Procedure when filling with incorrect fuel
211
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine,. Vcommon
olkswage rail) - Edition 04.2013
–
– Press the circlip to release the fuel line and then detach the
fuel supply line -3-.
– Connect pressure gauge pipe -VAS 6550/1- to the fuel supply
line -3-.
– Guide open end of line into a suitable container.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
Fuel pump is now activated for 30 seconds.
Prote
cted
by
– Repeat this procedure until fuel tank is completely empty.
AG.
– Remove fuel delivery unit ⇒ page 236 .
– Check fuel tank for dirt and filings.
– If necessary, clean fuel tank.
– Replace fuel delivery unit and install fuel tank ⇒ page 229 .
– Fill fuel tank with 5 litres of diesel fuel.
– Renew fuel filter ⇒ page 239 .
– Renew following high-pressure components:
♦ High-pressure pump ⇒ page 347 .
♦ High-pressure lines ⇒ page 338 .
♦ High-pressure accumulator (fuel rail) including fuel pressure
regulating valve - N276- and fuel pressure sender - G247⇒ page 340 .
♦ Injectors ⇒ page 327 .
♦ Fuel return lines (overflow oil lines).
– Reconnect fuel supply line.
– Fill fuel tank completely with diesel fuel.
– Fill/bleed fuel system ⇒ page 316 .
– Perform road test.
212
Rep. gr.20 - Fuel supply system
ht
rig
py
Co
t.
Note
r
fo
ng
– Connect ⇒ Vehicle diagnostic tester and carry out “Check
electric fuel pump(s)”.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
– Extract fuel with fuel extractor - VAS 5190- via the opening.
ility
ab
y li
an
pt
ce
un
le
–
n AG d
AG
agen
oes
ksw
n
l
o
Vfiller neck -1- on fuel tank -4-. ot gu
y
Thoroughly clean area around
b
ara
d
e
nte
ris
o
eo
h
Loosen clamp -2- for connecting
hose -1- of filler neck on fuel
t
u
ra
a
c
s
tank -4- and pull connecting
hose
off.
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2
Checking low-pressure fuel system
⇒ “2.1 Checking fuel low-pressure at high-pressure pump”, page
213
⇒ “2.2 Checking flow rate at high-pressure pump”, page 215
⇒ “2.3 Checking fuel low-pressureVoahead
of fuel filter”,
. lkswagen AG
gen AG
page 218
does
swa
k
Vol
not
g
y
ua
d b rate ahead of fuel filter”, page 222
⇒ “2.4 Checkingseflow
ran
tee
or
ac
Checking fuel low-pressure at highpressure pump
♦ The adapter lines/leads 1 to 4 listed below are not required for
the test.
♦ Hose - VAS 6551/1♦ Hose - VAS 6551/2♦ Test lead - VAS 6551/3♦ Test lead - VAS 6551/4Note
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
♦ Pressure gauge - VAS 6551-
ht
rig
py
Co
t.
Special tools and workshop equipment required
thi
sd
o
cu
m
en
To perform test, use ⇒ Vehicle diagnostic tester in conjunction
with test instrument box - VAS 6356- .
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Note
ility
ab
y li
an
pt
ce
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
2.1
ri
ho
ut
a
ss
AG.
♦ Adapter set - VAS 6551/5-
2. Checking low-pressure fuel system
213
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Vehicle diagnostic tester
♦ Laptop, vehicle diagnosis (remote head) - VAS 6150 A♦ Instrument box - VAS 6356-
Test prerequisites
•
Fuses must be OK.
•
Battery voltage at least 12 V
•
Ignition switched off
•
There must be at least 10 l of fuel in the fuel tank.
•
All electrical consumers, e.g. lights and rear window heating,
must be switched off.
•
The fuel lines must not be kinked or damaged.
WARNING
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
WARNING
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Procedure
ility
ab
y li
an
pt
ce
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.
♦ Read rules for cleanliness and the instructions for working
on the fuel system ⇒ page 8 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
♦ Wrap a clean cloth around the connection before opening
the fuel system, then carefully loosen the connection to
release the pressure.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Rep. gr.20 - Fuel supply system
do
c
um
en
214
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Loosen spring-type clip -2- of fuel supply line -1-.
– Pull fuel supply line -1- off high-pressure pump.
. Volkswage
ot g
ua
ran
tee
or
ac
– Connect pressure tester - VAS 6551- -1- with hoses from
adapter set - VAS 6551/5- .
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ss
ol
yV
db
e
ris
tho
au
ility
ab
y li
an
pt
ce
un
le
n AG d
gen AaG cleaning cloth.
– Collect escaping fuel
awith
oes
ksw
n
– Connect hose -VAS 6551/2- as well as connection fitting -VAS
6551/5-1- from adapter set - VAS 6551/5- to fuel supply line
-3- and connection -A - of pressure tester - VAS 6551- .
– Open shut-off tap -A-.
– Connect hose »-2« from adapter set - VAS 6551/5- to open
connection on high-pressure pump -2- and connection -B- of
pressure tester - VAS 6551- .
– Close shut-off taps -B- and -C-.
– Carefully open shut-off tap -B-.
ht
rig
py
Co
t.
r
fo
ng
– Switch on pressure tester - VAS 6551- by pressing on/off
pushbutton.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
– Connect ⇒ Vehicle diagnostic tester to test instrument box VAS 6356- .
agen
lksw
Vo
by
– Activate fuel pump using guided function “Fuel pump activa‐
tion”.
AG.
– The fuel pump is activated.
•
Specification: ≥ 3.5 bar.
If the specified value is not reached: check fuel low-pressure
ahead of fuel filter ⇒ page 218 .
♦ If the pressure ahead of fuel filter is “OK”:
♦ Renew fuel filter ⇒ page 239 .
2.2
Checking flow rate at high-pressure
pump
Note
♦ The adapter lines/leads 1 to 4 listed below are not required for
the test.
♦ Hose - VAS 6551/1♦ Hose - VAS 6551/2♦ Test lead - VAS 6551/3♦ Test lead - VAS 6551/4-
2. Checking low-pressure fuel system
215
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Note
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b may be used in con‐
To perform test, ⇒ Vehicle diagnostic tester
ara
d
e
nte
is6356r
junction with test instrument box - VAS
.
o
eo
h
t
u
ra
a
c
s
s
♦ Pressure gauge - VAS 6551-
Prote
cted
by
♦ Instrument box - VAS 6356-
♦ Transparent measuring beaker ≥ 1.5 litre
Test prerequisites
•
Fuses must be OK.
•
Battery voltage at least 12 V
•
Ignition switched off
•
There must be at least 10 l of fuel in the fuel tank.
216
Rep. gr.20 - Fuel supply system
AG.
♦ Laptop, vehicle diagnosis (remote head) - VAS 6150 A-
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
♦ Vehicle diagnostic tester
ht
rig
py
Co
t.
r
fo
ng
♦ Adapter set - VAS 6551/5-
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
ility
ab
y li
an
pt
ce
Special tools and workshop equipment required
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
•
All electrical consumers, e.g. lights and rear window heating,
n AG. Volkswagen AG do
must be switched off.
es
wage
ks
Vol
by
The fuel lines must not be kinked or damaged.
ed
ris
tho
u
a
ss
not
gu
ara
nte
eo
ra
c
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.
Procedure
WARNING
♦ Read rules for cleanliness and the instructions for working
on the fuel system ⇒ page 8 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
AG.
Prote
cted
by
Collect escaping fuel with a cleaning cloth.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
Note
ht
rig
py
Co
t.
r
fo
ng
♦ Wrap a clean cloth around the connection before opening
the fuel system, then carefully loosen the connection to
release the pressure.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
WARNING
un
le
•
– Loosen spring-type clip -2- of fuel supply line -1-.
– Pull fuel supply line -1- off high-pressure pump.
– Connect pressure tester - VAS 6551- -1- with hoses from
adapter set - VAS 6551/5- .
– Connect hose -VAS 6551/2- as well as connection fitting -VAS
6551/5-1- from adapter set - VAS 6551/5- to fuel supply line
-3- and connection -A - of pressure tester - VAS 6551- .
– Open shut-off tap -A- of pressure tester - VAS 6551- .
– Close shut-off tap -C- of pressure tester - VAS 6551- .
2. Checking low-pressure fuel system
217
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Connect hose »-2« -1- from adapter set - VAS 6551/5- to con‐
nection -B- of pressure tester - VAS 6551- .
– Hold open end of hose into measuring beaker -2-.
– Close shut-off tap -B-.
– Switch on pressure tester - VAS 6551- by pressing on/off
pushbutton.
Note
A 2nd mechanic is needed to check the flow rate in the vehicle.
– Connect ⇒ Vehicle diagnostic tester to test instrument box VAS 6356- .
– Activate fuel pump using guided function “Fuel pump activa‐
tion”.
– The fuel pump is activated.
– Carefully open shut-off tap -B- until specified value of 3.5 bar
is displayed on pressure tester - VAS 6551- .
– Empty measuring beaker.
AG. Volkswagen AG d
agen
es nmeasuring
w
– Hold hose -2 -1- fromVadapter
set - VAS 6551/5-oin
ot g
olks
y
ua
beaker -2- again.sed b
ran
i
or
tee
un
le
ility
ab
y li
an
pt
ce
th
– Activate fuelaupump
using guided function “Fuel pump activa‐or a
c
s
s
tion”.
pe
rm
itte
d
– The fuel pump is activated.
2.3
Checking fuel low-pressure ahead of
fuel filter
Note
♦ The adapter lines/leads 1 to 4 listed below are not required for
the test.
♦ Hose - VAS 6551/1♦ Hose - VAS 6551/2♦ Test lead - VAS 6551/4ht
rig
py
Co
t.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
Note
To perform test, use ⇒ Vehicle diagnostic tester in conjunction
with test instrument box - VAS 6356- .
AG.
Prote
cted
by
Special tools and workshop equipment required
218
Rep. gr.20 - Fuel supply system
do
c
um
en
r
te o
iva
r
rp
fo
g
n
♦ Test lead - VAS 6551/3-
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Specification: ≥ 550 ml
Amarok 2011 ➤
4-cylinder diesel engine
(2.0
l
engine,
common
rail)
Edition 04.2013
k
s
l
w
o
a
V
g
.
e
nA
AG
♦ Pressure gauge - VAS 6551-
G do
es n
ot g
ua
ran
tee
or
ac
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
ss
n
wage
olks
V
by
ed
ris
o
th
au
♦ Adapter set - VAS 6551/5-
thi
sd
o
cu
m
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
♦ Vehicle diagnostic tester
♦ Laptop, vehicle diagnosis (remote head) - VAS 6150 A♦ Instrument box - VAS 6356-
Test prerequisites
•
Fuses must be OK.
•
Battery voltage at least 12 V
•
Ignition switched off
•
There must be at least 10 l of fuel in the fuel tank.
•
All electrical consumers, e.g. lights and rear window heating,
must be switched off.
•
The fuel lines must not be kinked or damaged.
2. Checking low-pressure fuel system
219
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
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.
Procedure
WARNING
♦ Read rules for cleanliness and the instructions for working
on the fuel system ⇒ page 8 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
♦ Wrap a clean cloth around the connection before opening
the fuel system, then carefully loosen the connection to
release the pressure.
– Separate quick-release coupling of “black”
olkswsupply
agen AGline
n AG. Vfuel
does
wage
s
-3- from fuel filter -1-.
k
not
l
o
To do this, press locking mechanism on quick-release coupling.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Rep. gr.20 - Fuel supply system
do
c
um
en
220
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Collect escaping fuel with a cleaning cloth.
ility
ab
y li
an
pt
ce
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
gu
ara
nte
eo
ra
c
ht
rig
py
Co
t.
Note
yV
db
ir se
ho
ut
a
ss
Amarok 2011 ➤
olkswagen AG
en AG. V common
4-cylinder diesel engine (2.0
l
rail)
Edition 04.2013
gengine,
d
a
o
e
w
s
s
not
gu
ara
nte
eo
ra
c
ility
ab
y li
an
pt
ce
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
–
k
Vol
by
d
e
Connect hose »-3« from adapter set - VAS 6551/5to open
ris
thopressure tester
fuel line (from fuel tank) and connection -A -auof
ss
- VAS 6551- .
– Open shut-off tap -A- of pressure tester - VAS 6551- .
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
– Connect hose »-4« from adapter set - VAS 6551/5- to open
connection on fuel filter and connection -B- of pressure tester
- VAS 6551- .
– Open shut-off tap -B- of pressure tester - VAS 6551- .
– Close shut-off tap -C- of pressure tester - VAS 6551- .
– Switch on pressure tester - VAS 6551- by pressing on/off
pushbutton.
– Connect ⇒ Vehicle diagnostic tester or laptop, vehicle diag‐
nosis (remote head) - VAS 6150 A- to test instrument box VAS 6356– Activate fuel pump using guided function “Fuel pump activa‐
tion”.
♦ If the specification has been reached and the fuel low-pressure
AG.
Prote
cted
by
on the high-pressure pump has not been checked yet, the fuel
low-pressure downstream of fuel filter must be checked.
agen
lksw
Vo
by
Note
c
o
p
yri
gh
t
.
C
op
yi
Specification: ≥ 3.5 bar.
ht
rig
py
Co
t.
•
thi
sd
o
cu
m
en
– The fuel pump is activated.
♦ If the fuel low-pressure on the high-pressure pump has already
been checked and the specification has not been reached, re‐
new fuel filter ⇒ page 239 .
– Connect fuel supply line -3- to connection on fuel filter -1-.
– Separate quick-release coupling of fuel supply line -2- from
fuel filter -1-.
Note
To do this, press locking mechanism on quick-release coupling.
– Collect escaping fuel with a cleaning cloth.
2. Checking low-pressure fuel system
221
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Connect hose »-4« from adapter set - VAS 6551/5- to open
connection on fuel filter and connection -A- of pressure tester
- VAS 6551- .
– Open shut-off tap -A- of pressure tester - VAS 6551- .
– Connect hose »-3« from adapter set - VAS 6551/5- to open
fuel supply line leading to high-pressure pump -B- of pressure
tester - VAS 6551- .
– Open shut-off tap -B- of pressure tester - VAS 6551- .
– Close shut-off tap -C- of pressure tester - VAS 6551- .
– Switch on pressure tester - VAS 6551- by pressing on/off
pushbutton.
– Carefully open shut-off tap -B-.
– Connect ⇒ Vehicle diagnostic tester or laptop, vehicle diag‐
nosis (remote head) - VAS 6150 A- to test instrument box n AG. Volkswagen AG do
VAS 6356e
wage
s no
t
ks
Vol
gu
y guided function “Fuel pump activa‐
ara
– Activate fuel pump eusing
db
nte
s
i
r
tion”.
o
e
h
t
au
un
le
Specification: ≥ 3.5 bar.
pe
rm
itte
d
•
♦ Renew fuel filter ⇒ page 239 .
Checking flow rate ahead of fuel filter
Note
♦ The adapter lines/leads 1 to 4 listed below are not required for
the test.
♦ Hose - VAS 6551/1♦ Hose - VAS 6551/2♦ Test lead - VAS 6551/4ht
rig
py
Co
t.
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Note
To perform test, ⇒ Vehicle diagnostic tester may be used in con‐
junction with test instrument box - VAS 6356- .
AG.
Special tools and workshop equipment required
222
Rep. gr.20 - Fuel supply system
do
c
um
en
r
te o
iva
r
rp
fo
g
n
♦ Test lead - VAS 6551/3-
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
If the specified value is not attained:
2.4
or
ac
ility
ab
y li
an
pt
ce
ss is activated.
– The fuel pump
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Pressure gauge - VAS 6551-
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
♦ Laptop, vehicle diagnosis (remote head) - VAS 6150 A♦ Instrument box - VAS 6356-
•
Battery voltage at least 12 V
•
Ignition switched off
•
There must be at least 10 l of fuel in the fuel tank.
•
All electrical consumers, e.g. lights and rear window heating,
must be switched off.
•
The fuel lines must not be kinked or damaged.
AG.
Fuses must be OK.
agen
lksw
Vo
by
•
ht
rig
py
Co
t.
Test prerequisites
r
fo
ng
♦ Transparent measuring beaker ≥ 1.5 litre
Prote
cted
by
2. Checking low-pressure fuel system
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
♦ Vehicle diagnostic tester
un
le
♦ Adapter set - VAS 6551/5-
223
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
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.
Procedure
WARNING
♦ Read rules for cleanliness and the instructions for working
on the fuel system ⇒ page 8 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
♦ Wrap a clean cloth around the connection before opening
the fuel system, then carefully loosen the connection to
release the pressure.
– Disconnect “black” fuel supply line -3- from fuel filterge-1-.
n AG. Volkswagen AG d
ss
oes
not
gu
ara
nte
eo
ra
c
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
To do this, press locking mechanism on hose coupling.
– Collect escaping fuel with a cleaning cloth.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Rep. gr.20 - Fuel supply system
thi
sd
o
cu
m
en
224
ht
rig
py
Co
t.
Note
wa
olks
yV
b
ed
ris
ho
t
au
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Connect hose »-3« from adapter set - VAS 6551/5- -4- to fuel
supply line (from fuel tank) -5- and connection -A - of pressure
tester - VAS 6551- -1-.
– Open shut-off tap -A- of pressure tester - VAS 6551- .
– Close shut-off tap -C- of pressure tester - VAS 6551- .
– Connect hose »-3« from adapter set - VAS 6551/5- -2- to con‐
nection -B- of pressure tester - VAS 6551- .
– Hold open end of hose into measuring beaker -3-.
– Close shut-off tap -B- of pressure tester - VAS 6551- .
– Switch on pressure tester - VAS 6551- by pressing on/off
pushbutton.
Note
A 2nd mechanic is needed to check the flow rate in the vehicle.
– Connect ⇒ Vehicle diagnostic tester or laptop, vehicle diag‐
nosis (remote head) - VAS 6150 A- to test instrument box VAS 6356– Activate fuel pump using guided function “Fuel pump activa‐
tion”.
– The fuel pump is activated.
– Carefully open shut-off tap -B- until the specified value of
3.5 bar is displayed on pressure tester - VAS 6551- .
– Empty measuring beaker.
– Hold hose from adapter set - VAS 6551/5- -2- into measuring
beaker -3- again.
olkswagen AG
en AG. V
does
wag
– Activate fuel pump using
not activa‐
olks guided function “Fuel pump
gu
yV
b
tion”.
ara
ed
nte
eo
ra
c
is
or
th is activated.
– The fuel pump
au
ss
do
c
um
en
ht
rig
py
Co
t.
un
le
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
Specification: ≥ 550 ml
2. Checking low-pressure fuel system
225
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
3
Fuel tank
⇒ “3.1 Assembly overview - fuel tank”, page 226
⇒ “3.2 Assembly overview - fuel lines”, page 228 lkswagen
⇒ “3.3 Removing and installing
ility
ab
y li
an
pt
ce
3.1
AG. Volkswagen AG d
oes
not
gu
ara
nte
eo
ra
c
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
⇒ “3.4 Removing and installing
o
yV
d b 229
e
fuel tank”,ripage
s
tho
u
a
filler neck”,
page 232
ss
Assembly overview - fuel tank
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Caution
The fuel pump must not be allowed to run when the fuel tank
is empty, as this may cause deflagrations.
The fuel tank must contain at least 5 litres of fuel.
1 - Seal
❑ Renew if damaged.
❑ Moisten with fuel when
installing
6 - Screw-type clip
7 - Bolt
❑ 5 Nm
8 - Panel nut
❑ Renew after removing
9 - Filler neck
10 - Bolt
❑ 2 Nm
11 - Fuel tank
❑ When removing, sup‐
port using engine and
gearbox jack - V.A.G 1383 A- .
❑ Drain fuel tank using fuel extractor - VAS 5190❑ Removing and installing ⇒ page 229 .
226
Rep. gr.20 - Fuel supply system
AG.
5 - Connecting hose
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
4 - Spring-type clip
❑ Check for secure seat‐
ing.
ht
rig
py
Co
t.
3 - Supply line
❑ For vehicles with addi‐
tional heater ⇒ Rep. gr.
82 .
❑ Check for secure seat‐
ing.
thi
sd
o
cu
m
en
2 - Union nut
❑ Remove and install us‐
ing union nut tool 3217- .
❑ 110 Nm
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
12 - Bolt
❑ 8 Nm
13 - Cap
14 - Seal
❑ Renew if damaged.
15 - Tank flap unit
16 - Securing strap
❑ Note installation position.
❑ Check for secure seating.
17 - Return line
❑ Blue or with blue marking.
❑ Clipped onto fuel tank.
❑ Check for secure seating.
❑ To pull off flange, press release button on connecting piece.
18 - Nut
❑ 20 Nm
19 - Supply line
❑ To fuel filter ⇒ Item 1 (page 238) .
❑ Clipped onto fuel tank.
❑ Check for secure seating.
❑ Black
❑ To pull off flange, press release button on connecting piece.
20 - Bolt
❑ 30 Nm
n AG. Volkswagen AG do
es n
wage
ot g
ua
ran
tee
or
ac
ks
21 - Protective cover
Vol
by
d
❑ For bottom oforfuel
ise tank.
th
u
❑ Depending
s a on equipment.
24 - Spring-type clip
❑ Check for secure seating.
25 - Metering pump - V54❑ For vehicles with additional heater ⇒ Rep. gr. 82 .
26 - Mounting for metering pump - V54❑ For vehicles with additional heater ⇒ Rep. gr. 82 .
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
23 - Fuel delivery unit
❑ Note installation position on fuel tank ⇒ page 228 .
❑ To remove, first remove fuel tank ⇒ page 229 .
❑ Removing and installing fuel gauge sender ⇒ page 237 .
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
s
22 - Supply line
❑ For vehicles with additional heater ⇒ Rep. gr. 82 .
❑ Check for secure seating.
3. Fuel tank
227
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
with mark
ir se on fuel tank
tee
o
h
t
or
u
ac
a
ss
Installation position of fuel gauge sender
Arrow on sender flange -1- must align
-arrows-.
After installing fuel gauge sender, check whether fuel supply and
return lines are still clipped onto fuel tank.
3.2
Assembly overview - fuel lines
7 - Bracket
8 - Fuel filter with bracket
❑ Can only be renewed
complete.
❑ Removing and installing
⇒ page 239 .
9 - Quick-release coupling
❑ Check for secure seat‐
ing.
10 - Supply line
❑ From fuel tank.
❑ Check for secure seating.
11 - Return line
❑ To fuel tank.
❑ Check for secure seating.
228
Rep. gr.20 - Fuel supply system
Prote
cted
by
6 - Return line
❑ Check for secure seat‐
ing.
AG.
5 - Return line
❑ From the injectors
❑ Check for secure seat‐
ing.
agen
lksw
Vo
by
4 - Bracket
c
o
p
yri
gh
t
.
C
op
yi
3 - Fuel temperature sender G81❑ Fitting location
⇒ page 307
ht
rig
py
Co
t.
2 - Return line
❑ From high-pressure
pump.
❑ Check for secure seat‐
ing.
r
fo
ng
1 - Supply line
❑ To high-pressure pump
❑ Check for secure seat‐
ing.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
Note
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
ility
ab
y li
an
pt
ce
Connections for blue or blue-marked return line and black supply
line are marked with arrows on fuel gauge sender flange.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
12 - Return line
❑ Fuel return line from injectors to supply line leading to fuel filter
13 - Return line
❑ From high-pressure pump.
14 - Supply line
❑ To high-pressure pump
3.3
Removing and installing fuel tank
Caution
The fuel pump must not be allowed to run when the fuel tank
is empty, as this may cause deflagrations.
The fuel tank must contain at least 5 litres of fuel.
Special tools and workshop
equipment required
♦ Union nut tool - 3217♦ Torque wrench - V.A.G
1331♦ Torque wrench - V.A.G
1332♦ Engine and gearbox jack V.A.G 1383 A-
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
♦ Fuel extractor - VAS 5190-
3. Fuel tank
229
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Removing
Note
Fuel tank must be drained. Use the fuel extractor - VAS 5190- to
do this.
– Note safety precautions before starting installation work
⇒ page 3 .
– Observe rules for cleanliness ⇒ page 8 .
Note
Before carrying out further work, disconnect battery earth strap.
For this reason, first check whether a coded radio
olkswagObtain
. Vfitted.
en AG
n AGis
does
wage
anti-theft coding first if necessary.
not
olks
– Thoroughly clean area
-1- on fuel tank -4-.
– Extract fuel with fuel extractor - VAS 5190- via the opening.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Vehicles with lower protective cover
– Unbolt protective cover on bottom of fuel tank
⇒ Item 21 (page 227) .
Continuation for all vehicles:
– Support fuel tank with engine and gearbox jack - V.A.G 1383
A- .
– Disconnect supply line -3- and return line -2-.
Note
Press in buttons on hose couplings to do this.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
– Loosen securing straps in succession:
agen
lksw
Vo
by
AG.
– Unscrew bolt -arrow- for front securing strap -2- for fuel tank
-1-.
230
Rep. gr.20 - Fuel supply system
ht
rig
py
Co
t.
– Unscrew bolt -arrow- for securing fuel tank -1- on left cross
member.
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
– Loosen clamp -2- for connecting hose -1- of filler neck on fuel
tank -4- and pull connecting hose off.
gu
ara
nte
eo
ra
c
ility
ab
y li
an
pt
ce
yV
db
ise
r
around
tho filler neck
au
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unscrew bolt -arrow- for rear securing strap -2- for fuel tank
-1-.
– Unscrew bolts -arrows- for securing straps -2- for fuel tank
-1-.
Vehicles with additional heater:
– Pull fuel line -2- off at metering pump - V54- -1-.
Continuation for all vehicles:
– Unclip wiring harness -3- at supply line -arrow-.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
– Only lower fuel tank with engine and gearbox jack - V.A.G
1383 A- until filler neck and breather line can be removed.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– Loosen clamp -2- for connecting hose -1- of filler neck on fuel
tank -4- and pull connecting hose off.
– Unclip breather line -3- on fuel tank -4-.
Note
ht
rig
py
Co
t.
agen
lksw
Vo
by
3. Fuel tank
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Immediately seal all openings on fuel tank with clean cloths.
231
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Continue lowering fuel tank with engine and gearbox jack V.A.G 1383 A- until connector -2- can be pulled off fuel delivery
unit -1-.
– Press in securing clip to release fuel lines.
n AG. Volkswagen AG do
es n
ot g
ua
ran
tee
or
ac
age unit -1-.
– Unclip fuel lines -2 and 3- from fuelodelivery
lksw
un
le
Installing
pe
rm
itte
d
Installation is carried out in the reverse order; note the following:
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Caution
ility
ab
y li
an
pt
ce
yV
db
ir se
ho
ut
a
ss
– Carefully lower fuel tank.
The fuel pump must not be allowed to run when the fuel tank
is empty, as this may cause deflagrations.
The fuel tank must contain at least 5 litres of fuel.
Push hose -1- of filler neck onto connection on fuel tank -3-.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
♦ Connections for breather and fuel lines must engage audibly
when reconnected.
♦ Clip fuel lines onto fuel tank.
♦ Push connector onto fuel pump flange and clip wire onto fuel
tank.
♦ Ensure that fuel hose connections are tight.
Vehicles with lower protective cover
– Bolt protective cover to bottom of fuel tank .
Specified torques
♦ ⇒ “3.1 Assembly overview - fuel tank”, page 226
3.4
Removing and installing filler neck
Special tools and workshop equipment required
232
Rep. gr.20 - Fuel supply system
ht
rig
py
Co
t.
– Push on breather line -3- and engage securely.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Position clamp -2- at assembly markings -arrows- using hose clip
pliers - VAS 6362- .
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Hose clip pliers - VAS 6362-
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
– Remove fuel tank ⇒ page 229 .
– Unscrew bolt -2- for filler neck -1- on underbody.
– Open tank flap and clean inside tank flap unit thoroughly.
r
fo
ng
AG.
Prote
cted
by
– Unclip tank flap unit and remove completely.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
– Unscrew bolt -2- from tank flap unit.
ht
rig
py
Co
t.
– Unscrew cap.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
Removing
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
ility
ab
y li
an
pt
ce
un
le
♦ Torque wrench - V.A.G 1410-
3. Fuel tank
233
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unscrew nuts -2- from filler neck -1- at top of tank flap unit cutout.
– Remove filler neck -1- from below; filler neck must be turned
when doing this.
Installing
Installation is carried out in the reverse order; note the following:
– Thread filler neck -1- in through wheel housing and position at
top of tank flap unit cut-out with nuts -2-.
– Tighten nuts -2-.
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
– Installing fuel tank:
or
ac
– Push hose -1- of filler neck onto connection on fuel tank -3-.
r
fo
ng
AG.
Prote
cted
by
Rep. gr.20 - Fuel supply system
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
234
ht
rig
py
Co
t.
– Position clamp -2- at assembly markings -arrows- using hose
clip pliers - VAS 6362- .
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
– Tighten bolt -2-.
ua
ran
tee
b
ed
ris
o
h
t
au
ss
ility
ab
y li
an
pt
ce
un
le
– Renew speed nut in cross member on underbody
AG. Volkswagen AG d
agen
oes
⇒ Item 8 (page 226) .
ksw
not
l
o
g
yV
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Push on breather line -3- and engage securely.
♦ Connections for breather and fuel lines must engage audibly
when reconnected.
♦ Clip fuel lines onto fuel tank.
♦ Push connector onto fuel pump flange and clip wire onto fuel
tank.
♦ Ensure that fuel hose connections are tight.
Specified torques
♦ ⇒ “3.1 Assembly overview - fuel tank”, page 226
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
do
c
um
en
3. Fuel tank
235
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
4
Fuel delivery unit, fuel gauge sender
⇒ “4.1 Removing and installing fuel delivery unit”, page 236
⇒ “4.2 Removing and installing fuel gauge sender G ”,
page 237
4.1
Removing and installing fuel delivery
unit
Special tools and workshop equipment required
♦ Union nut tool - 3217-
Removing
– Remove fuel tank ⇒ page 229 .
– Unclip fuel lines -2 and 3- from fuel delivery unit -1-.
Vehicles with additional heater:
– Pull fuel line for metering pump - V54- off at fuel delivery unit.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
– Unscrew union nut with union nut tool - 3217- .
– Take fuel delivery unit out of the fuel tank.
Installing
AG.
Prote
cted
by
Rep. gr.20 - Fuel supply system
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
236
ht
rig
py
Co
t.
r
fo
ng
Installation is carried out in the reverse order; note the following:
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
Continuation for all vehicles:
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Install fuel delivery unit so that mark on flange of fuel delivery
unit -1- is aligned with mark on fuel tank -arrows-.
Specified torques
♦ ⇒ “3.1 Assembly overview - fuel tank”, page 226
4.2
Removing and installing fuel gauge
sender - G-
Removing
– Remove fuel tank ⇒ page 229 .
– Remove fuel delivery unit ⇒ page 236 .
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
– Free lines -2- and unclip fuel gauge sender - G- to side
-arrows-.
– Remove fuel gauge sender - G- -1- in -direction of arrow-.
– Release connectors on fuel gauge sender - G- .
Installing
Installation is carried out in the reverse order; note the following:
– Insert fuel gauge sender - G- into guides on fuel pump and
press downwards until it engages.
Specified torques
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
♦ ⇒ “3.1 Assembly overview - fuel tank”, page 226
agen
lksw
Vo
by
4. Fuel delivery unit, fuel gauge sender
237
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Fuel filter
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
⇒ “5.1 Assembly overview - fuel filter”, page
⇒ “5.2 Removing and installing fuel filter”, page 239
⇒ “5.3 Checking fuel filter”, page 239
Assembly overview - fuel filter
238
Rep. gr.20 - Fuel supply system
Prote
cted
by
5 - Water drain screw
❑ Loosen and allow ap‐
prox. 100 cm3 fluid to
drain
AG.
4 - Gasket
❑ Renew if damaged.
do
c
um
en
3 - Fuel filter
❑ Can only be renewed
complete.
❑ Removing and installing
⇒ page 239 .
❑ Checking ⇒ page 239 .
agen
lksw
Vo
by
2 - Supply line
❑ To high-pressure pump
❑ Check for secure seat‐
ing.
c
o
p
yri
gh
t
.
C
op
yi
1 - Supply line
❑ From fuel tank
❑ Check for secure seat‐
ing.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
5.1
ht
rig
py
Co
t.
5
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
238ss
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
5.2
Removing and installing fuel filter
Removing and installing fuel filter
Removing
– Unclip fuel lines -2 and 3- from fuel filter -1- and pull fuel filter
out of bracket in -direction of arrow-.
Note
Press in buttons on hose couplings to do this.
Installing
Install in reverse order.
5.3
Checking fuel filter
Special tools and workshop equipment required
♦ Pressure tester - VAS 6551-
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
♦ Hose - VAS 6551/3♦ Hose - VAS 6551/4Test prerequisites
Fuses must be OK.
•
Battery voltage at least 12 V
•
Ignition switched off
•
There must be at least 10 l of fuel in the fuel tank.
•
All electrical consumers, e.g. lights and rear window heating,
must be switched off.
WARNING
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
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.
thi
sd
o
cu
m
en
•
5. Fuel filter
239
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Procedure
WARNING
♦ Always read rules for cleanliness and
working on fuel system ⇒ page 8 .
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
instructions
for
r
o
eo
h
t
u
ra
a
c
s
s
pe
rm
itte
d
un
le
ility
ab
y li
an
pt
ce
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
♦ Wrap a clean cloth around the connection before opening
the fuel system, then carefully loosen the connection to
release the pressure.
– Pull fuel supply line -2- off fuel filter.
Prote
cted
by
– Close shut-off tap “C” of pressure tester - VAS 6551- .
– Carefully open shut-off valves -A- and -B-.
– Start engine.
•
Take specification reading: at least 3.5 bar on pressure tester
- VAS 6551-
If the specified value is attained, the fuel system is OK.
If the specified value is not attained:
– Connect fuel supply line -2- to fuel filter again.
– Pull fuel supply line -3- off fuel filter.
– Collect escaping fuel with a cleaning cloth.
240
Rep. gr.20 - Fuel supply system
AG.
– Switch on pressure tester - VAS 6551- by pressing On/Off
button.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
– Connect connection -B- of pressure tester - VAS 6551- to‐
gether with line -VAS 6551/4- to open line of high-pressure
pump.
ht
rig
py
Co
t.
– Connect connection -A- of pressure tester - VAS 6551- with
line -VAS 6551/3- to open end of fuel filter.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
– Collect escaping fuel with a cleaning cloth.
un
le
– Connect connection
line -VAS 6551/3- to open end of fuel filter.
pe
rm
itte
d
– Connect connection -B- of pressure tester - VAS 6551- to‐
gether with line -VAS 6551/4- to open line of fuel tank.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
– Switch on pressure tester - VAS 6551- by pressing On/Off
button.
– Close shut-off tap “C” of pressure tester - VAS 6551- .
– Carefully open shut-off valves -A- and -B-.
– Start engine.
•
Take specification reading: at least 3.5 bar on pressure tester
- VAS 6551-
If specification is attained:
– Renew fuel filter.
If the specified value is not attained:
– Check fuel pump ⇒ page 242 .
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Amarok 2011 ➤
- Edition 04.2013
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
no
l
o
V
ua
4-cylinder
diesel engine (2.0 l engine,t gcommon
rail)
by
d
ran
e
tee
ris
o
h
t
or
ac
au pressure tester - VAS 6551- with
-A- sof
s
5. Fuel filter
241
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
6
Fuel pump
⇒ “6.1 Checking fuel delivery rate of fuel pump (fuel low pressure)
”, page 242
⇒ “6.2 Checking voltage supply of fuel pump (fuel low pressure)”,
page 245
6.1
Checking fuel delivery rate of fuel pump
(fuel low pressure)
Note
♦ Hose - VAS 6551/1♦ Hose - VAS 6551/2AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
Test lead - VAS 6551/4e
nte
is
r
o
eo
h
ut not required for test
ra
Adapter lines/leads 1-4 are
a
c
s
s
♦ Test lead - VAS 6551/3♦
ility
ab
y li
an
pt
ce
un
le
♦
pe
rm
itte
d
Special tools and workshop equipment required
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
♦ Pressure tester - VAS 6551-
•
Fuses must be OK.
•
Battery voltage at least 12 V
•
Ignition switched off
•
There must be at least 10 l of fuel in the fuel tank.
242
Rep. gr.20 - Fuel supply system
AG.
Test prerequisites
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
ht
rig
py
Co
t.
♦ Vehicle diagnostic tester
do
c
um
en
r
te o
iva
r
rp
fo
g
n
♦ Adapter set - VAS 6551/5-
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
•
All electrical consumers, e.g. lights and rear window heating,
must be switched off.
•
Low-pressure fuel system checked ⇒ page 213 .
•
Fuel filter checked ⇒ page 239 .
•
Ensure that fuel lines are not blocked.
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
wagenoff
connection. Then release pressure by carefully
pulling
G. Volkshose
A
AG do
agen
es n
ksw
connection.
l
ot
o
V
Procedure
WARNING
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
♦ Read rules for cleanliness and the instructions for working
on the fuel system ⇒ page 8 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
♦ Wrap a clean cloth around the connection before opening
the fuel system, then carefully loosen the connection to
release the pressure.
Note
A 2nd mechanic is needed to check the fuel delivery rate in the
vehicle.
– Disconnect “black” fuel supply line -3-.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
To do this, press catches on hose couplings.
ht
rig
py
Co
t.
Note
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
gu
ara
nte
eo
ra
c
ility
ab
y li
an
pt
ce
ss
by
ed
ris
o
th
au
– Collect escaping fuel with a cleaning cloth.
6. Fuel pump
243
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Connect pressure tester - VAS 6551- to open ends of fuel
supply line -3- using lines/hoses from adapter set - VAS
6551/5- .
– Connect connection -A- of pressure tester - VAS 6551- to end
of fuel supply line from fuel tank using lines/hoses from adapt‐
er set - VAS 6551/5- and open shut-off tap -A-.
– Connect connection -B- of pressure tester - VAS 6551- to end
of fuel line to fuel tank using lines/hoses from adapter set VAS 6551/5- .
– Close shut-off tap -B- of pressure tester - VAS 6551- .
– Put the line leading from connection -C- into a ≥ 3 litre meas‐
uring container -3- and hold there.
– Close shut-off tap -C- of pressure tester - VAS 6551- .
– Switch on pressure tester - VAS 6551- by pressing on/off
pushbutton.
– Connect test instrument/DSO adapter (5-pin) - VAS 5565- to
fuel delivery unit.
– Switch ignition on.
– Connect ⇒ Vehicle diagnostic tester and carry out “Check
electric fuel pump(s)”.
Note
G. Volkswagen AG d
oes
not
o
V
gu
by
ara
d
e
nte
s
i
r
Carefully open shut-off
valve
-Ccompletely.
o
eo
h
ut
ra
a
c
s
s
Slowly close the shut-off
tap -C- again while reading the pres‐
–
sure shown on the pressure tester - VAS 6551- . Set specified
value 5 ± 0.2 bar by closing the shut-off tap carefully.
– Drain measuring container.
ility
ab
y li
an
pt
ce
–
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
gen A
Fuel pump is now activated for 30lkseconds.
swa
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Repeat function “Checking electronic fuel pump(s)”.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Rep. gr.20 - Fuel supply system
do
c
um
en
244
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Note
♦ Amount of fuel delivered by fuel pump depends on voltage at
fuel delivery unit.
♦ Therefore, also connect multimeter - V.A.G 1526- to outputs
-1 and 5- of test instrument/DSO adapter 5-pin - VAS 5565- .
Test prerequisites
•
•
Volkswa
AG.
AG do+At RT = room temperature or a fuel stemperature
of Tge=n (20
agen
es n
k w
l
ot g
o
V
5) °C .
ua
by
d
ise
r
At a pressure of 5 ± 0.2 bar
tho at flange output
au
If these voltages are not achieved, the fuel pump must be
subjected to a voltage test ⇒ page 245 .
– Carry out in the guided function “Checking electronic fuel
pump(s)”
*) Amount of fuel delivered in ml/30 s.
**) Voltage across fuel delivery unit (V) with engine at a standstill
and with pump running.
Example:
During the test, a voltage of 12.0 volts, for example, is measured
at the fuel delivery unit.
The minimum amount of fuel delivered is therefore 1100 ml/30 s.
If the required amount of delivered fuel is achieved, or if more is
measured: Fuel pump ok.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
♦ Visual inspection of fuel delivery unit for dirt.
ht
rig
py
Co
t.
If the amount of fuel to be delivered by the fuel pump is not ach‐
ieved, the following faults have occurred:
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
•
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
ss
During the checking process,
there must be voltages of 11 to
15 volts at the fuel pump. Measured at the flange connector of
the delivery unit.
ility
ab
y li
an
pt
ce
•
ran
tee
or
ac
♦ If voltages in the range of 11 to 15 volts were not achieved
during the testing process, check the voltage supply.
AG.
Prote
cted
by
Note
Check fuel system for leaks.
6.2
Checking voltage supply of fuel pump
(fuel low pressure)
Special tools and workshop equipment required
6. Fuel pump
245
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Hand-held multimeter - V.A.G 1526D-
♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
Fuses must be OK.
•
Battery voltage must be at least 12 V, if necessary connect a
battery charger.
•
All electrical consumers, e.g. lights and rear window heating,
must be switched off.
•
Visual check of cables OK.
Note
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
•
Procedure:
ility
ab
y li
an
pt
ce
Test prerequisites
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
♦ Vehicle diagnostic tester
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
The fuel tank has to be lowered in order to be able to remove the
connector from the flange of the fuel pump unit ⇒ page 229
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Rep. gr.20 - Fuel supply system
thi
sd
o
cu
m
en
246
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Detach connector -2- from fuel delivery unit -1-.
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- be‐
tween connector and flange.
– Connect hand-held multimeter - V.A.G 1526D- to contacts of
adapter.
– Connect ⇒ Vehicle diagnostic tester and carry out “Check
electric fuel pump(s)”.
Note
Fuel pump is now activated for 30 seconds.
– Read voltage value on hand-held multimeter - V.A.G 1526D- :
specification = battery voltage (- 0.5 V OK).
If a voltage of 11 to 15 volts is not measured:
– Check cables/wires for breakage and short-circuiting.
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
ht
rig
py
Co
t.
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
Voltage supply OK.
6. Fuel pump
247
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
7
Accelerator mechanism
⇒ “7.1 Function”, page 248
⇒ “7.2 Assembly overview - accelerator mechanism”, page 249
Volkswa
7.1
Function
Position of accelerator is transmitted to engine control unit by two
accelerator position senders (variable resistors together in one
housing) connected to accelerator.
Position of accelerator (driver's requirement) is a main input value
for engine control unit .
Throttle valve is actuated by an electric motor (throttle valve po‐
sitioner) in throttle valve module over full range of engine speeds
and load conditions.
Throttle valve is operated by throttle valve positioner which is
controlled by engine control unit .
When the engine is not running and the ignition is switched on,
the engine control unit moves the throttle valve exactly as pre‐
scribed by the accelerator position sender . This means that when
the accelerator is depressed half way, the throttle valve positioner
opens the throttle valve to the same extent. The throttle valve is
then approx. half open.
r
fo
ng
This also results in significantly improved consumption and ex‐
haust emission values under certain load conditions.
“EPC” is a system comprising all components which contribute to
determining, controlling or monitoring the position of the throttle
valve (e.g. accelerator position sender , throttle valve control
module , EPC warning lamp , engine control unit ).
248
Rep. gr.20 - Fuel supply system
AG.
After evaluating the torque requirements of the various compo‐
nents (e.g. air conditioning system, automatic gearbox, ABS/
ESP, etc.), the engine control unit calculates the optimal throttle
valve opening angle for the respective situation.
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
This means that the throttle valve can already be completely open
even though the accelerator is only depressed half way. This has
the advantage of preventing throttling losses at the throttle valve.
ht
rig
py
Co
t.
When the engine is running (under load), the engine control unit
can open or close the throttle valve independently of the accel‐
erator position sender .
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
the accelerator and the throttle valve.
gen AG
does
not
gu
ara
nte
eo
ra
c
ility
ab
y li
an
pt
ce
AG.
agen
ksw
l
o
yV
db
ise
r
With the EPC system, the throttle valve is unot
tho operated by a cable
a
from the accelerator There is no mechanical
connection between
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
7.2
Assembly overview - accelerator mechanism
1 - Bearing bracket
❑ Removing and instal‐
ling: ⇒ Rep. gr. 46 .
2 - Connector
❑ 6-pin
3 - Nut
❑ 9 Nm
4 - Accelerator position sender
- G79❑ Not adjustable.
❑ The accelerator position
sender - G79- transmits
the driver's input to the
engine control unit
❑ Remove footwell cover
to remove sender. gen AG. Volkswagen AG
does
not
gu
ara
nte
eo
ra
c
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
wa
olks
yV
b
ed
ris
ho
t
au
ss
do
c
um
en
7. Accelerator mechanism
249
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
21 –
Turbocharging/supercharging
1
Charge air system
⇒ “1.1 Assembly overview - charge air system”, page 250
⇒ “1.2 Removing and installing charge air cooler”, page 251
. Volkswagen AG
gen AG
does
not
gu
ara
nte
eo
N220 ”,
ra
c
a
ksw G42
⇒ “1.3 Removing and installing intake air temperature sender
Vol
with charge air pressure sender G31 ”, page 254 ed by
is
or
un
le
ility
ab
y li
an
pt
ce
h
ut
⇒ “1.4 Removing and installing exhaust gas aflap
valve
s
s
page 255
1.1
Assembly overview - charge air system
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.
AG.
Rep. gr.21 - Turbocharging/supercharging
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
250
ht
rig
py
Co
t.
r
fo
ng
Assembly of hose connections ⇒ page 11 .
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
⇒ “1.5 Checking charge air system for leaks”, page 256
un
le
2 - Bolt
❑ 2 Nm
3 - Intake air temperature
sender - G42- with charge air
pressure sender - G31❑ Removing and installing
⇒ page 254 .
4 - O-ring
❑ Renew if damaged or
leaking.
5 - Connecting hose
❑ Note installation posi‐
tion ⇒ page 251 .
r
fo
ng
ht
rig
py
Co
t.
6 - Connecting hose
❑ Note installation posi‐
tion ⇒ page 251 .
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
1 - Clamp
❑ Follow installation in‐
structions ⇒ page 11 .
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
7 - Charge air cooler
❑ Removing and installing
⇒ page 251 .
Amarok 2011 ➤
l engine, common rail) - Edition 04.2013
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
r a (2.0
4-cylinder diesel engine
a
c
s
s
8 - Connecting hose
❑ Note installation posi‐
tion ⇒ page 251 .
9 - Turbocharger
10 - Intake manifold
Installation position of connecting hoses
– Install connecting hose in such a way that marking -1- on con‐
necting hose is aligned with marking -2- on respective union.
1.2
Removing and installing charge air cool‐
er
Special tools and workshop equipment required
1. Charge air system
251
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
AG. Volkswagen AG d
♦ Torque wrench - V.A.G 1410agen
o
es n
ot g
ua
ran
tee
or
ac
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
ksw
Vol
by
d
e
ris
tho
u
a
ss
♦ Socket set 1/4", 22-piece - VAS 5528-
ht
rig
py
Co
t.
agen
lksw
Vo
by
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
– Remove bolts -2- for securing radiator to lock carrier -1-.
AG.
– Remove lock carrier ⇒ General body repairs, exterior; Rep.
gr. 66 ; Lock carrier .
– Drain coolant ⇒ page 182 .
– Remove radiator cowl ⇒ page 207 .
Observe instructions for hose connections with screw-type clips
⇒ page 11 .
– If fresh air supply system is present, partially remove
⇒ page 116 .
– Remove coolant hose -1- and connecting hose -2-.
– Remove right connecting hose leading to turbocharger from
chair air cooler and place to one side.
– Remove air duct mounting ⇒ Item 23 (page 369) .
– Squeeze left catch -2- and pull condenser -3- forwards a little.
252
Rep. gr.21 - Turbocharging/supercharging
do
c
um
en
Removing
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unclip right catch as well and pull condenser -3- off radiator
-1-.
Caution
•
Do not bend or stretch the refrigerant lines excessively.
•
During further removal work, make sure that the refriger‐
ant lines are not bent or stretched excessively.
– Support condenser, e.g. with cable ties.
– Do not bend or stretch the refrigerant lines excessively.
– Carefully remove radiator upwards together with charge air
cooler. When doing so, take the radiator -2- past the refrigerant
lines.
Note
♦ If the radiator -1- is to be replaced, undo bolts of charge air
cooler and remove it from radiator.
♦ Undo and remove bolt -2- on right and left (not shown in illus‐
tration) at radiator.
Installing
Installation is carried out in the reverse order; note the following:
Note
r
fo
ng
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ht
rig
py
Co
t.
un
le
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
no
l
o
gu are
y Vcheck that radiator mountings t-1b
Before installing radiator,
ara
d
e
nte
s
i
r
correctly seated on
front
part
of
car
-2and,
if
necessary,
reposi‐
o
eo
h
ut
ra
tion:
a
c
s
s
1. Charge air system
253
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Insert radiator mounting into lock carrier -2- at bottom -1-, do‐
ing so transversely to the direction of travel, and then turn it
90".
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
– When installing the radiator, make sure that the catches -1- of
the radiator mounting on the left and right at the top have en‐
gaged completely in the lock carrier.
AG.
– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
50 ; Lock carrier .
Assembly of hose connections ⇒ page 11 .
Specified torques
♦ ⇒ “1.1 Assembly overview - charge air system”, page 250
♦ ⇒ “3.1 Assembly overview - radiator/ radiator fan V7 ”,
page 202
♦ ⇒ “3.2 Assembly overview - radiator cowl and radiator fan V7
”, page 204
1.3
Removing and installing intake air tem‐
perature sender - G42- with charge air
pressure sender - G31-
Special tools and workshop equipment required
254
Rep. gr.21 - Turbocharging/supercharging
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
– Filling with coolant ⇒ page 182
ht
rig
py
Co
t.
– Install radiator cowl ⇒ page 207 .
do
c
um
en
– Insert top radiator mountings -1- on right and left into the
mounting on radiator -2- appropriately.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Torque wrench - V.A.G 1410-
Removing
– Release and pull off connector -1- for intake air temperature
sender - G42- together with charge air pressure sender - G31-1-.
– Undo and remove bolts for intake air temperature sender G42- and charge air pressure sender - G31- -1-.
– Pull intake air temperature sender - G42- together with charge
air pressure sender - G31- -1- out of union.
Installing
Installation is carried out in the reverse order;
ility
ab
y li
an
pt
ce
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Specified torques
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
note the
ir sefollowing:
tee
o
h
t
or
u
ac
a
ss
♦ ⇒ “1.1 Assembly overview - charge air system”, page 250
Removing and installing exhaust gas
flap valve - N220-
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
1.4
Special tools and workshop equipment required
do
c
um
en
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
♦ Socket set 1/4", 22-piece - VAS 5528-
ht
rig
py
Co
t.
♦ Torque wrench - V.A.G 1410-
1. Charge air system
255
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Removing
– Pull connector -3- and vacuum lines and pull off fuel pressure
regulating valve - N220- -1-.
– Remove spreader rivet -2- and exhaust gas flap valve - N220-1-.
Installing
Installation is carried out in the reverse order; note the following:
Caution
Do not kink, twist or crush the vacuum lines when routing. This
may cause breakdowns.
Connect all hoses to stop or at least 10 mm on the relevant
connection piece.
1.5
Checking charge air system for leaks
Special tools and workshop equipment required
♦ Charge air system tester - V.A.G 1687-
ility
ab
y li
an
pt
ce
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Rep. gr.21 - Turbocharging/supercharging
thi
sd
o
cu
m
en
256
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
♦
ht
rig
py
Co
t.
♦
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
Adapter - V.A.G 1687/10- ised
nte
r
o
eo
h
ut6122ra
Engine bung set - VAS
a
c
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Procedure
– Remove connecting pipe -arrow-.
– Seal union with a bung -2- (diameter 28 mm) fro the engine
bung set - VAS 6122- and secure with a clip -1-.
– Remove intake hose -1- from air filter.
– Insert adapter - V.A.G 1687/10- into intake hose -1- and se‐
cure with a clip.
does
not
gu
ara
nte
eo
ra
c
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
wag
olks
yV
b
ed
ris
ho
t
au
ss
ility
ab
y li
an
pt
ce
un
le
Prepare charge air system
tester
olkswa-gV.A.G
en AG 1687- as follows:
en AG. V
– Unscrew pressure control valve -2- completely and close
valves -3- and -4-.
Note
ht
rig
py
Co
t.
r
fo
ng
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
1. Charge air system
257
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Connect charge air system tester - V.A.G 1687- to adapter V.A.G 1687/10- as shown.
– Connect compressed air hose -1- (compressed air supply) toagen AG. Volkswagen AG d
oes
not
lksw
charge air system tester - V.A.G 1687- , using a standard
Vocon‐
gu
y
b
ara
necting piece.
d
e
n
ris
tho
u
a
ss
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
Note
tee
or
ac
Drain water in sight glass by removing drain plug -6-.
Caution
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Open valve -3-.
The pressure must not exceed 0.5 bar! If the pressure is too
high, this can cause damage to the charge air system.
– Adjust pressure to 0.5 bar with pressure control valve -2-.
– Open valve -4- and wait until test circuit is full. If necessary,
adjust pressure to 0.5 bar.
– Check charge air system for leaks as follows:
Prote
cted
by
♦ Slight leaks on the intake side of turbocharger are permissible,
as the intake hoses are not designed for high-pressure.
♦ A small amount of air escapes through the valves and enters
the engine. Therefore a holding pressure test is not possible.
♦ How to use the ultrasonic tester - V.A.G 1842- ⇒ operating
instructions
♦ Depressurise test circuit by detaching coupling from adapter -
V.A.G 1687/10- before removing adapter.
258
Rep. gr.21 - Turbocharging/supercharging
AG.
Note
agen
lksw
Vo
by
♦ or with ultrasonic tester - V.A.G 1842- .
c
o
p
yri
gh
t.
C
op
yi
♦ With leak detector spray
do
c
um
en
♦ By feeling
ht
rig
py
Co
t.
♦ By listening
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
ht
rig
py
Co
t.
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2. Turbocharger
259
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2
Turbocharger
⇒ “2.1 Assembly overview - turbocharger, 120 kW and 132 kW
engines”, page 260
⇒ “2.2 Assembly overview - turbocharger, 90 kW and 103 kW
engines”, page 264
⇒ “2.3 Removing and installing turbocharger - 120 kW and
132 kW engines”, page 267
⇒ “2.4 Removing and installing turbocharger - 90 kW and 103 kW
engines”, page 272
⇒ “2.5 Removing and installing charge pressure sender 2 G447
”, page 277
⇒ “2.6 Removing and installing regulating flap potentiometer
G584 and vacuum unit for turbocharger, 120 kW engine”,
page 278
⇒ “2.7 Removing and installing regulating flap potentiometer
G584 and vacuum unit for turbocharger, 132 kW engine”,
page 290
⇒ “2.8 Removing and installing charge pressure control solenoid
valve N75 ”, page 300
2.1
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Assembly overview - turbocharger, 120 kW and 132 kW engines
un
le
pe
rm
itte
d
ility
ab
y li
an
pt
ce
Note
♦ Sealed bolts and nuts must not be loosened.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
♦ All hose connections are secured.
♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ Before screwing on oil pressure line, fill turbocharger with engine oil through union.
♦ After installing turbocharger, allow engine to run at idling speed for about 1 minute to ensure that oil is
supplied to turbocharger.
1 - Heat shield
2 - Bolt
❑ 9 Nm
r
te o
iva
r
rp
fo
g
n
260
Rep. gr.21 - Turbocharging/supercharging
AG.
6 - Exhaust gas temperature
sender 1 - G235❑ Grease thread of sender
using high-temperature
paste ⇒ Electronic
Parts Catalogue (ET‐
KA) .
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
5 - Nut
❑ 9 Nm
ht
rig
py
Co
t.
4 - Regulating flap potentiom‐
eter - G584❑ Removing and installing
⇒ page 278 .
do
c
um
en
3 - Vacuum unit
❑ Removing and installing
⇒ page 321 .
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
❑
❑
❑
❑
Sender must not be bent when removing and installing.
Sender must not contact any other component when installed.
Black connector
45 Nm
7 - Nut
❑ Renew after removing
•
Tightening sequence ⇒ page 263 .
•
Installation sequence:
♦ Bolts ⇒ Item 11 (page 261) and ⇒ Item 12 (page 261) must be loosened at bracket.
♦ Fit turbocharger on studs on
cylinder head.
n AG. Volkswagen A
G do
es
ge
swa
k
not
Vol bolts ⇒ Item 9 (page 261) in
♦ Tighten turbocharger
sequence.
gspecified
ua
by
d
se
ran
8 - Gasket
❑ Renew after removing
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
ility
ab
y li
an
pt
ce
te
ri
♦ First, tighten
and ⇒ Item 12 (page 261) . After that, tighten
ho bolt by hand. Then, tighten ⇒ Item 11 (pagee261)
or
ut
ac
a
bolts to sspecified
torque.
s
❑ 25 Nm
9 - Exhaust manifold with turbocharger
❑ Renew complete only.
❑ Before removing, connecting pipes must be removed ⇒ page 250 .
❑ Always renew oil return line when it has been removed or opened in area of hose connection.
❑ Check oil supply lines for damage before installing them ⇒ Item 16 (page 261) .
❑ Note tightening sequence and installation procedure ⇒ page 263 .
❑ When turbocharger and connecting pipes are being assembled, it is essential that the correct repair kit
⇒ ETKA (Electronic Parts Catalogue) is used.
❑ Installation position of connecting hose at turbocharger ⇒ page 263
❑ Removing and installing ⇒ page 267 .
10 - Bracket
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
12 - Bolt
❑ 40 Nm
ht
rig
py
Co
t.
r
fo
ng
11 - Bolt
❑ Renew after removing
❑ Observe tightening sequence and procedure ⇒ page 263 .
❑ 40 Nm
13 - Banjo bolt
❑ 30 Nm
14 - Double seal
❑ Renew after removing
❑ Remember that there are various sizes
15 - Banjo bolt
❑ 24 Nm
16 - Oil supply line
❑ To remove oil supply line completely, engine support and starter must first be removed.
2. Turbocharger
261
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Note
♦ Risk of damage when removing
and installing turbocharger.
♦ Check oil supply line for damage
after removing (kinks in hose).
Oil supply line must be renewed
if damaged.
♦ Check oil supply line for damage
(kinks in hose) after installing tur‐
bocharger.
♦ Removing and installing
⇒ page 170 .
17 - Banjo bolt
❑ 60 Nm
18 - Seal
❑ Renew after removing
19 - Bolt
❑ 25 Nm
20 - Seal
❑ Renew after removing
21 - Banjo bolt
❑ For oil return line
❑ 60 Nm
22 - Oil return line
❑ Oil return line must always be renewed after removing turbocharger.
23 - Bolt
❑ 11 Nm
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
un
le
pe
rm
itte
d
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
25 - Bolt
❑ 15 Nm
ility
ab
y li
an
pt
ce
24 - Gasket
❑ Renew after removing
26 - Oil return line
❑ Oil return line must be renewed after removing turbocharger.
27 - Clip
28 - Bolt
❑ 9 Nm
29 - Pulsation damper
AG.
Rep. gr.21 - Turbocharging/supercharging
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
262
ht
rig
py
Co
t.
32 - Seal
❑ Renew after removing
do
c
um
en
31 - Banjo bolt
❑ 30 Nm
r
te o
iva
r
rp
fo
g
n
30 - O-ring
❑ Not available as replacement part.
❑ Included in ⇒ Item 29 (page 262) .
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
33 - Line to charge pressure sender 2 - G44734 - Retaining clamp
35 - Bolt
❑ 3 Nm
36 - Bolt
❑ 9 Nm
37 - Charge pressure sender 2 - G447Tightening sequence and installation procedure
♦ Position exhaust manifold together with turbocharger on studs
on cylinder head.
♦ Only screw bolt ⇒ Item 7 (page 261) loosely into turbocharger.
♦ Tighten nuts -1- to -8- to 25 Nm in specified sequence. Then
tighten nuts to 25 Nm again in specified sequence.
♦ Tighten bolt ⇒ Item 11 (page 261) .
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
s
i
r
Installation position
of
connecting
hose
at
turbocharger
o
eo
h
ut
ra
a
c
s
– Fit connecting
hose in such a way that the “rib” -1- of the con‐
s
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
necting hose is aligned with the middle of the nameplate -2-.
thi
sd
o
cu
m
en
2. Turbocharger
263
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2.2
Assembly overview - turbocharger, 90 kW and 103 kW engines
Note
♦ Sealed bolts and nuts must not be loosened.
♦ All hose connections are secured.
♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
2 - Bolt
❑ No replacement part
available
do
c
um
en
1 - Turbocharger
❑ Renew complete only.
❑ Connecting pipes must
be removed before re‐
moving ⇒ page 250 .
❑ Check oil pressure lines
for damage before in‐
stalling them.
❑ Note tightening se‐
quence and installation
procedure ⇒ page 263 .
❑ When turbocharger and
connecting pipes are
being assembled, it is
essential that the cor‐
rect repair set ⇒ ETKA
(Electronic Parts Cata‐
logue) is used.
❑ Installation position of
connecting hose at tur‐
bocharger ⇒ page 264
❑ Removing and installing
⇒ page 272 .
that oil is
ility
ab
y li
an
pt
ce
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
♦
ht
rig
py
Co
t.
♦
n AG. Volkswagen AG do
e n
wage
s
k
l
ot g
o
Before screwing on oil pressure line, fill turbocharger
with engine oil through sunion.
yV
ua
b
d
ran
ir se
ee
After installing turbocharger, allow enginethto
o run at idling speed for about 1 minute to tensure
or
u
ac
a
supplied to turbocharger.
ss
3 - Position sender for charge
pressure positioner - G5814 - Heat shield
5 - Bolt
❑ 9 Nm
6 - Exhaust gas temperature
sender 1 - G235❑ Grease thread of sender
using high-temperature paste ⇒ Electronic Parts Catalogue (ETKA) .
❑ Exhaust temperature sender 1 - G235- must not be bent or twisted when removing and installing.
❑ Exhaust temperature sender 1 - G235- must not contact any other component on installation.
❑ Black connector
❑ 45 Nm
264
Rep. gr.21 - Turbocharging/supercharging
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
7 - Bolt
❑ M10 x 35
8 - Bolt
❑ M10 x 18
9 - Support
10 - Nut
❑ No replacement part available
11 - Bolt
❑ M10 x 30
12 - Nut
❑ Renew after removing
•
Installation sequence:
♦ Position turbocharger on studs on cylinder head.
♦ First tighten nut finger-tight, then tighten nut to prescribed torque ⇒ page 266 .
♦ Tighten turbocharger bolts ⇒ page 266 in specified sequence.
❑ 25 Nm
13 - Exhaust manifold with turbocharger
❑ Renew complete only.
❑ Tightening sequence ⇒ page 266 .
14 - Gasket
❑ Renew after removing
15 - Gasket
❑ Renew after removing
16 - Oil pressure line
n AG. Volkswagen AG do
es n
wage
s
❑ Supply and return.
k
l
ot g
o
yV
ua
b
d
r
❑ Oil pressure line must be
ir serenewed after removing turbocharger. ant
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
Note
ee
or
ac
ho
ut
a
ss
♦ Risk of damage when removing
and installing turbocharger.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
♦ Always renew oil pressure line
after removing.
♦ Check oil pressure line for dam‐
age (kinks in hose) after instal‐
ling turbocharger.
♦ Removing and installing
⇒ page 170 .
17 - Bolt
18 - Seal
❑ Renew after removing
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
21 - O-ring
❑ Renew after removing
ht
rig
py
Co
t.
20 - Seal
❑ Renew after removing
do
c
um
en
19 - Banjo bolt
❑ 32 Nm
2. Turbocharger
265
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
22 - Banjo bolt
❑ 60 Nm
23 - Bolt
❑ M6 x 16
24 - Bolt
❑ No replacement part available
25 - Connection
❑ No replacement part available
26 - Gasket
❑ No replacement part available
Tightening sequence and installation procedure
♦ Position exhaust manifold together with turbocharger on studs
on cylinder head.
. Volkswagen AG
gen AG
does
not
gu
ara
nte
Then
eo
ra
c
a
♦ Tighten nut ⇒ Item 12 (page 265) finger-tight on stud.
ksw
Vol
y
db
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ss
ility
ab
y li
an
pt
ce
un
le
e
♦ Tighten nuts -1- to -8- to 25 Nm in specified osequence.
ris
h
t
tighten nuts to 25 Nm again in specified sequence.
au
Installation position of connecting hose at turbocharger
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Rep. gr.21 - Turbocharging/supercharging
ht
rig
py
Co
t.
266
do
c
um
en
r
te o
iva
r
rp
fo
g
n
– Fit connecting hose in such a way that the “rib” -1- of the con‐
necting hose is aligned with the middle of the nameplate -2-.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2.3
Removing and installing turbocharger - 120 kW and 132 kW engines
Special tools and workshop
equipment required
♦ Torque wrench (5…50 Nm)
- V.A.G 1331♦ Torque wrench (40…200
Nm) - V.A.G 1332♦ Torque wrench - V.A.G
1410♦ Engine bung set - VAS
6122-
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
thi
sd
o
cu
m
en
ht
rig
py
Co
t.
Caution
c
o
p
yri
gh
t.
C
op
yi
When a mechanical fault is found on the turbocharger, e.g. a
destroyed compressor impeller, it is not only sufficient to renew
the turbocharger. To avoid subsequent damage, the following
work must be carried out:
agen
lksw
Vo
by
AG.
Prote
cted
by
♦ Check air filter container, air filter element and intake ho‐
ses for dirt.
♦ Check the whole charge air path and charge air cooler for
foreign objects.
If foreign objects are found in the charge air system, the charg‐
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.
“Biturbo” is removed upwards.
Before the “biturbo” can be removed, the following parts must be
removed:
2. Turbocharger
267
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Exhaust pipe with catalytic converter
♦ Air filter with attachments
Removing
Observe rules for cleanliness ⇒ page 8 .
Observe instructions for hose connections with screw-type clips
⇒ page 11 .
Note
♦ After lines and hoses have been removed, the open connec‐
tions are to be sealed immediately with a plug from the engine
bung set - VAS 6122- .
♦ Only use clean plugs.
– Remove air filter with attachments ⇒ page 368
– Remove connecting pipe ⇒ page 250
– Loosen bolt -2- in screw-type clip -1- for front exhaust pipe
-4- at turbocharger.
– Unscrew and remove bolts -3- in bracket for front exhaust pipe
-4-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
– Loosen screw-type clip -3- for front exhaust pipe -1-.
AG.
Prote
cted
by
Rep. gr.21 - Turbocharging/supercharging
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
268
ht
rig
py
Co
t.
– Carefully remove front exhaust pipe upwards out of the engine
compartment.
do
c
um
en
– Undo and remove bolts -3- for front exhaust pipe -2- at bracket
-1-.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Loosen screw-type clip -2- for connecting hose -1- and detach
connecting hose from pulsation damper.
Note
Seal opening in turbocharger with clean cloths or similar.
– Pull connector -1- off regulating flap potentiometer - G584-3- and lay to side. There is no need to disconnect connector
-1- on exhaust gas recirculation valve - N18- -2-.
Note
The described procedure doesn Anot
compliant
olkswagto
. Vapply
e vehicles
AG do
ge 5Gas sensor nis
aEU
e
w
with the emission standard
secured
perma‐
s
s
k
n
l
ot g
nently to vehicle. d by Vo
ua
r
an
tee
or
ac
– Remove bolts -2 and 3- for pipe -1- from exhaust gas recircu‐
lation cooler.
– Remove pipe from exhaust gas recirculation cooler.
ht
rig
py
Co
t.
c
o
p
yri
gh
t.
C
op
yi
Caution
agen
lksw
Vo
by
•
Avoid damage to oil supply line. Observe notes.
•
When doing this, ensure that no pressure is exerted on the
rod.
•
Do not hold onto the rod when removing the turbocharger.
•
When carrying the turbocharger, always hold it by the
pipes and not by the rods.
do
c
um
en
– Remove oil supply line from turbocharger ⇒ page 170 .
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
– Detach connector -2- from charge air pressure sender 2 G447- -1-.
ility
ab
y li
an
pt
ce
e
ris
tho
u
a
ss
AG.
Prote
cted
by
Bent rods impair the functioning of the turbocharger.
– Loosen clamp ⇒ Item 27 (page 262) and disconnect oil return
line.
2. Turbocharger
269
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - oEdition
04.2013
lksw
agen AG
does
not
gu
ara
nte
eo
ra
c
ility
ab
y li
an
pt
ce
– Remove turbocharger with exhaust manifold upwards.
270
Rep. gr.21 - Turbocharging/supercharging
AG.
– Undo and remove bolts -1- to -8- for exhaust manifold with
turbocharger.
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
– Release and detach connector -1- of exhaust gas temperature
sender 1 - G235- on front right wheel housing -3- at the cou‐
pling point -2-. Then, free wiring harness from fittings and lay
it to one side.
ht
rig
py
Co
t.
r
fo
ng
– Undo and remove bolt -2- for turbocharger -1- at lower bracket.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
– Undo and remove bolts -2- for oil
bocharger -1-.
AG. V
agen
ksw
l
o
V bottom of tur‐
return line
yat
db
ise
r
tho
au
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Undo and remove bolts -1- in bracket for coolant pipe -2- and
remove exhaust manifold gasket -3-.
Installing
Installation is carried out in the reverse order; note the following:
– Renew all gaskets, O-rings and self-locking nuts.
– Install turbocharger with new oil return line.
– Fit new double seal -2- onto the respective line connection
-1- and secure by screwing in the corresponding banjo bolt
-3-.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ar
d
e
isline -arrow- for damage after installing ante
r
Check oil supply
o
eo
th 261) .
ra
⇒ Item 16 (page
au
c
s
s
–
Caution
Note tightening sequence and procedure when bolting
turbocharger on ⇒ page 263 .
Specified torques
♦ ⇒ “2.1 Removing and installing assembly mountings”,
page 31
♦ ⇒ “2.1 Assembly overview - turbocharger, 120 kW and 132 kW
engines”, page 260
♦ ⇒ “7.1 Assembly overview - air filter”, page 368
♦ ⇒ “2.1 Assembly overview - emission control (diesel particu‐
late filter)”, page 377
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
•
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
– Install connecting pipes ⇒ page 250 .
2. Turbocharger
271
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2.4
Removing and installing turbocharger - 90 kW and 103 kW engines
Special tools and workshop
equipment required
♦ Torque wrench (5…50 Nm)
- V.A.G 1331♦ Torque wrench (40…200
Nm) - V.A.G 1332♦ Torque wrench - V.A.G
1410♦ Engine bung set - VAS
6122-
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Caution
When a mechanical fault is found on the turbocharger, e.g. a
destroyed compressor impeller, it is not only sufficient to renew
the turbocharger. To avoid subsequent damage, the following
work must be carried out:
♦ Check air filter container, air filter element and intake ho‐
ses for dirt.
♦ Check the whole charge air path and charge air cooler for
foreign objects.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
“Turbocharger” is removed upwards.
AG.
Prote
cted
by
For removal of the “turbocharger”, the following parts must first
be removed:
272
Rep. gr.21 - Turbocharging/supercharging
ht
rig
py
Co
t.
If foreign objects are found in the charge air system, the charg‐
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Exhaust pipe with catalytic converter
♦ Air filter with attachments
n AG. Volkswagen A
G do
age
es n
ksw
ot g
Vol
y
ua
b
d
ran
e
tee
ris
Observethorules
for cleanliness ⇒ page 8 .
or
u
ac
a
ss
Observe
instructions for hose connections with screw-type
Removing
un
le
pe
rm
itte
d
Note
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
♦ After lines and hoses have been removed, the open connec‐
tions are to be sealed immediately with a plug from the engine
bung set - VAS 6122- .
♦ Only use clean plugs.
– Remove air filter with attachments ⇒ page 368
– Remove connecting pipe ⇒ page 250
– Loosen bolt -2- in screw-type clip -1- for front exhaust pipe
-4- at turbocharger.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
– Unscrew and remove bolts -3- in bracket for front exhaust pipe
-4-.
ht
rig
py
Co
t.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
clips
ility
ab
y li
an
pt
ce
⇒ page 11 .
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
– Loosen screw-type clip -3- for front exhaust pipe -1-.
– Undo and remove bolts -3- for front exhaust pipe -2- at bracket
-1-.
– Carefully remove front exhaust pipe upwards out of the engine
compartment.
2. Turbocharger
273
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Loosen screw-type clip -2- for connecting hose -1- and detach
connecting hose from pulsation damper.
Note
Seal opening in turbocharger with clean cloths or similar.
– Pull connector -1- off position sender for charge pressure po‐
sitioner - G581- -3- and lay to side. There is no need to
disconnect connector -1- on exhaust gas recirculation valve N18- -2-.
Note
The described procedure does not apply to vehicles compliant
with the emission standard EU 5 as sensor is secured perma‐
nently to vehicle.
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
– Detach connector -4- from charge air pressure sender 2 G447- -1-.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
– Remove bolts -2 and 3- for pipe -1- from exhaust gas recircu‐
lation cooler.
– Remove pipe from exhaust gas recirculation cooler.
Caution
Avoid damage to oil pressure line. Observe notes.
•
When doing this, ensure that no pressure is exerted on the
rod.
•
Do not hold onto the rod when removing the turbocharger.
•
When carrying the turbocharger, always hold it by the
pipes and not by the rods.
Bent rods impair the functioning of the turbocharger.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Rep. gr.21 - Turbocharging/supercharging
ht
rig
py
Co
t.
274
do
c
um
en
r
te o
iva
r
rp
fo
g
n
•
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unscrew nut -3- for support -2- of turbocharger -1-.
– Remove securing bolts -2 and 3- for support -1-.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
ht
rig
py
Co
t.
r
fo
ng
– Remove securing bolt and banjo bolt -1 and 2-.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
– Loosen clamp -2- on oil pressure line pipe -1- and separate oil
pressure line.
2. Turbocharger
275
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
– Remove nuts -1- to -8- for exhaust manifold with turbocharger.
– Remove turbocharger with exhaust manifold and oil line up‐
wards.
– Undo and remove bolts -1- in bracket for coolant pipe -2- and
remove exhaust manifold gasket -3-.
r
fo
ng
Installation is carried out in the reverse order; note the following:
c
o
p
yri
gh
t
.
C
op
yi
– Renew all gaskets, O-rings and self-locking nuts.
Prote
cted
by
– Install connecting pipes ⇒ page 250 .
Caution
•
Note tightening sequence and procedure when bolting
turbocharger on ⇒ Item 12 (page 265) .
Specified torques
♦ ⇒ “2.1 Removing and installing assembly mountings”,
page 31
♦ ⇒ “2.2 Assembly overview - turbocharger, 90 kW and 103 kW
engines”, page 264
♦ ⇒ “7.1 Assembly overview - air filter”, page 368
♦ ⇒ “2.1 Assembly overview - emission control (diesel particu‐
late filter)”, page 377
276
Rep. gr.21 - Turbocharging/supercharging
AG.
– Fit new seals -2- onto the respective line connection -3- and
secure by screwing in the corresponding banjo bolt -1-.
agen
lksw
Vo
by
– Install turbocharger with new oil pressure line.
ht
rig
py
Co
t.
Installing
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
– Release and detach connector -1- of exhaust gas temperature
sender 1 - G235- on front right wheel housing -3- at the cou‐
pling point -2-. Then, free wiring harness from fittings and lay
it to one side.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2.5
Removing and installing charge pres‐
sure sender 2 - G447Note
♦ On vehicles without particulate filter, the charge pressure
sender 2 - G447- can only be renewed together with bracket,
as one unit ⇒ Electronic parts catalogue (ETKA) .
♦ Charge air pressure sender 2 - G447- is integrated into turbo‐
charger and cannot be replaced on vehicles with a particulate
filter.
Special tools and workshop equipment required
♦ Torque wrench (5…50 Nm) - V.A.G 1331-
♦ Engine bung set - VAS 6122-
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Note
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Removing
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
♦ Due to risk of breakage, sensor is replaced complete with
bracket and hose.
♦ The described procedure does not apply to vehicles compliant
with the emission standard EU 5 as sensor is secured perma‐
nently to vehicle.
AG.
Prote
cted
by
♦ Only use clean plugs.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
tions are to be sealed immediately with a plug from the engine
bung set - VAS 6122- .
ht
rig
py
Co
t.
♦ After lines and hoses have been removed, the open connec‐
do
c
um
en
Note
2. Turbocharger
277
olkswagen AG
en AG. V
does
ag
Amarok 2011 ➤
ksw
not
Vol
gu
y
b
ara
4-cylinder diesel engine (2.0 l engine,
common
rail)
Edition
04.2013
d
e
nte
eo
ra
c
air pressure sender
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
– Release and pull connector
2 - G447- -1-.
ris
tho
u
-4-ss aoff charge
– Unscrew bolts -2- on bracket for charge air pressure sender 2
- G447- .
Installing
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
– Remove banjo bolt -3- from turbocharger and remove charge
air pressure sender 2 - G447- complete.
Install in reverse order.
Removing and installing regulating flap
potentiometer - G584- and vacuum unit
for turbocharger, 120 kW engine
2.6.1
Removing and installing regulating flap potentiometer - G584-
♦ Vehicle diagnostic tester
278
Rep. gr.21 - Turbocharging/supercharging
Prote
cted
by
♦ Torque wrench - V.A.G
1783- with open end span‐
ner insert AF10 - V.A.G
1783/1-
AG.
♦ Turbocharger tester V.A.G 1397A-
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
♦ Hand vacuum pump - VAS
6213- or hand vacuum
pump - V.A.G. 1390- .
ht
rig
py
Co
t.
Special tools and workshop
equipment required
thi
sd
o
cu
m
en
2.6
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Note
A spare-parts kit ⇒ ETKA (electronic parts catalogue) is available
for replacing the regulating flap potentiometer - G584- .
Removing
– Detach vacuum hose -2- from upper toothed belt guard -1-.
– Remove pipe -arrow- from cylinder head cover.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
– Detach hoses from connecting hose -3- bracket -arrow-.
agen
lksw
Vo
by
2. Turbocharger
do
c
um
en
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
– Remove connecting hose -3-.
ht
rig
py
Co
t.
– Open clips -1- and -4-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Release and pull off wiring harness connector -2-. Detach wir‐
ing harness -2- from connecting hose retainer -3-.
279
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Pull hose off regulating flap potentiometer - G584- -2-.
– Unclip connector -1- from regulating flap potentiometer G584- -2-.
Only for vehicles with charge air pressure sender 2 - G447- on
turbocharger.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
– Detach connector -2- from charge air
G447- -1-.
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
s
s
pressure sender 2 -
– Undo and remove bolts -2- securing bracket for charge air
pressure sender 2 - G447- -1- and place charge air pressure
sender 2 - G447- to one side.
Continuation for all vehicles
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Rep. gr.21 - Turbocharging/supercharging
ht
rig
py
Co
t.
280
do
c
um
en
– Seal opening -3- of turbocharger with a suitable cover.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Undo and remove bolts -2- securing heat shield -1- and re‐
move heat shield.
– Working from below, undo and remove nuts securing regulat‐
ing flap potentiometer - G584- -1- together with bracket -2- to
mounting of turbocharger (2 nuts).
– Remove regulating flap potentiometer - G584- upwards to‐
gether with bracket.
ht
rig
py
Co
t.
agen
lksw
Vo
by
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Installing
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
– Counterhold lock nut -3- with open-end spanner.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Undo and completely remove nut -2- securing control rod.
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
Installation is carried out in the reverse order; note the following:
AG.
Caution
Use only new bolts and nuts from the spare-parts kit if the reg‐
ulating flap potentiometer - G584- is being replaced complete‐
ly!
New part
– If necessary, remove lower nut securing the control rod of the
new regulating flap potentiometer - G584- .
Note
Lock nut must have been screwed onto control rod.
Old part
– Remove lock nut from control rod and carefully remove the
sealing paint from the control rod completely.
– Screw new lock nut from spare-parts kit onto control rod again.
Continuation for all
2. Turbocharger
281
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Carefully clean touching surfaces of regulating flap potenti‐
ometer - G584- -3- and bracket -2-.
– Carefully clean mounting for regulating flap potentiometer G584- on turbocharger.
– Insert regulating flap potentiometer - G584- -3- in such a way
that the location marker -1- fits into the hole in the bracket
-2-.
ility
ab
y li
an
pt
ce
the illustration.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
–
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
Install regulating flap potentiometer - G584- and guide control
u
ra
a
c
s
rod -1- through adjusting lever on turbocharger as shown
in
s
– Fit regulating flap potentiometer - G584- on the turbocharger
mounting with new nuts from the spare-parts kit -4- and tighten
nuts to 8 Nm.
– Screw nuts -2- onto control rod by hand in direction of vacuum
unit.
AG.
Prote
cted
by
Rep. gr.21 - Turbocharging/supercharging
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
282
ht
rig
py
Co
t.
Make sure that the guiding element -1- of the flap lever moves
easily along the control rod.
thi
sd
o
cu
m
en
Note
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
e o Amarok 2011 ➤
h
ut
ra
a
s
4-cylinder
diesel engine (2.0 l engine, common rail) -c Edition 04.2013
s
– Attach connector -1- to regulating flap potentiometer - G584-2-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Connect ⇒ Vehicle diagnostic tester.
Selecting operating mode:
– Press button on display for “Vehicle self-diagnosis”.
Selecting vehicle system:
– Press button “01 - Engine electronics” on display.
The display indicates the control unit identification and the coding
of the engine control unit.
Selecting diagnostic function:
– Press button for “011 - Measured values” on the display.
– The display shows the individual components.
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Switch on turbocharger tester - V.A.G 1397A- and move sliding
switch on device to position II.
ht
rig
py
Co
t.
– Connect turbocharger tester - V.A.G 1397A- and hand vac‐
uum pump - VAS 6213- or hand vacuum pump - V.A.G. 1390to vacuum connection -1- of regulating flap potentiometer G584- using a T-piece to do so.
do
c
um
en
– Select “Bypass Valve, Turbocharger, High Pressure Turbine
Input, Input Voltage” and confirm entry with Q .
AG.
– Apply a vacuum of 500 ± 50 mbar to regulating flap potenti‐
ometer - G584- .
– Move flap lever -1- on turbocharger in -direction of arrow- to
“Closed” position and hold it there.
– Screw securing nut -3- in direction of vacuum unit until it con‐
tacts flap lever -1-.
– Continue turning securing nut -3- until a voltage of 0.75 volt ±
0.02 volt of regulating flap potentiometer - G584- is reached.
– Tighten lock nut -2- to 8 Nm.
Note
Make sure that control rod -1- does not turn by counterholding on
nut -2-.
2. Turbocharger
283
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Slowly reduce vacuum. Flap lever -1- now moves in
-direction of arrow- “Open”.
– Apply a vacuum of 500 ± 50 mbar to regulating flap potenti‐
ometer - G584- again.
– Check voltage setting (0.75 volt ± 0.02 volt) of regulating flap
potentiometer - G584- and, if necessary, reset.
Slowly reduce vacuum.
Note
Flap lever -1- must now be resting against the stop. If the flap
lever is not resting against the stop, the setting procedure must
be repeated until the setting values agree with each other.
– After this, secure the nuts and lock nuts with sealing paint from
the replacement-parts kit.
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
pe
rm
itte
d
ility
ab
y li
an
pt
ce
AG.
Prote
cted
by
Rep. gr.21 - Turbocharging/supercharging
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
284
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– Tighten securing bolts -2- for heat shield -1-.
ht
rig
py
Co
t.
un
le
– Press securing clip from replacement-parts kit onto control rod
and turn 90° in -direction of arrow-.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2.6.2
Removing and installing vacuum unit for turbocharger
Special tools and workshop
equipment required
♦ Universal dial gauge brack‐
et - VW 387♦ Hand vacuum pump - VAS
6213- or hand vacuum
pump - V.A.G. 1390- .
♦ Turbocharger tester V.A.G 1397A♦ Dial gauge set, 4-part - VAS
6341♦ Torque wrench - V.A.G
1783- with open end span‐
ner insert AF10 - V.A.G
1783/1-
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
A spare-parts kit ⇒ ETKA (electronic parts catalogue) is available
for replacing the vacuum unit.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
– Remove pipe -arrow- from cylinder head cover.
ht
rig
py
Co
t.
Removing
thi
sd
o
cu
m
en
Note
2. Turbocharger
285
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Detach vacuum hoses from connecting hose -3- bracket
-arrow-.
– Release and pull off wiring harness connector -2-. Detach wir‐
ing harness -2- from connecting hose retainer -3-.
– Open clips -1- and -4-.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
– Remove connecting hose -3-.
ht
rig
py
Co
t.
– Undo and remove bolts -2- securing heat shield -1-.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
– Pull hose -1- off vacuum unit -2-.
– Undo and completely remove lower nut -3- of control rod -5-.
286
Rep. gr.21 - Turbocharging/supercharging
do
c
um
en
r
te o
iva
r
rp
fo
g
n
– Pull hose off regulating flap potentiometer - G584- -2-.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Undo nuts of vacuum unit -1- and remove vacuum unit -2-.
Installing
Installation is carried out in the reverse order; note the following:
Caution
Only use new nuts from the spare-parts kit!
– Carefully cleaning touching surfaces of vacuum unit.
– If necessary, remove lower securing nut -3- of the control rod
from the new vacuum unit -2-.
olkswagen AG
en AG. V
do
ag
– Install new vacuum unit -2- and push
ksw control rod -5- throughes not
Vol
gu
y
b as shown in illustration.
adjusting lever on turbocharger
ara
ed
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Fit vacuum unit -2- in place and fit nuts -1-, tighten nuts to 8
Nm.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Note
ht
rig
py
Co
t.
– Screw nuts -3- onto control rod by hand in direction of vacuum
unit.
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Location marker on vacuum unit must fit into mounting on turbo‐
charger.
ility
ab
y li
an
pt
ce
Note
nte
eo
ra
c
ris
ho
ut
a
ss
Make sure that the guiding element of the flap lever moves easily
along the control rod.
2. Turbocharger
287
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Connect turbocharger tester - V.A.G 1397A- -2- and hand
vacuum pump - VAS 6213- or hand vacuum pump - V.A.G.
1390- -3- to vacuum connection of vacuum unit -1- using a Tpiece to do so.
Switch turbocharger tester - V.A.G 1397A- on and move sliding
switch on device to position II.
– Apply a vacuum of 390 ± 10 mbar to vacuum unit.
Caution
The following adjusting work must be carried out with extreme
care and precision as, otherwise, there is a risk that the turbo‐
charger will be damaged.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
ility
ab
y li
an
pt
ce
un
le
– Move flap lever -4- on turbocharger in -direction of arrow- to
“Closed” position.
Make sure that control rod -1- does not turn by counterholding on
the nut -3-.
– Reduce vacuum again and apply a vacuum of 390 ± 10 mbar
to vacuum unit again.
Note
Flap lever must now be resting against the stop (closed position).
– Reduce vacuum again.
288
Rep. gr.21 - Turbocharging/supercharging
Prote
cted
by
Repeat this procedure approx. 3-5 times.
AG.
The check must be repeated at least 3 to 5 times in order to ensure
that the vacuum unit has been set precisely and in order to avoid
possible damage to the turbocharger.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
Note
ht
rig
py
Co
t.
r
fo
ng
– Check set value and, if necessary, reset.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
Note
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
– Screw nut -3- in direction of vacuum unit until it is touching the
flap lever, while applying a tightening torque of 8 Nm to the
lock nut -2- at the same time.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Secure dial gauge - VAS 6079- together with universal dial
gauge bracket - VW 387- to turbocharger with a suitable bolt
-1- (as shown in illustration) and move gauge to end of control
rod -2-.
Note
The dial gauge rod and the control rod of the vacuum unit must
be in line with each other.
– Operate hand vacuum pump - VAS 6213- until the turbocharg‐
er tester - V.A.G 1397A- indicates 390 ± 10 mbar.
– Set dial gauge, 0-30 mm - VAS 6341/1- to 0.
– Operate hand vacuum pump - VAS 6213- until turbocharger
tester - V.A.G 1397A- indicates 410 ± 10 mbar.
–
–
n AG. Volkswagen AG do
es n
wage
s
k
l
Read value on dial gauge - VAS 6079- .
ot g
o
yV
ua
b
ran
ed
s
i
tee
r
Make sure that value on dial gauge - VAS 6079does
not
o
h
t
or
u
change.
ac
a
ss
– Secure securing nut and lock nut with sealing paint from the
spare-parts kit.
– Press retaining clip from spare-parts kit onto control rod and
turn 90° in the -direction of the arrow-.
r
fo
ng
c
o
p
yri
gh
t
.
C
op
yi
Further assembly is carried out in the reverse order of removal.
ht
rig
py
Co
t.
– Tighten bolts -2- securing heat shield -1- to 9 Nm.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
ility
ab
y li
an
pt
ce
– If the value has changed, correct the setting of the vacuum unit
and repeat the measurement until the setting agrees with the
specified values.
2. Turbocharger
289
agen
lksw
Vo
by
AG.
Prote
cted
by
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2.7
Removing and installing regulating flap
potentiometer - G584- and vacuum unit
for turbocharger, 132 kW engine
2.7.1
Removing and installing regulating flap potentiometer - G584-
Special tools and workshop
equipment required
♦ Hand vacuum pump - VAS
6213- or hand vacuum
pump - V.A.G. 1390- .
♦ Turbocharger tester V.A.G 1397A♦ Torque wrench - V.A.G
1783- with open end span‐
ner insert AF10 - V.A.G
1783/1♦ Vehicle diagnostic tester
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Note
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
A replacement-parts kit for replacing the regulating flap potenti‐
ometer - G584- is available in the ⇒ ETKA (electronic parts
catalogue) .
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Rep. gr.21 - Turbocharging/supercharging
thi
sd
o
cu
m
en
290
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Removing
– Remove pipe -arrow- from cylinder head cover.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Detach hoses from retainer -arrow- on connecting hose -3-.
– Release and pull off wiring harness connector -2-. Detach wir‐
ing harness -2- from connecting hose retainer -3-.
– Open clips -1- and -4-.
– Remove connecting hose -3-.
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
– Pull hose off regulating flap potentiometer - G584- -2-.
– Unclip connector -1- from regulating flap potentiometer G584- -2-.
2. Turbocharger
291
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Undo and remove bolts -2- securing heat shield -1- and re‐
move heat shield.
– Lever off retaining clamp.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
– Loosen and completely unscrew securing nut -2- for control
rod.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Counterhold lock nut -3- with open-end spanner.
– Working from below, unbolt regulating flap potentiometer G584- -1- together with bracket -2- from mounting of turbo‐
charger (3 nuts).
c
o
p
yri
gh
t
.
C
op
yi
Installation is carried out in the reverse order; note the following:
Prote
cted
by
New part
– If necessary, remove lower securing nut on control rod of new
regulating flap potentiometer - G584- .
Note
The lock nut must be screwed onto control rod.
Old part
– Unscrew lock nut from control rod and carefully remove seal‐
ing paint from control rod completely.
– Screw new lock nut from replacement-parts kit onto control
rod.
Continuation for all
292
Rep. gr.21 - Turbocharging/supercharging
AG.
Use only new bolts and nuts from the replacement-parts kit if
the regulating flap potentiometer - G584- is being renewed
completely!
agen
lksw
Vo
by
Caution
ht
rig
py
Co
t.
Installing
do
c
um
en
– Remove regulating flap potentiometer - G584- upwards to‐
gether with bracket.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Carefully clean contact surfaces of regulating flap potentiom‐
eter - G584- -3- and bracket -2-.
– Carefully clean mounting for regulating flap potentiometer G584- on turbocharger.
ility
ab
y li
an
pt
ce
illustration.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
–
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut guide control
ra
Install regulating flap potentiometer - G584- and
a
c
s
s
rod -1- through adjusting lever on turbocharger
as shown in
– Fit regulating flap potentiometer - G584- on the turbocharger
mounting with new nuts from the replacement-parts kit -4- and
tighten nuts to 8 Nm.
– Screw securing nut -2- onto control rod by hand in direction of
vacuum unit.
ht
rig
py
Co
t.
Make sure that the guiding element -1- of the flap lever moves
easily along the control rod.
thi
sd
o
cu
m
en
Note
agen
lksw
Vo
by
2. Turbocharger
293
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine,
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
s
i
r
common
rail)
Edition
04.2013
o
eo
h
ut
ra
a
c
s
s
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
– Attach connector -1- to regulating flap potentiometer - G584-2-.
Connect ⇒ Vehicle diagnostic tester.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Selecting operating mode:
– Press button on display for “Vehicle self-diagnosis”.
Selecting vehicle system:
– Press button “01 - Engine electronics” on display.
The display indicates the control unit identification and the coding
of the engine control unit.
Selecting diagnostic function:
– Press button for “011 - Measured values” on the display.
– The display shows the individual components.
– Move flap lever -1- on turbocharger in -direction of arrow- to
“Closed” position and hold it there.
– Screw securing nut -3- in direction of vacuum unit until it con‐
tacts flap lever -1-.
– Continue turning securing nut -3- until a voltage of 0.75 volt ±
0.02 volt of regulating flap potentiometer - G584- is reached.
– Tighten lock nut -2- to 8 Nm.
Note
Make sure that control rod -1- does not turn by counterholding on
nut -2-.
294
Rep. gr.21 - Turbocharging/supercharging
AG.
– Apply a vacuum of 500 ± 50 mbar to regulating flap potenti‐
ometer - G584- .
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Switch on turbocharger tester - V.A.G 1397A- and move sliding
switch on device to position II.
ht
rig
py
Co
t.
– Connect turbocharger tester - V.A.G 1397A- and hand vac‐
uum pump - VAS 6213- or hand vacuum pump - V.A.G. 1390to vacuum connection -1- of regulating flap potentiometer G584- using a T-piece to do so.
thi
sd
o
cu
m
en
– Select “Bypass Valve, Turbocharger, High Pressure Turbine
Input, Input Voltage” and confirm entry with Q .
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Slowly reduce vacuum. Flap lever -1- now moves in
-direction of arrow- “Open”.
– Apply a vacuum of 500 ± 50 mbar to regulating flap potenti‐
ometer - G584- again.
– Check voltage setting (0.75 volt ± 0.02 volt) of regulating flap
potentiometer - G584- and, if necessary, reset.
Slowly reduce vacuum.
Note
Flap lever -1- must now be resting against the stop. If the flap
lever is not resting against the stop, the setting procedure must
be repeated until the setting values agree with each other.
– After this, secure the nuts and lock nuts with sealing paint from
the replacement-parts kit.
and turn 90° in -direction of arrow-.
– Tighten securing bolts -2- for heat shield -1-.
Further assembly is carried out in the reverse order of removal.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
–
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
Press
securing
clip
from
replacement-parts
kit
onto
control
rod
s
thi
sd
o
cu
m
en
2. Turbocharger
295
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Removing and installing vacuum unit for turbocharger
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
un
le
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
♦ Universal dial gauge brack‐
et - VW 387-
ility
ab
y li
an
pt
ce
Special tools and workshop
equipment required
pe
rm
itte
d
2.7.2
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
♦ Hand vacuum pump - VAS
6213- or hand vacuum
pump - V.A.G. 1390- .
♦ Turbocharger tester V.A.G 1397A-
♦ Dial gauge set, 4-part - VAS
6341-
– Remove pipe -arrow- from cylinder head cover.
296
Rep. gr.21 - Turbocharging/supercharging
AG.
Removing
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
A replacement-parts kit for replacing the vacuum unit is available
in the ⇒ ETKA (electronic parts catalogue) .
ht
rig
py
Co
t.
Note
do
c
um
en
r
te o
iva
r
rp
fo
g
n
♦ Torque wrench - V.A.G
1783- with open end span‐
ner insert AF10 - V.A.G
1783/1-
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Detach vacuum hoses from retainer -arrow- on connecting
hose -3-.
– Release and pull off wiring harness connector -2-. Detach wir‐
ing harness -2- from connecting hose retainer -3-.
– Open clips -1- and -4-.
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
– Pull hose off regulating flap potentiometer - G584- -2-.
ht
rig
py
Co
t.
r
fo
ng
– Undo and remove bolts -2- securing heat shield -1-.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
– Remove connecting hose -3-.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
– Pull hose -1- off vacuum unit -2-.
– Loosen and completely unscrew lower securing nut -3- of con‐
trol rod -5-.
2. Turbocharger
297
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unscrew nuts of vacuum unit -1- and remove vacuum unit
-2-.
Installing
Installation is carried out in the reverse order; note the following:
Caution
Use only new nuts from the replacement-parts kit!
– Carefully clean contact surfaces of vacuum unit.
– If necessary, unscrew lower securing nut -3- of control rod
from new vacuum unit -2-.
– Install new vacuum unit -2- and push control rod -5- through
adjusting lever on turbocharger as shown in illustration.
Note
Location marker on vacuum unit must fit into mounting on turbo‐
charger.
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
– Fit vacuum unit -2- in place and fit nuts -1-, tighten nuts to 8
Nm.
Note
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Rep. gr.21 - Turbocharging/supercharging
ht
rig
py
Co
t.
298
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Make sure that the guiding element of the flap lever moves easily
along the control rod.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– Screw securing nut -3- onto control rod by hand in direction of
vacuum unit.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Connect turbocharger tester - V.A.G 1397A- -2- and hand
vacuum pump - VAS 6213- or hand vacuum pump - V.A.G.
1390- -3- to vacuum connection of vacuum unit -1- using a Tpiece to do so.
Volkswagen AG
does
not
gu
ara
nte
eo
ra
c
n AG.
Switch turbocharger tester - V.A.G 1397A- on and move
agesliding
ksw
l
o
V
switch on device to position II.
by
d
se
ri
– Apply a vacuum of 390 ± 10 mbar to vacuum
unit.
tho
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
Caution
au
ss
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
The following adjusting work must be carried out with extreme
care and precision as, otherwise, there is a risk that the turbo‐
charger will be damaged.
– Move flap lever -4- on turbocharger in -direction of arrow- to
“Closed” position.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Note
thi
sd
o
cu
m
en
– Screw nut -3- in direction of vacuum unit until it is touching the
flap lever, while applying a tightening torque of 8 Nm to the
lock nut -2- at the same time.
The control rod -1- must not turn. Therefore, counterhold on se‐
curing nut -3-.
– Reduce vacuum again and apply a vacuum of 390 ± 10 mbar
to vacuum unit again.
Note
Flap lever must now be resting against the stop (closed position).
– Check set value and, if necessary, reset.
Note
The check must be repeated at least 3 to 5 times in order to ensure
that the vacuum unit has been set precisely and in order to avoid
possible damage to the turbocharger.
Repeat this procedure approx. 3-5 times.
– Reduce vacuum again.
2. Turbocharger
299
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Secure dial gauge - VAS 6079- together with universal dial
gauge bracket - VW 387- to turbocharger with a suitable bolt
-1- (as shown in illustration) and move gauge to end of control
rod -2-.
Note
The dial gauge rod and the control rod of the vacuum unit must
align with each other.
– Operate hand vacuum pump - VAS 6213- until the turbocharg‐
er tester - V.A.G 1397A- indicates 390 ± 10 mbar.
– Set dial gauge, 0-30 mm - VAS 6341/1- to 0.
– Operate hand vacuum pump - VAS 6213- until turbocharger
tester - V.A.G 1397A- indicates 410 ± 10 mbar.
AG. Volkswagen AG d
agen
oes
not
gu
ara
nte
eo
ra
c
ksw
Vol
by
d
e
ris
ho does not
t
VAS 6079au
ss
– Read value on dial gauge - VAS 6079- .
un
le
ility
ab
y li
an
pt
ce
– Make sure that value on dial gauge change.
– Secure securing nut and lock nut with sealing paint from re‐
placement-parts kit.
– Press securing clip from replacement-parts kit onto control rod
and turn 90° in -direction of arrow-.
Further assembly is carried out in the reverse order of removal.
Special tools and workshop equipment required
300
Rep. gr.21 - Turbocharging/supercharging
AG.
Removing and installing charge pres‐
sure control solenoid valve - N75-
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
2.8
ht
rig
py
Co
t.
r
fo
ng
– Tighten securing bolts -2- for heat shield -1-.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
– If value has changed, correct setting of vacuum unit and repeat
measurement until setting complies with specified values.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
♦ Socket set 1/4", 22-piece - VAS 5528-
do
c
um
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Removing
Amarok 2011 ➤
common rail) - Edition 04.2013
ility
ab
y li
an
pt
ce
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
♦ Torque
AG. Volkswagen AG d
agen 4-cylinder diesel
oengine
es n
(2.0 l engine,
ksw
l
ot g
o
V
y
ua
b
d
ran
e
tee
ris - V.A.G 1410wrench
o
h
or
ut
ac
a
ss
– Pull connector -2- and vacuum lines off charge pressure con‐
trol solenoid valve - N75- -1-.
– Remove spreader rivet -3- and charge pressure control sole‐
noid valve - N75- -1-.
Installing
Installation is carried out in the reverse order; note the following:
Caution
Do not kink, twist or crush the vacuum lines when routing. This
may cause breakdowns.
Connect all hoses to stop or at least 10 mm on the relevant
connection piece.
2. Turbocharger
301
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
23 –
Mixture preparation - injection
1
Injection system
⇒ “1.1 Schematic overview - fuel system”, page 302
⇒ “1.2 Fitting location overview - injection system”, page 304
⇒ “1.3 Assembly overview - fuel system”, page 311
⇒ “1.4 Checking fuel system for leaks”, page 316
⇒ “1.5 Filling/bleeding fuel system”, page 316
1.1
Schematic overview - fuel system
WARNING
♦ Read through the rules for cleanliness and the instructions
for working on the fuel system ⇒ page 7 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
♦ If components of the fuel system between the fuel tank
and the high-pressure pump are removed or renewed, the
fuel system must be filled to be bled ⇒ page 316 . (It is
important not to allow the high-pressure pump to run while
still empty.)
To prevent the high-pressure pump from running while it is empty
and to ensure that the engine starts quickly after parts have been
renewed, it is important to observe the following:
♦ If components of the fuel system between the fuel tank and
AG. Volkswagen AG d
oes
the high-pressure pump are removed or renewed, it is neces‐ olkswagen
not
gu
sary for the fuel system to be bled. To do this, perform thed by V
ara
e
nte
“Bleeding fuel system” function using the ⇒ Vehicle diagnostic
ris
o
eo
h
t
tester ⇒ page 316 .
u
ra
a
c
ss
agen
lksw
Vo
by
AG.
Prote
cted
by
un
le
c
o
p
yri
gh
t
.
C
op
yi
Rep. gr.23 - Mixture preparation - injection
ht
rig
py
Co
t.
302
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
♦ This process takes 130 seconds. Fuel pumps are actuated a
total of 3 times in this case. The process must not be termi‐
nated prematurely.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
1 - Fuel tank
❑ With fuel system pres‐
surisation pump - G6- .
2 - Fuel filter
❑ With pre-heating valve.
❑ Assembly overview fuel filter ⇒ page 238 .
❑ Removing and installing
⇒ page 239 .
3 - Fuel temperature sender G81-
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
4 - High-pressure pump
❑ Removing and installing
⇒ page 347 .
5 - Fuel metering valve - N290-
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
DANGER!
Valve
•
must not be re‐
moved.
❑ Valve is not available as
separate part.
6 - Fuel pressure regulating
valve - N276❑ Removing and installing
⇒ page 362 .
7 - High-pressure accumulator
(fuel rail)
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
9 - Restrictor
❑ Cannot be renewed separately
do
c
um
en
8 - Fuel pressure sender G247❑ Removing and installing
⇒ page 365 .
10 - Injectors
❑ Injector, cylinder 1 - N30❑ Injector, cylinder 2 - N31❑ Injector, cylinder 3 - N32❑ Injector, cylinder 4 - N33❑ Removing and installing ⇒ page 327 .
1. Injection system
303
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
1.2
Fitting location overview - injection system
1 - Intake manifold pressure
sender - G71❑ Fitting location
⇒ page 307
2 - Air mass meter - G70❑ Fitting location
⇒ page 307
3 - Regulating flap potentiom‐
eter - G584❑ “Position sender for
charge pressure posi‐
tioner” in vehicles with
single turbo engine G581- .
❑ Fitting location
⇒ page 308
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Rep. gr.23 - Mixture preparation - injection
ht
rig
py
Co
t.
304
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
5 - Injectors
❑ Injector, cylinder 1 N30❑ Injector, cylinder 2 N31❑ Injector, cylinder 3 N32❑ Injector, cylinder 4 N33❑ Fitting location
un
le
4 - Vacuum unit for exhaust
flap
❑ In vehicles with “biturbo
engine” only.
❑ Fitting location
⇒ page 308
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
⇒ page 307
❑ Removing and installing
⇒ page 327 .
6 - Coolant temperature sender - G62❑ Fitting location ⇒ page 304
❑ Removing and installing ⇒ page 196 .
7 - Fuel pressure sender - G247❑ Fitting location ⇒ page 307
8 - Fuel pressure regulating valve - N276❑ Fitting location ⇒ page 307
10 - Engine speed sender - G28❑ Fitting location ⇒ page 310
❑ Removing and installing ⇒ page 406 .
11 - Glow plugs
❑ Glow plug 1 - Q10❑ Glow plug 2 - Q11❑ Glow plug 3 - Q12❑ Glow plug 4 - Q13❑ Fitting location ⇒ page 307
❑ Removing and installing ⇒ page 405 .
12 - Throttle valve module - J338- with throttle valve potentiometer - G69- and intake manifold flap motor V157❑ Fitting location ⇒ page 307
13 - Fuel temperature sender - G81. Volkswagen AG
gen AG
does
swa
k
not
l
o
❑ Fitting location ⇒ page
gu
y V 307
b
ed
ara
nte
e
or
ac
pe
rm
itte
d
un
le
ility
ab
y li
an
pt
ce
is - J62314 - Engine controlthunit
or
u
a
❑ Fitting location
⇒ page 306
ss
❑ Removing and installing ⇒ page 372 .
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
15 - Intake air temperature sender - G42- with charge air pressure sender - G31❑ Fitting location ⇒ page 308
16 - High-pressure pump
❑ Fitting location ⇒ page 307
17 - Fuel metering valve - N290❑ Fitting location ⇒ page 307
18 - Hall sender - G40❑ Fitting location ⇒ page 309
❑ Removing and installing ⇒ page 407 .
19 - Exhaust gas recirculation valve - N18- with exhaust gas recirculation potentiometer - G212❑ Fitting location ⇒ page 307
r
te o
iva
r
rp
fo
g
n
ht
rig
py
Co
t.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
21 - Radiator outlet coolant temperature sender - G83❑ Fitting location ⇒ page 311
do
c
um
en
20 - Charge pressure sender 2 - G447❑ Adaptation must be carried out after renewing.
❑ Removing and installing ⇒ page 277 .
❑ Fitting location ⇒ page 308
1. Injection system
305
agen
lksw
Vo
by
AG.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
22 - Coupling point
❑ For exhaust gas temperature sender 1 - G235- ⇒ Item 6 (page 260) (black connector) at coupling point
of air filter
❑ For exhaust gas temperature sender 3 - G495- ⇒ Item 5 (page 377) (brown connector) at coupling point
of air filter
❑ For exhaust gas temperature sender 4 - G648- ⇒ Item 6 (page 377) (orange connector) at coupling point
of air filter
23 - Charge pressure control solenoid valve - N75❑ Fitting location ⇒ page 309
24 - Exhaust gas flap valve - N220❑ Fitting location ⇒ page 309
25 - Exhaust gas recirculation cooler changeover valve - N345❑ Fitting location ⇒ page 309
A - Brake light switch on brake master cylinder - F❑ Fitting location ⇒ page 310
B - Clutch pedal switch - F36❑ Fitting location ⇒ page 310
C - Accelerator position sender - G79❑ Fitting location ⇒ page 249
D - Exhaust temperature sender 1 - G235- or exhaust
sender
2 - G448G. Volkswagen A
Atemperature
G do
agen
es n
ksw
l
o
o
t gu
V
❑ Installed in exhaust manifold/turbocharger.
by
a
d
se
ran
tee
or
ac
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
E - Exhaust gas temperature sender t3ho-ri G495au
❑ Fitting location ⇒ Item 5 (page
ss 377)
F - Exhaust gas temperature sender 4 - G648❑ Fitting location ⇒ Item 6 (page 377)
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
G - Lambda probe - G39❑ Fitting location ⇒ Item 3 (page 377)
H - Particulate filter
❑ Fitting location ⇒ page 377
Engine control unit - J623-
Location: in engine compartment on left.
94-pin connector - T94-
4-
Engine control unit - J623-
c
o
p
yri
gh
t.
C
op
yi
306
Rep. gr.23 - Mixture preparation - injection
Prote
cted
by
3-
AG.
60-pin connector - T60-
agen
lksw
Vo
by
2-
ht
rig
py
Co
t.
Securing bolts/shear bolts
do
c
um
en
1-
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Mounting locations on right on top of engine
1-
Intake manifold pressure sender - G71-
2-
Exhaust gas recirculation valve - N18- with exhaust gas re‐
circulation potentiometer - G212-
3-
Air mass meter - G70-
Mounting locations on top of engine
1-
Fuel pressure sender - G247-
2-
Injector, cylinder 1 - N30-
3-
Injector, cylinder 2 - N31-
4-
Injector, cylinder 3 - N32-
5-
Injector, cylinder 4 - N33-
6-
Fuel pressure regulating valve - N276-
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
un
le
1-
Glow plug 1 - Q10-
2-
Glow plug 2 - Q11-
3-
Glow plug 3 - Q12-
4-
Glow plug 4 - Q13-
5-
Fuel temperature sender - G81-
Mounting locations on top of engine (continued)
r
fo
ng
Fuel temperature sender - G81-
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
1-
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
Mounting locations on top of engine (continued)
1. Injection system
307
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Components on top of turbocharger
1-
Regulating flap potentiometer - G584-
2-
n AG
“Position sender for charge pressure positioner” in vehicles
wage
olks
V
with single turbo engine - G581- .
by
3-
Vacuum unit for exhaust flap
Intake air temperature sender - G42- with charge air pressure
sender - G31-
2-
Connector
Throttle valve module - J338- with throttle valve potentiom‐
eter - G69- and intake manifold flap motor - V157-
2-
Fuel metering valve - N290-
3-
High-pressure pump
308
Rep. gr.23 - Mixture preparation - injection
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Charge pressure sender 2 - G447- -arrow-
AG.
1-
agen
lksw
Vo
by
Mounting locations on top of engine on left
r
fo
ng
Intake air temperature sender - G42- with charge air pres‐
sure sender - G31-
ht
rig
py
Co
t.
1-
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ss
ed
ris
ho
t
au
does
not
gu
ara
nte
eo
ra
c
ility
ab
y li
an
pt
ce
un
le
. Volkswagen AG
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Solenoid valves at air filter
♦ Changeover valve for exhaust gas recirculation cooler - N345-1♦ Exhaust gas flap valve - N220- -2♦ Charge pressure control solenoid valve - N75- -3-
Hall sender - G40-
Vacuum unit for exhaust flap
1-
Vacuum hose
2-
swagen AG
n AG. Volkflap
Vacuum unit wfor
doe
ageexhaust
s no
t gu
ara
nte
eo
ra
c
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Regulating flap potentiometer - G584Vacuum hose
3-
Vacuum unit for wastegate
AG.
2-
agen
lksw
Vo
by
Electrical line connection
ht
rig
py
Co
t.
1-
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
ks
Vol
by
d
e
ris
tho
u
a
ss
1. Injection system
309
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Coolant temperature sender G62
1-
Coolant temperature sender - G62-
2-
Electrical line connection
3-
Connection
Engine speed sender - G28Installation location of engine speed sender - G28- -2- below the
oil filter holder -1-.
Brake light switch on brake master
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
cylinder
Fa
c
s
s
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
Brake light switch - F- with brake pedal switch - F47- -1- is fitted
underneath the brake master cylinder.
Clutch pedal switch - F36-
c
o
p
yri
gh
t.
C
op
yi
Rep. gr.23 - Mixture preparation - injection
do
c
um
en
310
Prote
cted
by
Clutch pedal switch - F36-
AG.
2-
agen
lksw
Vo
by
Connector
ht
rig
py
Co
t.
1-
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Radiator outlet coolant temperature sender - G83Coolant temperature sender at radiator outlet - G83- : Installed at
the bottom on the left in front of the radiator.
WARNING
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
♦ Read through the rules for cleanliness and the instructions
for working on the fuel system ⇒ page 7 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
♦ If components of the fuel system between the tank and the
high-pressure pump are removed or renewed, the fuel
system must be filled to be bled ⇒ page 316 . (It is im‐
portant not to allow the high-pressure pump to run while
still empty.)
♦ The engine must not be run when the fuel return line is
disconnected, this is because the coupling chamber will
be emptied due to the lack of the counterpressure.
To prevent the high-pressure pump from running while it is empty
and to ensure that the engine starts quickly after parts have been
renewed, it is important to observe the following:
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
Assembly overview - fuel system
ility
ab
y li
an
pt
ce
1.3
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
ht
rig
py
Co
t.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
♦ If components of fuel system between fuel tank and high-pres‐
sure pump are unbolted, removed or renewed, “Bleeding fuel
system” function must be carried out to bleed fuel system us‐
ing ⇒ Vehicle diagnostic tester.
agen
lksw
Vo
by
AG.
♦ This process takes 130 seconds. Fuel pumps are actuated a
total of 3 times in this case. The process must not be termi‐
nated prematurely.
1. Injection system
311
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
1 - Return line
❑ From high-pressure
pump.
❑ General diagram of fuel
lines leading to engine
⇒ page 228
2 - Supply line
❑ To high-pressure pump.
❑ General diagram of fuel
lines leading to engine
⇒ page 228
3 - Bolt
❑ 10 Nm
4 - Hose
❑ Connection to return
lines of the injectors
5 - Hose
❑ Around high-pressure
accumulator (fuel rail)
6 - Return line
❑ To fuel tank.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
8 - Return line
❑ To fuel filter
ility
ab
y li
an
pt
ce
7 - Supply line
❑ To high-pressure pump
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
9 - High-pressure line
❑ Between high-pressure
accumulator (common
rail) and injectors
❑ Install so that compo‐
nent is not stressed.
❑ Removing and installing ⇒ page 338 .
General diagram of fuel lines leading to engine ⇒ page 228
Note
♦ The high-pressure lines may be
sure line for deformation and
cracks.
♦ Corroded lines should no longer
be used.
❑ 30 Nm
10 - Clamp
❑ For high-pressure line ⇒ Item 26 (page 314)
11 - Bolt
❑ 10 Nm
312
Rep. gr.23 - Mixture preparation - injection
AG.
formed, constricted or damaged.
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
♦ The line hole must not be de‐
ht
rig
py
Co
t.
♦ Check taper seat of high-pres‐
do
c
um
en
re-used after the following
checks:
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
12 - High-pressure accumulator (fuel rail)
❑ Removing and installing ⇒ page 340 .
13 - Seal
❑ Renew after removing
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s - N276valve
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
14 - Fuel pressure regulating
❑ Cannot be re-installed.
❑ 80 Nm
❑ Removing and installing ⇒ page 362 .
15 - O-ring
❑ Renew after removing
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
18 - O-ring
❑ Renew after removing
ht
rig
py
Co
t.
17 - Copper washer
❑ Renew after removing
thi
sd
o
cu
m
en
16 - Injectors (piezo injectors or solenoid valves)
❑ Do not interchange!
❑ When removing and installing, always renew the following components and seals/O-rings: “copper seal”
⇒ Item 17 (page 313) and ⇒ Item 19 (page 313) , “O-ring for injector bore”, ⇒ Item 15 (page 313) , “Oring for injector return connection” ⇒ Item 15 (page 313) and “bolt for clamping plate”
⇒ Item 21 (page 313) .
❑ Before re-using high-pressure lines ⇒ Item 9 (page 312) , perform visual check of taper seals for damage,
e.g. transverse scores or corrosion. Always renew if damaged.
❑ If piezo injectors, high-pressure lines ⇒ Item 9 (page 312) and clamping plates ⇒ Item 20 (page 313)
which were removed are to be reinstalled, they must always be re-fitted in their original positions (i.e. on
the same cylinder).
❑ Removing and installing ⇒ page 327 .
19 - Copper washer
❑ Renew after removing
20 - Clamping plates
❑ Reusable.
21 - Bolt
❑ Renew after removing
❑ 8 Nm +180°
22 - Fuel return line
❑ To fuel tank.
❑ The fuel return line must not be kinked, damaged or blocked.
❑ The fuel return lines must not be dismantled.
❑ Release ⇒ page 315
❑ Check locks ⇒ page 315
❑ Attach ⇒ page 315
❑ Lock ⇒ page 316
23 - Restrictor
❑ Cannot be renewed separately
24 - Fuel pressure sender - G247❑ 100 Nm
❑ Removing and installing ⇒ page 365 .
25 - Bolt
❑ 22 Nm
1. Injection system
313
04.2013
un
le
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise➤
Amarok 2011
r
o
eo
h
t
u
ra
4-cylinder
a diesel engine (2.0 l engine, common rail) - Edition
c
s
s
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Note
♦ The high-pressure lines may be
re-used after the following
checks:
♦ Check taper seat of high-pres‐
sure line for deformation and
cracks.
♦ The line hole must not be de‐
formed, constricted or damaged.
♦ Corroded lines should no longer
be used.
r
fo
ng
❑ 30 Nm
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
26 - High-pressure line
❑ Secured with 3 clamps ⇒ Item 10 (page 312)
❑ Between high-pressure pump and high-pressure accumulator (fuel rail)
27 - High-pressure fuel pump
❑ With fuel metering valve - N290- (must not be opened).
❑ After renewing, initial fuel filling must be carried out (never allow the pump to run while it is still empty)
⇒ page 316 .
❑ Removing and installing ⇒ page 347 .
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
29 - Bolt
❑ Renew after removing
❑ 20 Nm +45°
30 - Bolt
❑ Renew after removing
❑ 23 Nm
31 - Hub
❑ With sender ring.
❑ Use counterhold tool - T10051- to loosen and tighten.
❑ To remove, use puller - T40064- .
❑ Removing and installing ⇒ page 347 .
32 - Nut
❑ 95 Nm
33 - Toothed belt pulley on high-pressure pump
34 - Fuel temperature sender - G81-
314
Rep. gr.23 - Mixture preparation - injection
ht
rig
py
Co
t.
28 - Bolt
❑ Renew after removing
❑ 20 Nm +180°
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Release fuel return line
– With engine switched off, carefully pull return line connections
off at piezo injectors. To do this, press the two clips downwards
-arrow A- and, at the same time, pull the release bolt upwards
-arrow B-.
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Check locks
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Caution
•
Always replace damaged fuel return lines.
•
A damaged fuel return line that becomes loose when en‐
gine is running causes damage to piezo injectors. The
piezo injector must then be replaced.
•
The engine must not be run when the fuel return line is
disconnected, this is because the coupling chamber will
be emptied due to the lack of the counterpressure.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Fit fuel return line
AG.
After disconnecting, check the 4 catches -arrow- to see
whether they are fractured or have broken off.
agen
lksw
Vo
by
•
ht
rig
py
Co
t.
Carefully pull fuel return lines upwards when disconnect‐
ing as the 4 catches -arrow- can fracture.
thi
sd
o
cu
m
en
•
– Apply a thin coating of diesel fuel to the new O-rings on the
return-line connections.
– Connect fuel return line and press the two clips downwards as
far as they will go -arrows-.
1. Injection system
315
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Lock fuel return line
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Checking fuel system for leaks
DANGER!
♦ Observe safety precautions when working on the injection
system ⇒ page 4 .
♦ Observe rules for cleanliness ⇒ page 8 .
Follow these instructions before starting work and while work‐
ing on system.
Renew the affected component if leakage still occurs after tight‐
ening to the correct torque.
Note
If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off engine, erase event memory and then continue
road test.
– Then check high-pressure section again for leaks.
1.5
Filling/bleeding fuel system
Caution
After new or removed parts such as the fuel filter or fuel lines
have been fitted, the high-pressure pump must be filled with
fuel before the engine is started for the first time. Avoid allowing
the high-pressure pump to run dry under all circumstances.
316
Rep. gr.23 - Mixture preparation - injection
AG.
– Then, road-test the vehicle for more than 20 km. Accelerate
with full throttle at least once.
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
– Check entire fuel system for leaks.
ht
rig
py
Co
t.
r
fo
ng
– Allow engine to idle for a few minutes but do not accelerate.
Then switch off engine again. (Fuel system will bleed itself au‐
tomatically).
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
1.4
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
ility
ab
y li
an
pt
ce
un
le
– After fuel return line has been pushed on completely, press
the locking bolt downwards -arrow-.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Note
♦ When installing the high-pressure
pump, it is essential to en‐
n AG. Volkswagen A
wagesystem.
sure that no dirt enters the
fuel
olks
♦ Only remove
fuel lines.
immediately prior
Proceed as follows to fill high-pressure pump with fuel.
– Connect ⇒ Vehicle diagnostic tester, and carry out function
“Bleed fuel system”.
Note
This process takes 130 seconds. Fuel pumps are actuated a total
of 3 times in this case. The process must not be terminated pre‐
maturely.
– Then, start the engine.
– After filling fuel system, leave engine running at moderate
speed for a few minutes and then switch off again.
– Check fuel system for leaks.
– Read event memory and, if necessary, delete event memory
entry.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Switch ignition on.
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
♦ There must be sufficient fuel in the tank.
G do
es n
ot g
u
to installationaraofnte
eo
ra
c
ility
ab
y li
an
pt
ce
yV
db
sealing
ise plugs
r
tho
au
s
s
ht
rig
py
Co
t.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
– Then, road-test the vehicle for more than 20 km. Accelerate
with full throttle at least once.
agen
lksw
Vo
by
AG.
Note
♦ If there is any air left in the fuel system, the engine may switch
to the backup mode ('emergency running' mode) during the
road test. Switch off the engine and erase the fault memory.
Then continue road test.
♦ Then check high-pressure part of fuel system again for leak‐
age.
– Read event memory again.
1. Injection system
317
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2
Vacuum system
⇒ “2.1 Schematic diagram - vacuum system”, page 318
⇒ “2.2 Testing vacuum system for leaks”, page 321
. Volkswage
n AG d
AG
⇒ “2.2.1 Checking vacuum hoses
leading
to non-return
agen
ovalve,
es n
ksw
l
o
V changeover valve N345 ”, ot gu
solenoid valves N220 and N75
y
b
ara
d
e
nte
page 322
ris
ho
ut
2.1
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
⇒ “2.2.4 Checking vacuum hose to vacuum unit on exhaust gas
recirculation cooler”, page 325
Schematic diagram - vacuum system
Caution
Do not kink, twist or crush the vacuum lines when routing. This
may cause breakdowns.
Connect all hoses to stop or at least 10 mm on the relevant
connection piece.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Rep. gr.23 - Mixture preparation - injection
ht
rig
py
Co
t.
318
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
⇒ “2.2.3 Checking vacuum hose to vacuum unit on turbocharger”,
page 324
eo
ra
c
ility
ab
y li
an
pt
ce
⇒ “2.2.2 Checking svacuum
hose leading to changeover valve for
sa
exhaust gas recirculation cooler N345 ”, page 324
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
1 - Exhaust gas recirculation
cooler changeover valve N345❑ Checking ⇒ page 401 .
2 - Bracket
❑ Attach bracket to bottom
of air filter housing
⇒ page 320
3 - Bolt
❑ 1 Nm
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
r
fo
ng
7 - Regulating flap potentiom‐
eter - G584❑ With vacuum unit with
potentiometer
❑ On turbocharger.
❑ Connection of vacuum
hose to regulating flap ⇒ page 320
❑ Checking ⇒ page 401 .
❑ Removing and installing ⇒ page 278 .
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
8 - Vacuum line
❑ Fastened with cable ties
ht
rig
py
Co
t.
6 - T-piece
❑ Installed between brake
servo and vacuum
pump.
❑ Connection of vacuum
hose to T-piece
⇒ page 320
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
5 - Vacuum unit
❑ Vacuum unit is installed
on exhaust gas recircu‐
lation cooler. Both parts
can only be renewed to‐
gether.
❑ Connection of vacuum
hose to vacuum unit
⇒ page 320
un
le
4 - Connection to air filter
9 - Cylinder head cover
❑ Vacuum reservoir is installed in cylinder head cover. Both parts can only be renewed together.
❑ Connection of vacuum hose to cylinder head cover ⇒ page 320
AG.
10 - Exhaust gas flap valve - N220❑ Checking ⇒ page 255 .
❑ 6 Nm
11 - To vacuum unit on turbocharger
❑ Vacuum unit not available as a separate part.
12 - Charge pressure control solenoid valve - N75❑ With individual air filter.
❑ Checking ⇒ page 322 .
❑ 6 Nm
13 - Charge pressure sender 2 - G447❑ Old fitting location ⇒ page 321
2. Vacuum system
319
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
❑ New fitting location: fastened to solenoid valve bracket
Secure bracket to bottom of air filter housing
– Insert bracket together with valves -1- at bottom into mount‐
ings on air filter housing -2-.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Secure bracket to top of air filter housing
– Fit and tighten bolt holding bracket with valves -1- to top of air
filter housing -2-.
Installation of vacuum lines on engine on right-hand side
3-
Connect vacuum hose of recirculation valve leading to cyl‐
inder head cover.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Installation of vacuum lines on engine on left-hand side
1-
Connect vacuum hose to junction piece on vacuum pump.
2-
Connect vacuum hose of recirculation valve leading to junc‐
tion piece.
3-
Connect vacuum hose of junction piece leading to cylinder
head cover.
320
Rep. gr.23 - Mixture preparation - injection
AG.
Connect vacuum hose to regulating flap potentiometer G584- .
agen
lksw
Vo
by
2-
ht
rig
py
Co
t.
Connect vacuum hose to vacuum unit of cooler for waste
gas recirculation.
do
c
um
en
1-
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Charge pressure sender 2 - G447- -arrow-
2.2
Testing vacuum system for leaks
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-
ility
ab
y li
an
pt
ce
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
♦ Hand vacuum pump - VAS
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
6213ut
ra
a
c
s
s
Caution
Do not kink, twist or crush the vacuum lines when routing. This
may cause breakdowns.
ht
rig
py
Co
t.
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Checking vacuum hoses to non-return valve, exhaust gas flap
valve - N220- , charge pressure control solenoid valve - N75- ,
changeover valve for exhaust gas recirculation cooler - N345- and
vacuum reservoir ⇒ page 322
do
c
um
en
Connect all hoses to stop or at least 10 mm on the relevant
connection piece.
AG.
Checking vacuum hose to regulating flap potentiometer - G584⇒ page 324
Checking vacuum hose to vacuum unit on turbocharger
⇒ page 324
2. Vacuum system
321
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
agen recircu‐
G. Volkswgas
AG do
Checking vacuum hose to vacuum unit
onn Aexhaust
es n
wage
s
k
l
ot g
o
lation cooler ⇒ page 325
V
y
u
ara
nte
e
Test procedure
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
– Pull vacuum hose -3- off at outer connection of exhaust gas
flap valve - N220- -4-.
or
ac
ility
ab
y li
an
pt
ce
Checking vacuum hoses leading to nonreturn valve, solenoid valves -N220- and
-N75- changeover valve -N345-
– Pull vacuum hose -2- off at outer connection of charge pres‐
sure control solenoid valve - N75- -1-.
– Pull vacuum hose -6- off at outer connection of changeover
valve for exhaust gas recirculation cooler - N345- -5-.
– Connect hand vacuum pump - VAS 6213- to the 3 valves one
after the other and then generate a vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213for approx. 30 seconds.
•
Vacuum must not drop.
If vacuum drops:
– Replace valve if it does not seal properly.
c
o
p
yri
gh
t
.
C
op
yi
agen
lksw
Vo
by
– Seal connecting piece -2- with a clean bung from engine bung
set - VAS 6122- .
AG.
Prote
cted
by
– Pull vacuum hose -arrow- off vacuum reservoir. Seal opening
of vacuum hose with clean bung from engine bung set - VAS
6122- .
322
Rep. gr.23 - Mixture preparation - injection
ht
rig
py
Co
t.
– Seal vacuum hoses -2, 3 and 6- with clean bungs from engine
bung set - VAS 6122- .
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
2.2.1
b
ed
ris
o
th
au
ss
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Pull vacuum hose off T-piece -2-.
Volkswa
gen AG
AG. vacuum
– Connect hand vacuum pump - VAS 6213- toswremoved
does
agen
k
not
l
o
V
hose and generate a vacuum of 0.6 bar.
gu
by
a
d
se
ran
tee
or
ac
If vacuum drops:
un
le
Vacuum must not drop.
– Locate damage or leaking vacuum hose connection. To do
this, pull individual vacuum hoses off from relevant connection
and check for leak to connected component.
– Pull off vacuum hoses -1- and -2- at connector -arrow- and
check non-return valve and vacuum hose to exhaust gas re‐
circulation cooler changeover valve - N345- .
– Locate damage or leaking vacuum hose connection.
– Renew non-return valve or leaking vacuum hose.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
– Connect hand vacuum pump - VAS 6213- to removed vacuum
hose and generate a vacuum of 0.6 bar.
agen
lksw
Vo
by
– Pull vacuum hose -arrow- off vacuum reservoir. Seal opening
of vacuum hose with clean bung from engine bung set - VAS
6122- .
ht
rig
py
Co
t.
r
fo
ng
– Reconnect all vacuum hoses to valves and to union -arrow-.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
•
ility
ab
y li
an
pt
ce
ri
– Observe pressure gauge of handthovacuum
pump - VAS 6213u
a
for approx. 30 seconds.
s
s
AG.
– Observe pressure gauge of hand vacuum pump - VAS 6213for approx. 30 seconds.
•
Vacuum must not drop.
If vacuum drops:
– Replace vacuum hose if it leaks -1-.
If pressure does not drop:
– Connect hand vacuum pump - VAS 6213- to vacuum reservoir
and generate a vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213for approx. 30 seconds.
•
Vacuum must not drop.
If vacuum drops:
– Replace cylinder head cover if it leaks ⇒ page 93 .
If pressure does not drop:
– Check following vacuum hoses:
♦ Vacuum hose to regulating flap potentiometer - G584⇒ page 324
♦ Vacuum hose to vacuum unit on turbocharger ⇒ page 324
♦ Vacuum hose to vacuum unit on exhaust gas recirculation
cooler ⇒ page 325
2. Vacuum system
323
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2.2.2
Checking vacuum hose leading to
changeover valve for exhaust gas recir‐
culation cooler - N345-
Test procedure
•
Vacuum hoses to non-return valve, exhaust flap valve N220- , charge pressure control solenoid valve - N75- , ex‐
haust gas recirculation cooler changeover valve - N345- and
vacuum reservoir must first have been checked for leaks
n AG. Volkswagen AG do
⇒ page 322 .
es
wage
ks
Vol
not
g
y
– Pull vacuum hose off at emiddle
connection of exhaust gas flapuaran
db
tee
ris
valve - N220- .
o
th
o
au
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
•
Vacuum must not drop.
If vacuum drops:
– Pull vacuum hose -arrow- off regulating flap potentiometer G584- . Seal opening of vacuum hose with clean bung from
engine bung set - VAS 6122- .
– Connect hand vacuum pump - VAS 6213- to pulled-off vacuum
reservoir and generate a vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213for approx. 30 seconds.
Vacuum must not drop.
c
o
p
yri
gh
t
.
C
op
yi
If vacuum drops:
– Renew leaking vacuum hose.
agen
lksw
Vo
by
Prote
cted
by
If pressure does not drop:
– Connect hand vacuum pump - VAS 6213- to potentiometer for
regulating flap - G584- and generate a vacuum of 0.6 bar.
AG.
– Observe pressure gauge of hand vacuum pump - VAS 6213for approx. 30 seconds.
•
Vacuum must not drop.
If vacuum drops:
– Replace turbocharger ⇒ page 267 .
2.2.3
Checking vacuum hose to vacuum unit
on turbocharger
Test procedure
•
Vacuum hoses to non-return valve, exhaust flap valve N220- , charge pressure control solenoid valve - N75- , ex‐
haust gas recirculation cooler changeover valve - N345- and
vacuum reservoir must first have been checked for leaks
⇒ page 322 .
324
Rep. gr.23 - Mixture preparation - injection
ht
rig
py
Co
t.
•
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
– Observe pressure gauge of hand vacuum pump - VAS 6213for approx. 30 seconds.
ra
c
ility
ab
y li
an
pt
ce
ss
– Connect hand vacuum
pump - VAS 6213- to removed vacuum
hose and generate a vacuum of 0.6 bar.
4-cylinder
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
a2011
d
ran
Amarok
➤
e
is
tee
r
o
h
diesel engine
(2.0
l
engine,
common
rail)
Edition
04.2013
t
o
ra
au
c
ss
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
– Pull vacuum hose off at middle connection of charge pressure
control solenoid valve - N75- -1-.
– Connect hand vacuum pump - VAS 6213- to removed vacuum
hose -2- and generate a vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213for approx. 30 seconds.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
If vacuum drops:
– Remove underbody guard, if fitted ⇒ Rep. gr. 66 .
ht
rig
py
Co
t.
Vacuum must not drop.
do
c
um
en
•
agen
lksw
Vo
by
AG.
– Pull vacuum hose -1- from vacuum unit -2-. Seal opening of
vacuum hose with clean bung from engine bung set - VAS
6122- .
– Connect hand vacuum pump - VAS 6213- to pulled-off vacuum
reservoir and generate a vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213for approx. 30 seconds.
•
Vacuum must not drop.
If vacuum drops:
– Renew leaking vacuum hose.
If pressure does not drop:
– Connect hand vacuum pump - VAS 6213- to vacuum unit and
generate a vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213for approx. 30 seconds.
•
Vacuum must not drop.
If vacuum drops:
– Replace turbocharger ⇒ page 267 .
2.2.4
Checking vacuum hose to vacuum unit
on exhaust gas recirculation cooler
Test procedure
•
Vacuum hoses to non-return valve, exhaust flap valve N220- , charge pressure control solenoid valve - N75- , ex‐
haust gas recirculation cooler changeover valve - N345- and
vacuum reservoir must first have been checked for leaks
⇒ page 322 .
2. Vacuum system
325
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Pull vacuum hose off at central connection of changeover
valve for exhaust gas recirculation cooler - N345- -5-.
– Connect hand vacuum pump - VAS 6213- to removed vacuum
hose and generate a vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213for approx. 30 seconds.
•
Vacuum must not drop.
If vacuum drops:
– Bring lock carrier into service position ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Lock carrier service position .
– Pull off vacuum hose -arrow 2-. Seal opening of vacuum hose
with clean bung from engine bung set - VAS 6122- .
– Connect hand vacuum pump - VAS 6213- to pulled-off vacuum
reservoir and generate a vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213for approx. 30 seconds.
•
Vacuum must not drop.
If vacuum drops:
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
pressure does not drop:
is
r
o
eo
h
ut
ra
a
c
Connect hand vacuum pump
VAS
6213to
vacuum
unit
and
s
s
– Renew leaking vacuum hose.
If
– Observe pressure gauge of hand vacuum pump - VAS 6213for approx. 30 seconds.
•
Vacuum must not drop.
If vacuum drops:
AG.
Rep. gr.23 - Mixture preparation - injection
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
326
ht
rig
py
Co
t.
r
fo
ng
– Replace exhaust gas recirculation cooler ⇒ page 251 .
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
generate a vacuum of 0.6 bar.
ility
ab
y li
an
pt
ce
–
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
3
Injectors and high-pressure accumu‐
lator (rail)
⇒ “3.1 Overview of injectors”, page 327
un
le
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
⇒ “3.2 Injector delivery calibration”, page 327
b
d
ran
ir se
tee
o
h injectors)”,
⇒ “3.3 Removing and installing injectors (piezo
t
or
u
ac
a
page 328
ss
pe
rm
itte
d
⇒ “3.4 Removing and installing injectors (solenoid valves)”, page
332
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
⇒ “3.5 Removing and installing high-pressure lines”, page 338
⇒ “3.6 Removing and installing high-pressure accumulator (rail)”,
page 340
⇒ “3.7 Checking return flow rate of injectors with engine running”,
page 343
Overview of injectors
Solenoid valves with Piezo injectors with
restrictor
pressure retention
valve
CDBA, CDCA
CNEA, CNFA,
CSHA
Injector delivery calibration
Special tools and workshop equipment required
Prote
cted
by
The function “injector delivery calibration” serves to correct the
injection rates for each cylinder of a common rail system individ‐
ually across the entire map range.
AG.
Check “injector delivery calibration” adaptation
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
♦ Vehicle diagnostic tester
do
c
um
en
3.2
X
X
r
te o
iva
r
rp
fo
g
n
Engine codes
ht
rig
py
Co
t.
3.1
The 7-digit adaptation values -1- (details in illustration are only an
example) are marked separately on each piezo injector. They
may consist of letters and/or numbers (ASCII code).
3. Injectors and high-pressure accumulator (rail)
327
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Table of characters for reading the characters on the injector.
When a new injector is installed, the adaptation value for the new
injector must be written to the engine control unit.
When the engine control unit is renewed, the “injector delivery
calibration values” must be written into the new engine control
unit.
The work procedure for the adaptation is described in ⇒ Vehicle
diagnostic tester.
Also check that the “injector delivery calibration” values are cor‐
rectly entered for all the other injectors. Do NOT attempt to reenter these calibration values if the correct values are already
stored in the engine control unit.
Select “Adapt injector delivery calibration” ⇒ Vehicle diagnostic
tester.
3.3
Removing and installing injectors (piezo injectors)
Special tools and workshop
equipment required
♦ Puller - T10055♦ Assembly sleeve - T10377♦ Socket - T40055-
ility
ab
y li
an
pt
ce
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Rep. gr.23 - Mixture preparation - injection
thi
sd
o
cu
m
en
328
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
♦ Ratchet - V.A.G 1331/1-
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
ht
rig
py
Co
t.
♦ Torque wrench (5…50 Nm)
- V.A.G 1331-
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Puller - T10402-
Caution
•
Do not interchange removed piezo injectors.
•
k
When a new piezo injector is installed,
Volthe adaptation val‐
by
d
ue for the new injector must berientered
in the engine
se
ho tester.
control unit ⇒ Vehicle diagnostic
ut
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Removing
ility
ab
y li
an
pt
ce
a
ss
. Volkswagen AG
gen AG
does
swa
not
gu
ara
nte
eo
ra
c
– Pull off connector -1- at piezo injector to be removed.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Disconnecting fuel return lines
•
After disconnecting, check the 4 catches -arrow- to see
whether they are fractured or have broken off.
•
Always replace damaged fuel return lines.
•
A damaged fuel return line that becomes loose when en‐
gine is running causes damage to piezo injectors. The
piezo injector must then be replaced.
•
The engine must not be run when the fuel return line is
disconnected, this is because the coupling chamber will
be emptied due to the lack of the counterpressure.
agen
lksw
Vo
by
Carefully pull fuel return lines upwards when disconnect‐
ing as the 4 catches -arrow- can fracture.
ht
rig
py
Co
t.
•
do
c
um
en
Caution
AG.
3. Injectors and high-pressure accumulator (rail)
329
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition
04.2013
. Volkswage
n AG d
oes
not
gu
ara
nte
eo
ra
c
ility
ab
y li
an
pt
ce
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Note
pe
rm
itte
d
un
le
–
AG
agen
ksw
l
o
V
With engine switched off, carefully pull returndline
by connections
ise clips downwards
off at piezo injectors. To do this, press the two
r
tho
-arrow A- and, at the same time, pull the
au release bolt upwards
s
s
-arrow B-.
Ensure cleanliness. It must be assured that no dirt gets into the
disconnected fuel return lines or the open connections of the pie‐
zo injectors.
– Unscrew high-pressure line ⇒ Item 9 (page 312) between
high-pressure accumulator (fuel rail) and injectors to be re‐
moved.
– Remove bolts ⇒ Item 21 (page 313) of the injectors to be re‐
moved.
r
te o
iva
r
rp
fo
g
n
c
o
p
yri
gh
t.
C
op
yi
Installation is carried out in the reverse order; note the following:
Prote
cted
by
•
When removing and installing, always renew the following
components and seals/O-rings: “copper seal”, “O-ring for in‐
jector bore”, “O-ring for injector return connection”.
•
Used piezo injectors may only be re-installed on the cylinder
they were removed from.
•
Make sure that the piezo injector and the installation area are
clean before installing.
•
Piezo injector must not be damaged in any way.
•
Lubricate all O-rings with diesel before installing.
If a used piezo injector is being re-installed:
330
Rep. gr.23 - Mixture preparation - injection
AG.
Important instructions for installation of piezo injectors:
agen
lksw
Vo
by
– The 7-digit adaptation values -1- (details in illustration are only
an example) are marked separately on each piezo injector.
Read off and note down this value before installing new piezo
injector.
ht
rig
py
Co
t.
Installing
do
c
um
en
– Place puller - T10055- with adapter - T10055/1- in position as
shown and pull injector out downwards with tapping move‐
ments.
–
– Clean piezo injector tip and sealing surface.
– Fit new copper seal -1- on piezo injector -2- with help of as‐
sembly sleeve - T10377- . Use “narrow” side of assembly
sleeve - T10377- for this.
– Carefully slide new O-ring over fuel return connection to avoid
damaging O-ring.
WARNING
thi
sd
o
cu
m
en
– Clean sealing surface of injector in cylinder head and injector
shaft.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
piezo injector out of the copper seal by hand.
Amarok 2011 ➤
common rail) - Edition 04.2013
ility
ab
y li
an
pt
ce
lkswagen AGdiesel engine (2.0 l engine,
AG. Vo4-cylinder
does
agen
ksw
not
l
o
V
gu
y
b old copper seal from the piezo injector,
ara
To removeedthe
carefully
nte
s
i
r
clampththe
o copper seal in a pair of pliers so the copper
e o seal is
ra
au
just sprevented
from spinning. Then carefully pull and twist
c the
s
ht
rig
py
Co
t.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Only cleaning set - VAS 6811- may be used for cleaning seal‐
ing surface of injector bore.
agen
lksw
Vo
by
For detailed information on how to use the cleaning set as well
as the order in which its components are applied, refer to the
⇒ operating manual provided with the cleaning set - VAS
6811- .
AG.
– Renew seal for injector shaft. Use assembly sleeve - T10377to do this.
– Push clamping plate onto piezo injectors.
Piezo injectors are installed “dry”. Therefore, do not install with
any fluid to facilitate assembly.
– Insert piezo injectors with clamping plate into injector bores
without exerting excessive force.
– Check O-rings for damage. Replace damaged O-rings.
– Apply a thin coating of diesel fuel to the new O-rings on the
return-line connections.
3. Injectors and high-pressure accumulator (rail)
331
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Connect fuel return line and press the two clips downwards as
far as they will go -arrows-.
AG. Volkswagen
AG do
n
agecompletely,
– After fuel return line has been pushed
press
es n
won
ot g
olks
V
y
the locking bolt downwards -arrow-.
ua
b
d
ran
tee
or
ac
e
ris
pe
rm
itte
d
Note
a
ss
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
After renewing one or more injectors, the “injector delivery cali‐
bration” values for the new injectors must be written into the
engine control unit with ⇒ Vehicle diagnostic tester ⇒ page 327 .
ility
ab
y li
an
pt
ce
un
le
– Install high-pressure linesu⇒
tho page 338 .
Specified torques
♦ ⇒ “1.3 Assembly overview - fuel system”, page 311
Special tools and workshop equipment required
AG.
Rep. gr.23 - Mixture preparation - injection
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
332
ht
rig
py
Co
t.
♦ Puller - T10055-
do
c
um
en
Removing and installing injectors (sole‐
noid valves)
r
te o
iva
r
rp
fo
g
n
3.4
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
WARNING
pe
rm
itte
d
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Removing
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
♦ Puller -T10415-
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
ility
ab
y li
an
pt
ce
un
le
♦ Assembly sleeve - T10377-
♦ Read rules for cleanliness and the instructions for working
on the fuel system ⇒ page 8 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
Caution
r
te o
iva
r
rp
fo
g
n
AG.
Prote
cted
by
– Pull return line connections off injectors. To do this, press the
catches -1- and -2- downwards and, at the same time, pull the
release pin upwards -arrow-.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
♦ The open connections must be sealed with a suitable cap.
ht
rig
py
Co
t.
♦ Observe rules for cleanliness when working on the injec‐
tion system.
do
c
um
en
♦ Mark allocation of injectors to cylinders. They must always
be re-installed on the same cylinders.
3. Injectors and high-pressure accumulator (rail)
333
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Detach connectors -arrows- from injectors.
Caution
When releasing high-pressure line, counterhold high-pressure
connection using an open-ended spanner. Leaks occur if highpressure connection is released.
– Unscrew union nuts of relevant high-pressure line -1 to 4- and
remove corresponding high-pressure line.
– Unscrew bolt -1- of the clamping piece of the injector that is to
be removed.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Rep. gr.23 - Mixture preparation - injection
thi
sd
o
cu
m
en
334
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Fit puller - T10055- with puller -T10415- and pull injector out
upwards using tapping movements.
Note
Pull injector out using rotary movements in order not to damage
sealing lip.
– Place the removed injectors on a clean cloth.
Installing new injectors
When a fitting a new injector, the
ility
ab
y li
an
pt
ce
♦ O-ring for fuel return connection
Note
♦ Observe cylinder specific markings when reusing high-pres‐
sure lines.
♦ The high-pressure lines may be re-used after the following
checks:
♦ Check taper seat of respective high-pressure line for defor‐
mation and cracks.
♦ The line hole must not be deformed, constricted or damaged.
♦ Corroded lines should no longer be used.
Installing used injectors
AG.
– Spray tip of injector with an rust removal spray. Wait approx.
5 minutes and wipe off soot and oil particles with a cloth.
agen
lksw
Vo
by
♦ O-ring for fuel return connection
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
♦ O-ring 3 for shaft of injector
ht
rig
py
Co
t.
♦ Copper seal
r
fo
ng
When a used injector is re-fitted, the following must be replaced:
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
♦ O-ring 3 for shaft of injector
un
le
♦ Copper seal
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
following
must
be
replaced:
nte
is
r
o
eo
h
ut
ra
a
c
s
s
– If an injector is very dirty, the tip of the nozzle should also be
cleaned with a soft brass wire brush to make it easier to re‐
move the copper seal. Do not apply the wire brush to the bores
in the nozzle.
– To remove the old copper seal from the injector, clamp the seal
carefully in a vice so that it is just held between the jaws without
turning. Then carefully pull and twist the injector out of the
copper seal by hand.
– Use a scraper to clean off the deposits under the copper seal.
– Clean sealing surface of injector in cylinder head and injector
shaft.
3. Injectors and high-pressure accumulator (rail)
335
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
WARNING
Only cleaning set - VAS 6811- may be used for cleaning seal‐
ing surface of injector bore.
For detailed information on how to use the cleaning set as well
as the order in which its components are applied, refer to the
⇒ operating manual provided with the cleaning set - VAS
6811- .
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Rep. gr.23 - Mixture preparation - injection
do
c
um
en
336
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Replace O-ring for shaft of injector. Use assembly sleeve T10377- to do this.
– Install injectors.
Note
If any of the seals for injectors in cylinder head cover are dam‐
aged, replace the affected seal .
– Tighten union nuts of high-pressure lines hand-tight. Check
they are seated without stress.
– Tighten high-pressure lines to specified torque.
•
Press return line connections carefully over the seals and onto
the injectors (first check seal for damage). The catch should
engage audibly. Then press release pin down carefully.
After one or more injectors has been replaced, the correction val‐
ues for the new injectors must be entered into the engine control
unit ⇒ Vehicle diagnostic tester.
Also check all the other injectors to find out whether the correct
correction values have been stored in the engine control unit. Do
not attempt to re-enter these values if the correct values are al‐
ready stored in the engine control unit.
Note
The high-pressure connections must not be opened for bleeding.
–
–
n AG. Volkswagen AG do
es n
wage
s
k
l
Start engine and run
then
ot g
o at idling speed for a few minutes,
yV
ua
b
d
ran
switch off again.
ir se
tee
tho
or
Switch offs auignition.
ac
s
Renew the affected component if leakage still occurs after tight‐
ening to the correct torque.
Note
The return lines can only be renewed complete.
– Then, road-test the vehicle for more than 20 km. Accelerate
with full throttle at least once. Then check high-pressure part
of fuel system again for leakage.
Note
c
o
p
yri
gh
t
.
C
op
yi
agen
lksw
Vo
by
♦ ⇒ “1.3 Assembly overview - fuel system”, page 311
ht
rig
py
Co
t.
Specified torques
do
c
um
en
If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Stop engine and delete event memory ⇒ Vehicle diagnostic
tester . Then continue the road test.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
– Check the complete fuel system and return line connections
for leaks ⇒ page 316 .
3. Injectors and high-pressure accumulator (rail)
337
AG.
Prote
cted
by
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
3.5
Removing and installing high-pressure
lines
Special tools and workshop equipment required
♦ Torque wrench (5…50 Nm) - V.A.G 1331-
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
♦ Socket - T40055-
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Removing
Caution
♦ Mark high-pressure lines to indicate which ones belong to
which cylinders. They must always be re-installed on the
same cylinders.
♦ Open connections must be sealed immediately with a suit‐
able cap.
♦ Do not crush or damage fuel return lines during removal
or installation.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
♦ The engine must not be run when the fuel return line is
disconnected, this is because the coupling chamber will
be emptied due to the lack of the counterpressure.
– Use socket - T40055- to unscrew high-pressure line between
high-pressure accumulator (fuel rail) and injectors to be re‐
moved.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Installing
Installation is carried out in the reverse order; note the following:
338
Rep. gr.23 - Mixture preparation - injection
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Caution
To position injection lines more easily and stress-free, loosen
and shift high-pressure accumulator (fuel rail) slightly if nec‐
essary. The lines must never be bent or tensioned. Tension
would otherwise cause the respective line to break in the longterm.
Note
swagennew
This section describes
how
toolkinstall
AG. V
AG doinjection lines. If the
agen
s no to be used again,
injection lines which
ksw were previously fitted eare
l
o
t gu
V
by under ⇒ Item 9 (page 312) must
the points listed
abe
d
ra checked
e
s
ri from that the procedure is identical. ntee
again. Apart
o
h
t
or
ac
au
ss
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
Installing individual injection lines (cylinders 1…4, between highpressure accumulator (fuel rail) and injector)
– First, tighten the union nuts of the injection line hand-tight
without a tool. Ensure that line is correctly seated.
– Proceed in the same way with other injection lines.
– Tighten high-pressure accumulator (fuel rail) bolts again, if
necessary. Specified torque ⇒ Item 11 (page 312) .
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
– Remove new injection line from its packaging. Remove seal‐
ing plug and position line between high-pressure accumulator
(fuel rail) and injector (without laying down).
– Tighten union nuts of all new injection lines using torque
wrench (5...50 Nm) - V.A.G 1331- and socket bit - T40055- .
Specified torque ⇒ Item 9 (page 312) .
Installing fuel line between high-pressure pump and high-pres‐
sure accumulator (fuel rail) or complete wiring harness
thi
sd
o
cu
m
en
Note
ht
rig
py
Co
t.
♦ If high-pressure lines are used again, bear in mind the mark‐
c
o
p
yri
gh
t.
C
op
yi
ings you have already made on them.
agen
lksw
Vo
by
♦ High-pressure lines may be re-used after the following checks:
AG.
Prote
cted
by
♦ Check taper seat of respective high-pressure line for defor‐
mation and cracks.
♦ Line hole must not be deformed, constricted or damaged.
♦ Corroded lines should no longer be used.
– Install high-pressure lines (without tension).
– If you have not yet done so, loosen the bolts of the high-pres‐
sure accumulator (fuel rail) to allow it to be moved.
– Then remove the packaging from the fuel line between highpressure pump and high-pressure accumulator (fuel rail). Re‐
move sealing plug and position the line without laying down
again.
– First, tighten the union nuts of the injection line hand-tight
without a tool. Ensure that line is correctly seated.
– If a complete wiring harness needs to be installed, adopt the
same procedure for all 4 injection lines.
3. Injectors and high-pressure accumulator (rail)
339
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Fit all fastening clips to the fuel line. Make sure they are aligned
correctly.
– Screw in the screws -2- of the clips approx. 3 turns of the
screw.
– Tighten high-pressure accumulator (fuel rail) bolts again.
Specified torque ⇒ Item 11 (page 312) .
– Tighten clamp on top of intake manifold.
– Tighten union nuts of all new injection lines using torque
wrench (5...50 Nm) - V.A.G 1331- and
- AT40055.
agen
. Volkswbit
n AGsocket
G do
es n
wage
Specified torque ⇒ Item 9 (page
ot
olks 312) .
V
by
gu
ara
nte
eo
h
ut
ra
a
c
Press return line connections
carefully
over
the
seals
and
onto
s
s
d
– Then, tighten 2 remaining
ise securing bolts.
or
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Filling fuel system ⇒ page 316 .
Specified torques
♦ ⇒ “1.3 Assembly overview - fuel system”, page 311
3.6
Removing and installing high-pressure
accumulator (rail)
Special tools and workshop equipment required
♦ Torque wrench (5…50 Nm) - V.A.G 1331-
AG.
Rep. gr.23 - Mixture preparation - injection
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
340
ht
rig
py
Co
t.
♦ Socket - T40055-
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
the injectors and check seal for damage. You should hear
them click into place. Then press the release pin downwards
carefully.
ility
ab
y li
an
pt
ce
–
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Removing
ility
ab
y li
an
pt
ce
r
fo
ng
Carefully pull fuel return lines upwards when disconnect‐
ing as the 4 catches -arrow- can fracture.
•
After disconnecting, check the 4 catches -arrow- to see
whether they are fractured or have broken off.
•
Always replace damaged fuel return lines.
•
A damaged fuel return line that becomes loose when en‐
gine is running causes damage to piezo injectors. The
piezo injector must then be replaced.
•
The engine must not be run when the fuel return line is
disconnected, this is because the coupling chamber will
be emptied due to the lack of the counterpressure.
AG.
•
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Caution
ht
rig
py
Co
t.
Disconnecting fuel return lines
3. Injectors and high-pressure accumulator (rail)
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
– Unscrew bolts -2- for fuel line -1-.
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
– Pull connector -2- off fuel pressure sender -
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
G247- -1-. y V
ua
b
d
ran
e
tee
ris
o
h
t
or
u
ac
a
ss
341
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
– With engine switched off, carefully pull return line connections
off at piezo injectors. To do this, press the two clips downwards
-arrow A- and, at the same time, pull the release bolt upwards
-arrow B-.
– Pull all fuel return lines -1- off piezo injectors.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– Release connectors -2- and pull them off piezo injectors.
– Unscrew union nuts -1- from piezo injectors.
r
te o
iva
r
rp
fo
g
n
– Unscrew bolts -2- from high-pressure accumulator (fuel rail).
Prote
cted
by
342
Rep. gr.23 - Mixture preparation - injection
AG.
– Pull fuel hose -3- from high-pressure accumulator (fuel ail)
-4-.
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
– Unclip connector -2- and pull off from fuel pressure regulating
valve - N276- -1-.
ht
rig
py
Co
t.
– Pull cable guide -3- from high-pressure accumulator (fuel rail).
do
c
um
en
– Ensure cleanliness. No dirt must be allowed to get into the
disconnected fuel return lines or the open connections on the
piezo injectors.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
olkswagen AG
en AG. V
does
not
gu
ara
nte
eo
ra
c
injector holes on
ag
– Remove high-pressure accumulator (fuel rail)
ksw-1-. Guide highVol
y
pressure accumulator (fuel rail) past fuel
b return line and fuel
ed
ris
lines.
ho
t
au
un
le
pe
rm
itte
d
ility
ab
y li
an
pt
ce
– Ensure cleanliness. No dirt may
ss get into the
the cylinder head cover.
Installing
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Installation is carried out in the reverse order; note the following:
– Install high-pressure lines (without tension).
– Observe instructions for installing high-pressure lines
⇒ page 338 .
– The fuel system must first be filled with fuel before the engine
is started ⇒ page 316 .
Specified torques
♦ ⇒ “1.3 Assembly overview - fuel system”, page 311
Checking return flow rate of injectors
with engine running
Special tools and workshop equipment required
♦ Return flow meter - VAS 6684-
do
c
um
en
r
te o
iva
r
rp
fo
g
n
3.7
ht
rig
py
Co
t.
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
AG.
♦ Hose clamps, up to Ø 25 mm - 3094-
WARNING
Wear eye protection and protective clothing to avoid eye inju‐
ries and skin contact. Before loosening hose connections,
wrap a cloth around the connection. Then release pressure by
carefully pulling hose off connection.
3. Injectors and high-pressure accumulator (rail)
343
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Procedure
WARNING
♦ Read rules for cleanliness and the instructions for working
on the fuel system ⇒ page 8 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
♦ Wrap a clean cloth around the connection before opening
the fuel system, then carefully loosen the connection to
release the pressure.
Note
♦ Adhere strictly to the rules for cleanliness; no dirt must be al‐
lowed to get into the disconnected return lines and the open
return line connections.
♦ Clean all return line connections with commercially available
degreaser before removing them.
♦ Dry all cleaned parts.
Note
♦ The test sequence is described for the solenoid valves with
restrictor. The test sequence for piezo injectors with pressure
retention valve is the same.
♦ For checking the return flow rate of the solenoid valves the
ua
ran
tee
or
ac
The hoses of the return flow meter - VAS 6684- must be of the
same length.
AG.
Rep. gr.23 - Mixture preparation - injection
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
344
ht
rig
py
Co
t.
r
fo
ng
– Carefully pull return line connections off injectors. To do this,
press tabs -1- and -2- downwards and simultaneously pull re‐
lease pin -arrow- upwards.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ss
by
ed
ris
o
th
au
ility
ab
y li
an
pt
ce
Note
un
le
olksw
“transparent” hoses of the return flow meter - VASag6684en AG. Vare agen AG doe
s no
ksw
required.
l
o
tg
V
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Clamp off fuel return hose -arrow- using hose clamp up to
25 mm - 3094- .
– Connect the “transparent” hoses -2- of return flow meter - VAS
6684- -1- to the return line connections of all 4 injectors.
Caution
Risk of damage to injectors when return lines are pulledAGoff.
. Volkswagen
n
wage
ks
♦ Do NOT press the accelerator during thisy test;
Vol the engine
b
d
must only run at idling speed.
e
ris
tho
pe
rm
itte
d
un
le
ility
ab
y li
an
pt
ce
♦ If one of the inspection glasses is
auabout to overflow, ter‐
ss
minate the measurement.
AG do
es n
ot g
ua
ran
tee
or
ac
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– Start engine and allow to idle for 3.5 minutes.
– When the engine is warm and running at idling speed the re‐
turn flow rates at each of the 4 injectors must not differ by more
than a small amount -1-.
– If the return flow rate of one injector is significantly higher than
the return flow rate of the other injectors -2-, renew the re‐
spective injector, ⇒ page 328 or ⇒ page 332 .
Installing
Note
♦ The O-rings of all return line connections must be renewed.
♦ Lubricate O-rings with engine oil or assembly oil before instal‐
agen
lksw
Vo
by
AG.
c
o
p
yri
gh
t.
C
op
yi
– Carefully fit return lines onto injectors and press down tabs on
side -arrows- until they engage audibly.
ht
rig
py
Co
t.
ling.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Installation is carried out in the reverse order; note the following:
3. Injectors and high-pressure accumulator (rail)
345
Prote
cted
by
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Then carefully press the release pin downwards -arrow-.
– Check fuel system for leaks ⇒ page 316 .
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Rep. gr.23 - Mixture preparation - injection
do
c
um
en
346
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
4
High-pressure pump
⇒ “4.1 Removing and installing high-pressure pump”, page 347
olkswagen AG
n AG. V350
⇒ “4.2 Checking high-pressure pump”,
page
doe
wage
4.1
s no
t gu
ara
nte
eo
ra
c
olks
yV
b
Removingrisand
installing high-pressure
ed
o
h
t
pump s au
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
♦ Risk of irreparable damage to high-pressure pump if al‐
lowed to run dry.
♦ The high pressure pump must be filled with fuel before the
engine is started the 1st time ⇒ page 316 . (It is important
not to allow the high-pressure pump to run while still emp‐
ty.)
Special tools and workshop
equipment required
♦ Counterhold tool - T10051♦ Puller - T40064-
♦ Thrust piece - T40064/1ht
rig
py
Co
t.
♦ Torque wrench (5…50 Nm)
- V.A.G 1331-
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
Caution
ility
ab
y li
an
pt
ce
s
4. High-pressure pump
347
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Pliers - 3314-
Removing
– If fresh air supply system is present, partially remove
⇒ page 116 .
– Removing toothed belt from camshaft and high-pressure
pump ⇒ page 107 .
– Undo and remove bolts -2- for high-pressure line -1-.
– Remove union nuts and remove high-pressure line -1-.
– Detach connector -arrow- from fuel metering valve - N290- .
– Loosen clips from fuel hoses -1- and pull fuel hoses off highpressure pump.
r
fo
ng
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
– Remove pulley from high-pressure pump.
AG.
Rep. gr.23 - Mixture preparation - injection
agen
lksw
Vo
by
348
ht
rig
py
Co
t.
– Unscrew bolts -arrows- for high-pressure pump toothed belt
pulley.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ss
s no
t gu
ara
nte
eo
ra
c
ks
Vol
by
d
e
ris
ho
t
au
ility
ab
y li
an
pt
ce
un
le
. Volkswagen AG
n AGsurface.
– Place removed high-pressure line -1- on a
clean
doe
wage
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Hold hub of high-pressure pump with counterhold - T10051and undo nut -1-.
– Position puller - T40064- with thrust piece - T40064/1- and pin
- T40064/2- as shown and pull hub off high-pressure pump. If
necessary, use a 24 mm open-ended spanner as a counter‐
hold.
– Free wiring harness above high-pressure pump from fittings,
and lay it to one side.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
do
c
um
en
4. High-pressure pump
349
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unscrew bolts -arrows- of high-pressure pump.
– Remove high-pressure pump.
Installing
Installation is carried out in the reverse order; note the following:
Caution
After new or removed parts such as the fuel filter or fuel lines
have been fitted, the high-pressure pump must be efilled
olkswagen AG
. Vwith
g n AG
does
swa allowing
fuel before the engine is started for the first time.
kAvoid
not
l
o
V
gu
y
the high-pressure pump to run dry undereall
ara
d b circumstances.
nte
eo
ra
c
ris
ho
ut
a
ss
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
♦ If components of the fuel system between the fuel tank and
the high-pressure pump are removed or renewed, it is neces‐
sary for the fuel system to be bled. To do this, perform the
“Bleeding fuel system” function using the ⇒ Vehicle diagnostic
tester ⇒ page 316 .
♦ This process takes 130 seconds. Fuel pumps are actuated a
total of 3 times in the process. The process must not be ter‐
minated prematurely.
– Install toothed belt ⇒ page 107 .
– Install high-pressure lines ⇒ page 338 .
Note
♦ High-pressure lines may be re-used after the following checks:
♦ Check taper seat of high-pressure line for deformation and
♦ Line hole must not be deformed, constricted or damaged.
♦ ⇒ “1.3 Assembly overview - fuel system”, page 311
4.2
Checking high-pressure pump
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
350
Rep. gr.23 - Mixture preparation - injection
AG.
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 105
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Specified torques
ht
rig
py
Co
t.
♦ Corroded lines should no longer be used.
thi
sd
o
cu
m
en
cracks.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Socket - T40055-
♦ Ratchet - V.A.G 1331/1-
♦ High-pressure pump tester - VAS 6683-
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
WARNING
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
Wear eye protection and protective clothing to avoid eye inju‐
ries and skin contact. Before loosening hose connections,
wrap a cloth around the connection. Then release pressure by
carefully pulling hose off connection.
do
c
um
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
4. High-pressure pump
351
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Procedure
WARNING
♦ Read rules for cleanliness and the instructions for working
on the fuel system ⇒ page 8 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
♦ Wrap a clean cloth around the connection before opening
the fuel system, then carefully loosen the connection to
release the pressure.
Note
♦ Adhere strictly to rules of cleanliness. No dirt must be allowed
to get into the union nut and the disconnected high-pressure
line.
♦ Clean all high-pressure connections with commercially avail‐
able degreaser before removing them.
♦ Dry all cleaned parts.
Specified torques
. Volkswagen AG
gen AG
does
not
gu
ara
nte
eo
ra
c
a
Nm
ksw
Vol
ility
ab
y li
an
pt
ce
y
db
ise 30
r
tho
au
30
s
s
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Rep. gr.23 - Mixture preparation - injection
do
c
um
en
352
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
High-pressure line on injector
High-pressure line on fuel rail
ht
rig
py
Co
t.
Component
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unscrew union nut -2- of high-pressure line -1- from cylinder
1.
– Loosen union nut -4- of high-pressure line -1- from fuel rail by
2 turns.
– Connect high-pressure pump tester - VAS 6683- -3- to union
nut -2- of open high-pressure line, screw on nut “to stop” and
tighten it by hand.
– Screw union nut -4- of high-pressure line -1- “to stop” onto fuel
rail and tighten by hand.
– Using torque wrench - V.A.G 1331- , ratchet - V.A.G 1331/1and socket - T40055- , tighten union nuts -2- and -4- to
specified torque of 30 Nm.
– Disconnect the 4 connectors of the injectors.
– Start engine.
ility
ab
y li
an
pt
ce
Note
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
•
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
Vo
y
ua
b
Fuel must be supplied to the high-pressure pump tester
- VAS
ran
ed
s
i
tee
r
6683- .
o
h
t
or
u
ac
a
ss
Installing
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
If there is fuel in the high-pressure pump tester - VAS 6683- , the
high-pressure pump is “OK”.
Installation is carried out in the reverse order; note the following:
Note
♦ The high-pressure line may be re-used after the following
checks:
♦ Check taper seat of high-pressure line for deformation and
cracks.
♦ The line hole must not be deformed, constricted or damaged.
ht
rig
py
Co
t.
agen
lksw
Vo
by
– Using torque wrench - V.A.G 1331- , ratchet - V.A.G 1331/1and socket - T40055- , tighten high-pressure line to specified
torque of 30 Nm.
do
c
um
en
♦ Corroded lines should no longer be used.
4. High-pressure pump
353
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
5
Intake manifold
⇒ “5.1 Assembly overview - intake manifold”, page 354
⇒ “5.2 Removing and installing intake manifold”, page 354
⇒ “5.3 Removing and installing throttle valve module J338 with
throttle valve potentiometer G69 and intake manifold flap motor
V157 ”, page 357
5.1
Assembly overview - intake manifold
1 - Oil dipstick
2 - Seal
❑ Renew if damaged.
3 - Gasket
❑ Renew if damaged.
4 - Bolt
❑ 8 Nm
5 - Intake manifold
❑ Removing and installing
⇒ page 354 .
6 - Gasket
❑ Renew if damaged.
7 - Bolt
❑ 20 Nm
8 - Pipe
❑ To cylinder head
9 - Clamp
❑ 5 Nm
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
11 - Bolt
❑ 8 Nm
ility
ab
y li
an
pt
ce
10 - Connection
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
12 - Seal
❑ Renew if damaged.
13 - Throttle valve module J338- with throttle valve poten‐
tiometer - G69- and intake
manifold flap motor - V157❑ Removing and installing
⇒ page 357 .
Removing and installing intake manifold
Prote
cted
by
354
Rep. gr.23 - Mixture preparation - injection
AG.
Special tools and workshop equipment required
agen
lksw
Vo
by
5.2
c
o
p
yri
gh
t
.
C
op
yi
16 - Clip
thi
sd
o
cu
m
en
15 - Bolt
❑ 9 Nm
ht
rig
py
Co
t.
14 - Bolt
❑ 8 Nm
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
♦ Torque wrench - V.A.G 1410-
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
♦ XZN 8 bit - T40159- or Torx T 30 bit - T10405agen
lksw
Vo
by
Removing
ht
rig
py
Co
t.
Special tools and workshop equipment required
do
c
um
en
r
te o
iva
r
rp
fo
g
n
♦ Socket set, 22 piece - VAS 5528-
– Remove high-pressure accumulator (fuel rail) ⇒ page 340 .
AG.
– Pull connector off glow plugs ⇒ page 405 .
– Free fuel lines and engine wiring harness above intake mani‐
fold from fittings, and lay them to one side.
– Undo and remove bolts from charge air pipe bracket -2- at
coolant pipe -1-.
5. Intake manifold
355
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Loosen screw-type clip -2- and pull charge air pipe -1- off
throttle valve control module - J338- together with throttle
valve potentiometer - G69- and intake manifold flap motor V157- .
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
– Pull connector -2- off throttle valve module - J338- together
with throttle valve potentiometer - G69- and intake manifold
flap motor - V157- .
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Note
Bolt -1- for oil dipstick has already been removed!
– Continue releasing oil dipstick by forcing off the spreader clip
with removal lever - 80 - 200- .
AG.
Rep. gr.23 - Mixture preparation - injection
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
356
ht
rig
py
Co
t.
– Remove connecting pipe.
thi
sd
o
cu
m
en
– Loosen clip -1- and remove screws -2-.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Undo and remove bolts holding intake manifold in place
-arrows- in diagonal sequence from the outside to the inside
with XZN 8 bit - T40159- or Torx T30 bit - T10405- .
– Carefully remove intake manifold upwards.
Installing
Renew all gaskets and seals.
ility
ab
y li
an
pt
ce
Note
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
Installation is carried out in the reverse order; note
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
the following:
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
– Tighten bolts holding intake manifold in place -arrows- in di‐
agonal sequence from the inside to the outside with XZN 8 bit
- T40159- or Torx T30 bit - T10405- .
– Observe instructions for installing high-pressure lines
⇒ page 338 .
– Install high-pressure lines (without tension).
– The fuel system must first be filled with fuel before the engine
is started ⇒ page 316 .
Specified torques
♦ ⇒ “5.1 Assembly overview - intake manifold”, page 354
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Special tools and workshop equipment required
agen
lksw
Vo
by
Removing and installing throttle valve
module - J338- with throttle valve poten‐
tiometer - G69- and intake manifold flap
motor - V157-
ht
rig
py
Co
t.
5.3
thi
sd
o
cu
m
en
♦ ⇒ “1.3 Assembly overview - fuel system”, page 311
♦ Torque wrench - V.A.G 1410-
Removing
Observe rules for cleanliness ⇒ page 8 .
Removing screw-type clips ⇒ page 11 .
5. Intake manifold
357
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Loosen screw-type clip -2- and pull charge air pipe -1- off from
throttle valve module - J338- with throttle valve potentiometer
- G69- and intake manifold flap motor - V157- .
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
– Pull connector -2- off throttle valve module - J338- together
with throttle valve potentiometer - G69- and intake manifold
flap motor - V157- .
– Undo bolts -arrows- and remove throttle valve module - J338together with throttle valve potentiometer - G69- and intake
manifold flap motor - V157- -4-.
Installing
Installation is carried out in the reverse order; note the following:
Specified torques
AG.
Prote
cted
by
Rep. gr.23 - Mixture preparation - injection
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
358
ht
rig
py
Co
t.
r
fo
ng
♦ ⇒ “5.1 Assembly overview - intake manifold”, page 354
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
– Loosen clamp -1- and detach connecting pipe.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
6
Senders and sensors
⇒ “6.1 Removing and installing air mass meter G70 ”, page 359
⇒ “6.2 Removing and installing exhaust
pressure sensor 1 G450
. Volkswagen AG
gen AG
”, page 360
does
a
w
s
k
Vol
not
g
ua
by
⇒ “6.3 Removing and
ran
ed installing fuel pressure regulating valve
tee
ris
o
N276 ”, page 362
th
o
au
⇒ “6.5 Removing and installing fuel pressure sender G247 ”, page
365
Removing and installing air mass meter
- G70-
Special tools and workshop equipment required
♦ Hose clip pliers - VAS 6340-
ht
rig
py
Co
t.
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Removing
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
6.1
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ra
c
ility
ab
y li
an
pt
ce
ss
⇒ “6.4 Checking
fuel pressure regulating valve N276 ”,
page 364
– Pull off connector -3- for air mass meter - G70- .
AG.
– Loosen screw-type clip -4- and remove intake hose from air
mass meter - G70- .
6. Senders and sensors
359
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unscrew bolts -arrows- from air mass meter - G70- and care‐
fully pull air mass meter - G70- -1- out of air filter housing
guide.
Installing
Installation is carried out in the reverse order; note the following:
To ensure the proper function of the air mass meter - G70- , it is
AG. Volkswagen AG d
important to observe the following notes and instructions.
agen
o
Note
ss
es n
ot g
ua
ran
tee
or
ac
ksw
Vol
by
d
e
ris
ho
t
au
un
le
ility
ab
y li
an
pt
ce
♦ If the air filter element is very dirty or wet, dirt or water could
♦ Always use genuine part for air filter element.
♦ Use a lubricant (silicon) to amount the air intake hose.
– Check for salt residues, dirt and leaves in air mass meter G70- and air intake hose (pure air side).
– Check intake channel for contamination as far as air filter el‐
ement. If contamination is found, remove salt residues, dirt
and leaves from top and bottom part of air filter housing by
rinsing out or using a vacuum cleaner if necessary.
Specified torques
♦ ⇒ “7.1 Assembly overview - air filter”, page 368
r
fo
ng
Removing and installing exhaust pres‐
sure sensor 1 - G450-
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Special tools and workshop equipment required
360
Rep. gr.23 - Mixture preparation - injection
AG.
♦ Hose clip pliers - VAS 6340-
agen
lksw
Vo
by
♦ Torque wrench - V.A.G 1410-
ht
rig
py
Co
t.
6.2
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
reach the air mass meter - G70- and affect the air mass value.
This would lead to loss of power, since a smaller injection
quantity is calculated.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Removing
Note
Some connectors are difficult to see. A small hand-held mirror is
required to unscrew and insert the threaded connection.
Note
Exhaust pressure sensor 1 - G450- -arrow- is located on rear left
engine bracket.
– Release connector -2- and pull off from exhaust gas pressure
sensor 1 - G450- -1-.
swagdetach
Volkand
en AG exhaust
– Undo and remove bolt -3- in bracket
en AG.-4does
wag-1-.
not
gas pressure sensor 1 - VG450olks
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
– Open spring-type clips -1- and pull hoses off -2 and 3-.
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
ss
gu
ara
nte
eo
ra
c
by
ed
ris
o
th
au
6. Senders and sensors
361
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Undo and remove bolt -2- on line retainer -1- and detach line
retainer -1- from vacuum pump -3-.
– Completely remove exhaust gas pressure sensor 1 - G450- .
Installing
Installation is carried
If exhaust pressure sensor 1 - G450- is renewed, then adaptation
must be carried out using ⇒ Vehicle diagnostic tester.
ility
ab
y li
an
pt
ce
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Specified torques
♦ ⇒ “2.1 Assembly overview - emission control (diesel particu‐
late filter)”, page 377
6.3
Removing and installing fuel pressure
regulating valve - N276-
The fuel pressure regulating valve is located in the high pressure
accumulator. The valves ensure that pressure is constant in the
high pressure accumulator and in the injector lines (fuel high
pressure circuit).
If pressure is too high in the fuel high pressure circuit, the regu‐
lating valve will open. A small amount of fuel from the high
pressure accumulator will thereby make its way back to the fuel
tank via the return line.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Procedure
Note
Fuel pressure regulating valve - N276- must be renewed each
time after removing.
Caution
Read through the rules for cleanliness and the instructions for
working on the fuel system ⇒ page 7 .
Follow these instructions before starting work and while work‐
ing on the fuel system.
– Clean threaded area around the regulating valve with com‐
mercially available degreaser, for example, before removing
it. Under no circumstances may dirt enter the hole of the highpressure accumulator (fuel rail).
Note
Clean carefully; cleaning solvent must not enter the electrical
connector.
– Dry fuel pressure regulating valve - N276- .
362
Rep. gr.23 - Mixture preparation - injection
ht
rig
py
Co
t.
If pressure is too low in the fuel high pressure circuit, the regulat‐
ing valve will close. The valve seals the high pressure side against
the low pressure side in this way.
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Note
n AG. Volkswagen AG do
es n
wage
s
k
l
out in the reverse
order; note the following:
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Remove high-pressure accumulator (fuel rail) ⇒ page 340 .
– Clamp high-pressure accumulator (fuel rail) in a vice with pro‐
tective jaws.
– Counterhold at 36 mm hexagon -3- and loosen 30 mm union
nut -2-. Then unscrew regulating valve by hand.
– Use suction device to extract dirt from high-pressure accumu‐
lator bore (threads and sealing surface). Do not use any
mechanical tools to do this.
Note
Seal off high-pressure accumulator hole immediately with a suit‐
able plug to prevent dirt from entering.
Installing
WARNING
Note
♦ The fuel pressure regulating valve - N276- has a deformable
sealing lip and no separate seal; it can therefore be used only
once.
♦ Check that sealing surfaces (deformable sealing lip) and
threads on fuel pressure regulating valve - N276- are undam‐
aged.
♦ Check the sealing surface of the high-pressure accumulator
hole as well.
♦ Thread on fuel pressure regulating valve - N276- must be free
ht
rig
py
Co
t.
r
fo
ng
of oil and grease.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ar
d
For vehicles with solenoids,
ise the learnt values from the fuel sys‐ ante
r
o
eo
h
t
tem must be reset following
the renewal of the fuel pressure
ra
au
c
s
regulating valve - N276⇒
Vehicle
diagnostic
tester.
s
6. Senders and sensors
363
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
Amarok
ir se 2011 ➤
tee
o
h
t
or 4-cylinder
diesel engine (2.0 l engine, common rail)
u
ac
a
ss
Edition 04.2013
– Tighten union nut -2- by hand.
Note
Connector connection piece must point vertically upwards.
– Align fuel pressure regulating valve - N276- so that connector
connection piece points vertically upwards.
– Counterhold at housing hexagon -3- and tighten union nut
-2-.
– Bleeding fuel system ⇒ page 316 .
– After mounting, leave engine running at moderate speed for a
few minutes and then switch off again.
– Check fuel system for leaks.
do
c
um
en
– Read event memory again.
– Then test drive the vehicle, accelerating to full throttle at least
once. Check high pressure part of fuel system again for leaks.
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
AG.
Prote
cted
by
Specified torques
ht
rig
py
Co
t.
– Read event memory again.
♦ ⇒ “1.3 Assembly overview - fuel system”, page 311
6.4
Checking fuel pressure regulating valve
- N276-
Special tools and workshop equipment required
♦ Transparent measuring beaker ≥ 500 ml
WARNING
Wear eye protection and protective clothing to avoid eye inju‐
ries and skin contact. Before loosening hose connections,
wrap a cloth around the connection. Then release pressure by
carefully pulling hose off connection.
Procedure
WARNING
♦ Read rules for cleanliness and the instructions for working
on the fuel system ⇒ page 8 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
♦ Wrap a clean cloth around the connection before opening
the fuel system, then carefully loosen the connection to
release the pressure.
364
Rep. gr.23 - Mixture preparation - injection
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
– Renew seal -1-.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦
. Volkswagen AG
gen AG
does
swa
k
not
l
o
Note
gu
yV
b
ara
d
e
nte
is
r
o
th
Adhereaustrictly
to the rules for cleanliness; no dirt muste obe
r a al‐
c
lowedssto get into the disconnected return line and the open
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
ility
ab
y li
an
pt
ce
return line connection.
♦ Clean all return line connections with commercially available
degreaser before removing them.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
♦ Dry all cleaned parts.
– Release spring-type clip -arrow- and pull fuel return hose off
fuel rail.
ht
rig
py
Co
t.
r
fo
ng
– Seal the open fuel return hose -1- with a clean sealing plug.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
– Connect an auxiliary hose -2- to return connection of fuel rail
-3-.
agen
lksw
Vo
by
– Hold auxiliary hose in measuring beaker -4- to measure return
flow rate.
AG.
– Start engine and run at idling speed for 30 seconds.
Note
The fuel in the auxiliary hose is disregarded for determining the
return flow rate.
•
Specified amount in 30 seconds: 90 ... 110 ml
If the specification is not attained, the fuel pressure regulating
valve - N276- is defective and must be renewed ⇒ page 364 .
Installing
– Installation is performed in the reverse sequence.
6.5
Removing and installing fuel pressure
sender - G247-
Special tools and workshop equipment required
6. Senders and sensors
365
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Torque wrench (40…200 Nm) - V.A.G 1332-
Fuel pressure sender - G247- is located in high-pressure accu‐
mulator. It measures the fuel pressure and sends a voltage signal
to the control unit for direct diesel injection system - J248- .
In the event of sender failure, pressure regulation is controlled
using a map from the engine control unit. In back-up function, the
AG. Volkswagen AG d
agen
oes
maximum engine speed is limited to approx. 3000 rpm.
ksw
not
l
o
V
gu
by
ara
d
e
Removing
nte
ris
eo
ra
c
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
Caution
tho
au
s
s
Read through the rules for cleanliness and the instructions for
working on the fuel system ⇒ page 7 .
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Follow these instructions before starting work and while work‐
ing on the fuel system.
– Clean threaded area around the regulating valve with com‐
mercially available degreaser, for example, before removing
it. Under no circumstances may dirt enter the hole of the highpressure accumulator (fuel rail).
Note
Clean carefully; cleaning solvent must not enter the electrical
connector.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Rep. gr.23 - Mixture preparation - injection
ht
rig
py
Co
t.
366
thi
sd
o
cu
m
en
– Dry fuel pressure sender - G247- .
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Release connector -1- from fuel pressure sender - G247- -2and pull off.
– Unscrew fuel pressure sender - G247- .
– Use suction device to extract dirt from high-pressure accumu‐
lator bore (threads and sealing surface). Do not use any
mechanical tools to do this.
Note
Seal off high-pressure accumulator hole immediately with a suit‐
able plug to prevent dirt from entering.
Installing
gen AG note the following:
G. Volkswaorder;
en Areverse
Installation is carried outswinagthe
does
k
Vol
by
d
e
ris
Note utho
a
ss
♦ Check that sealing surfaces (deformable sealing lip) and
threads on fuel pressure sender - G247- are undamaged.
ility
ab
y li
an
pt
ce
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
not
gu
ara
nte
eo
ra
c
♦ Check the sealing surface of the high-pressure accumulator
♦ Thread of fuel pressure sender - G247- is coated with an anti-
friction lacquer. The thread must therefore be free of oil and
grease.
– Tighten fuel pressure sender - G247- by hand.
– Tightening sender.
– Bleeding fuel system ⇒ page 316 .
– After mounting, leave engine running at moderate speed for a
few minutes and then switch off again.
– Check fuel system for leaks.
– Read event memory again.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
hole as well.
do
c
um
en
– Then test drive the vehicle, accelerating to full throttle at least
once. Check high pressure part of fuel system again for leaks.
c
o
p
yri
gh
t
.
C
op
yi
agen
lksw
Vo
by
Prote
cted
by
Specified torques
ht
rig
py
Co
t.
– Read event memory again.
♦ ⇒ “1.3 Assembly overview - fuel system”, page 311
6. Senders and sensors
367
AG.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
7
Air filter
⇒ “7.1 Assembly overview - air filter”, page 368
⇒ “7.2 Removing and installing air filter”, page 370
7.1
Assembly overview - air filter
1 - Air duct
❑ Check for secure
gagement.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
e
nte
en‐ horis
eo
t
u
ra
a
c
s
s
3 - Air filter lower part
4 - Bolt
❑ Rubber bush clipped in‐
to lower part of air filter.
❑ 8.5 Nm
5 - Water drainage pipe
⇒ page 370
❑ Clipped onto lower part
of air filter.
❑ Make sure it is mounted
in correct position on
longitudinal member
❑ Clean if soiled
r
fo
ng
Prote
cted
by
9 - O-ring
❑ Renew if damaged.
10 - Intake manifold pressure sender - G7111 - Bolt
❑ 1.6 Nm
12 - Bracket
❑ For coolant hose mounting.
13 - O-ring
❑ Renew if damaged.
14 - Air mass meter - G70❑ Removing and installing ⇒ page 359 .
368
Rep. gr.23 - Mixture preparation - injection
AG.
8 - Bolt
❑ 2 Nm
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
7 - Air filter upper part
ht
rig
py
Co
t.
6 - Filter element
❑ Renewng air filter: clean
and replace filter ele‐
ment ⇒ Maintenance ;
Booklet 11
❑ Renewing air filter: with
saturation indication in
dash panel insert
⇒ Maintenance ; Book‐
let 11
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
ility
ab
y li
an
pt
ce
2 - Rubber bush
❑ Clipped into lower part
of air filter.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
15 - Bolt
❑ 1.6 Nm
16 - Screw-type clip
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
Caution
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
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.
❑ 5.5 Nm
18 - Screw-type clip
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
AG.
Prote
cted
by
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.
ht
rig
py
Co
t.
Caution
thi
sd
o
cu
m
en
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.
❑ To turbocharger.
❑ With heater element for crankcase breather - N79- and connection for crankcase breather/cylinder head
cover connecting pipe.
❑ 5.5 Nm
19 - Vacuum hose
20 - Bracket
❑ For wiring harness.
21 - Heat shield
22 - Bolt
❑ 2 Nm
23 - Mounting for air duct
❑ Secured to lock carrier.
❑ Check for secure engagement.
24 - Bolt
❑ 8.5 Nm
7. Air filter
369
– Water drainage pipe -1- is clipped into lower part of air filter
-arrow-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
7.2
Removing and installing air filter
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1410-
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
♦ Hose clip pliers - VAS 6340-
Removing
– Pull vacuum hose -1- off upper part of air filter.
– Remove cowling -3- from lower part of air filter and unscrew
securing bolt -2- for bracket.
370
Rep. gr.23 - Mixture preparation - injection
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Water drainage pipe on lower part of air filter
04.2013
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
Amarok 2011d➤
by
ara
e
s
i
r
ee
4-cylinderhodiesel engine (2.0 l engine, common rail) -ntEdition
t
or
ac
au
s
s
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
n AG. Volkswagen AG do
es n
wage
ot g
ua
ran
tee
or
ac
of air filter.
lks
– Pull off connector -1- for intake manifold pressure
Vosender
by
d
e
G71- .
s
ri
tho
s
ility
ab
y li
an
pt
ce
un
le
u
– Unclip coolant hose -2- from bracket ons aupper
part
– Loosen screw-type clip -4- and remove intake hose from air
mass meter - G70- .
– Open screwed-attached clip -2- and pull intake pipe -4- off the
air filter container.
– Unclip wiring harness from brackets on air filter housing.
– Unscrew securing bolt -2- ⇒ Item 4 (page 368) for air filter
housing -1- in area of coolant expansion tank.
– Pull air filter out of mountings.
Installing
Install in reverse order. In the process, note the following:
Specified torques
ht
rig
py
Co
t.
r
fo
ng
♦ ⇒ “7.1 Assembly overview - air filter”, page 368
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
– Pull off connector -3- for air mass meter - G70- .
7. Air filter
371
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
8
Engine control unit
⇒ “8.1 Removing and installing engine control unit”, page 372
⇒ “8.2 Renewing engine control unit”, page 372
8.1
Removing and installing engine control
unit
Removing
– Switch off ignition.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
suitable
ise tool and
r
o
eo
h
t
u
ra
a
c
s
s
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .
– If fitted, remove shear-head bolts -1- using a
remove retaining bar -4-.
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
– Release and pull off connectors -2- and -3-.
– Pull engine control unit out of its bracket.
Installing
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Installation is carried out in the reverse order; note the following:
Note
Use new shear-head bolts.
8.2
Renewing engine control unit
Note
Prote
cted
by
Removing
– Before removing engine control unit, read identification and
coding of present control unit ⇒ Vehicle diagnostic tester.
– Remove engine control unit ⇒ page 372 .
372
Rep. gr.23 - Mixture preparation - injection
AG.
When the engine control unit is renewed, the “injector de‐
livery calibration values” must be written into the new
engine control unit ⇒ page 327 .
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
•
ht
rig
py
Co
t.
Caution
thi
sd
o
cu
m
en
The diesel direct injection system control unit is equipped with an
event memory. Read event memory before and after making re‐
pairs or adjustments ⇒ Vehicle diagnostic tester.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Remove shear-head bolts -2- using a suitable tool and remove
bracket -1-.
Installing
n AG. Volkswagen AG do
e
wage
ot g the following:
olks out in the reverse order;s nnote
Installation is carried
yV
u
ara
nte
e
s
sNote
– Install engine control unit ⇒ page 372 .
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Use new shear-head bolts.
or
ac
ility
ab
y li
an
pt
ce
un
le
b
ed
ris
o
h
t
au
ht
rig
py
Co
t.
r
fo
ng
– Check previous coding and code new control unit ⇒ Vehicle
diagnostic tester.
8. Engine control unit
373
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
26 –
Exhaust system
1
Exhaust pipes, silencers
⇒ “1.1 Assembly overview - silencers”, page 374
⇒ “1.2 Checking exhaust system for leaks”, page 375
⇒ “1.3 Aligning exhaust system free of stress”, page 375
1.1
Assembly overview - silencers
1 - Screw-type clip
❑ Note installation posi‐
tion.
❑ 35 Nm
2 - Rubber mounting
❑ Note installation posi‐
tion ⇒ page 375 .
3 - Front silencer
❑ Removing:
–
Remove front propshaft.
–
Remove gearbox sup‐
port and gearbox
mountings ⇒ page 31 .
ers at separating point.
Detach front silencer
from rubber mounting
⇒ Item 2 (page 374) and
completely remove front
silencer.
–
Detach front and rear si‐
lencers at separating
point.
–
Detach rear silencer
from rubber mounting
⇒ Item 2 (page 374) and completely remove rear silencer.
AG.
6 - Mounting
❑ Fasten mounting on gearbox cross member ⇒ page 375
374
Rep. gr.26 - Exhaust system
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
5 - Double clamp
❑ Note installation position.
❑ Installation of double clamp ⇒ page 375
❑ 31 Nm
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
–
ht
rig
py
Co
t.
Undo bolts holding
hanger
⇒ Item 6 (page 374) on
gearbox cross member.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
–
4 - Rear silencer
❑ Removing:
ility
ab
y li
an
pt
ce
–
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
Detach front/rear silenc‐ss
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
7 - Bolt
❑ 20 Nm
Fasten mounting on gearbox cross member
– Secure mounting -2- to gearbox cross member -1- with bolts
-3-.
Installation of double clamp
– Mark the distances 39 mm -a and b- at end of pipe of front
silencer -2- and beginning of pipe of rear silencer -1- - 4-.
G. Volkswage
n AG d
nA
oes
wage
not
– Insert front silencer -2- and rear silencer
olks-1- into double clamp
V
gu
y
b
ara
-3- up to dimensions -a and b-. ed
is
or
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Installation location of rubber mounting
– Align rubber mounting -1- in such a way that the distance -ais 8 mm.
Note
Check entire installation location of exhaust system.
Checking exhaust system for leaks
– Start engine and run at idling speed.
c
o
p
yri
gh
t
.
C
op
yi
– Seal end exhaust pipes with cloths or plugs, for example, for
the duration of the leakage test.
agen
lksw
Vo
by
Prote
cted
by
– Check (by listening) points of connection between exhaust
manifold and cylinder head, and between turbocharger and
front exhaust pipe to make sure there are no leaks.
ht
rig
py
Co
t.
1.2
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
– Align front silencer -2- and rear silencer -1- horizontally, and
tighten bolts -3- for double clamp.
nte
eo
ra
c
ility
ab
y li
an
pt
ce
h double clamp -3- horizontally
– Align screw-type connectionautof
and lightly tighten bolts. ss
AG.
– Rectify any leaks that are found.
1.3
Aligning exhaust system free of stress
Special tools and workshop equipment required
1. Exhaust pipes, silencers
375
. Volkswagen AG
gen AG
does
not
gu
ara
nte
eo
ra
c
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Exhaust system must be aligned when cold.
Procedure
– Loosen bolts of double clamp -3-.
– Tighten bolts hand tight.
– Tighten bolts for double clamp -3-.
Specified torques
♦ ⇒ “1.1 Assembly overview - silencers”, page 374
376
Rep. gr.26 - Exhaust system
AG.
– Align rubber mountings -1- for front silencer -2- and rear si‐
lencer -1- in such a way that dimension -a- is 8 mm.
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
– Align bolts of double clamp -3- horizontally.
ht
rig
py
Co
t.
r
fo
ng
– Align exhaust system until the marking- 4- is visible.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
•
r
ho
ut
a
ss
ility
ab
y li
an
pt
ce
♦ Torque wrench (5…50 Nm) - V.A.G 1331-
un
le
wa
Amarok 2011 ➤
olks
yV
b
d
4-cylinder diesel engine (2.0 l engine, common rail) -isEdition
04.2013
e
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
2
Cleansing exhaust emissions
⇒ “2.1 Assembly overview - emission control (diesel particulate
filter)”, page 377
⇒ “2.2 Assembly overview - emission control (catalytic convert‐
er)”, page 379
⇒ “2.3 Removing and installing particulate filter”, page 381
⇒ “2.4 Removing and installing catalytic converter”, page 387
2.1
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
- Screw-type clip
nte
ise
r
o
eo
h
t after re‐
❑ Always renew
u
ra
a
c
s
moving
s
un
le
1
Assembly overview - emission control (diesel particulate filter)
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
❑ Fit screw-type clip by
hand
❑ When installing, first fit
screw-type clip on tur‐
bocharger for exhaust
pipe.
❑ 8 Nm
2 - Gasket
❑ Renew after removing
❑ Note installation posi‐
tion.
r
te o
iva
r
rp
fo
g
n
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
AG.
Prote
cted
by
5 - Exhaust gas temperature
sender 3 - G495❑ Grease thread of sender
using high-temperature
paste ⇒ Electronic
Parts Catalogue (ET‐
KA) .
❑ Connector (brown) at
coupling point of air filter
❑ 45 Nm
ht
rig
py
Co
t.
4 - Control line with union nut
❑ 20 Nm
do
c
um
en
3 - Lambda probe - G39❑ Grease only thread. The
high-temperature paste
⇒ Electronic parts cata‐
logue (ETKA) must not
get into the slots on the
probe body.
❑ 50 Nm
6 - Exhaust gas temperature sender 4 - G648❑ Grease thread of sender using high-temperature paste ⇒ Electronic Parts Catalogue (ETKA) .
❑ Connector (orange) at coupling point of air filter
❑ 45 Nm
2. Cleansing exhaust emissions
377
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
7 - Bracket with control lines
8 - Clip
9 - Control pipe
10 - Union nut
❑ 20 Nm
11 - Exhaust gas pressure sensor 1 - G450❑ Adaptation is necessary after this component has been renewed ⇒ Vehicle diagnostic tester.
❑ Removing and installing ⇒ page 360 .
12 - Bolt
❑ 5 Nm
13 - Front exhaust pipe
❑ Take into account the fact that there are different types ⇒ ETKA (electronic parts catalogue)
❑ Handle carefully to avoid damage.
•
Transport shock-free.
•
Do not kink flexible hose.
•
Do not stretch flexible hose.
❑ Removing and installing ⇒ page 381 .
14 - Particulate filter
•
Assembly sequence must be adhered to during installation to ensure stress-free installation.
♦ Position particulate filter with new gasket ⇒ Item 2 (page 377) and new screw-type clip
⇒ Item 1 (page 377) .
♦ Tighten screw-type clip ⇒ Item 1 (page 377) .
❑ Removing and installing ⇒ page 381 .
15 - Bracket
❑ Secured to gearbox on right
n AG. Volkswagen AG do
es n
wage
ks⇒
l
❑ Attaching bracket to gearbox
page
380
ot g
o
V
ss
by
ed
ris
o
th
au
ua
ran
tee
or
ac
ility
ab
y li
an
pt
ce
un
le
16 - Bolt
❑ 20 Nm
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
18 - Bolt
❑ 20 Nm
AG.
Rep. gr.26 - Exhaust system
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
378
ht
rig
py
Co
t.
r
fo
ng
19 - Mounting
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
17 - Bracket
❑ Fastened to engine support on right
❑ Metal type
❑ Fasten to bracket on engine support ⇒ page 380
Amarok 2011 ➤
Volkswaengine
gen AG (2.0 l engine, common rail) - Edition 04.2013
n AG.diesel
e
4-cylinder
g
d
a
o
e
w
s no
t gu
ara
nte
eo
ra
c
ks
Vol
by
d
e
ris
tho
u
a
ss
Assembly overview - emission control (catalytic converter)
ility
ab
y li
an
pt
ce
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
2.2
Note
♦ After working on the exhaust system, ensure that the system is not under stress and that there is sufficient
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
clearance to the bodywork. Loosen double clamp and clip if necessary. Align silencer and exhaust pipe so
that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.
♦ Renew self-locking nuts.
Prote
cted
by
Transport shock-free.
•
Do not kink flexible hose.
•
Do not stretch flexible hose.
❑ Removing and installing
⇒ page 387 .
AG.
•
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
3 - Front exhaust pipe with cat‐
alytic converter
❑ Take into account the
fact that there are differ‐
ent types ⇒ ETKA (elec‐
tronic parts catalogue)
❑ Handle carefully to
avoid damage.
❑ When installing, first
fasten the top screwtype clip for the exhaust
pipe on turbocharger
ht
rig
py
Co
t.
2 - Gasket
❑ Renew after removing
❑ Note installation posi‐
tion.
thi
sd
o
cu
m
en
1 - Screw-type clip
❑ Always renew after re‐
moving
❑ Fit screw-type clip by
hand
❑ When installing, first
fasten the screw-type
clip for the exhaust pipe
on turbocharger
❑ 8 Nm
4 - Bolt
❑ 20 Nm
5 - Bracket
❑ Secured to gearbox on right
❑ Attaching bracket to gearbox ⇒ page 380
6 - Bolt
❑ 20 Nm
7 - Bracket
❑ Fastened to engine support on right
❑ Metal type
❑ Attaching bracket to engine support ⇒ page 380
2. Cleansing exhaust emissions
379
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
8 - Bolt
❑ 20 Nm
9 - Bolt
❑ 20 Nm
Fasten to bracket on gearbox
– Secure bracket -2- to gearbox -1- with bolts -3-.
Fasten bracket to engine support
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
r
fo
ng
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Rep. gr.26 - Exhaust system
ht
rig
py
Co
t.
380
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
– Secure bracket -2- to engine support -1- with bolts -3-.
Amarok 2011 ➤
olkswagen AG
en AG. Vengine
4-cylinder
(2.0
l
engine,
common
rail)
Edition 04.2013
gdiesel
d
a
o
e
w
s
s
not
gu
ara
nte
eo
ra
c
Removing and installing particulate filter
ility
ab
y li
an
pt
ce
un
le
2.3
k
Vol
by
d
e
ris
tho
u
a
ss
pe
rm
itte
d
Special tools and workshop
equipment required
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
♦ Torque wrench (5…50 Nm)
- V.A.G 1331♦ Torque wrench (40…200
Nm) - V.A.G 1332-
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
♦ Hose clip pliers - VAS
6362-
2. Cleansing exhaust emissions
381
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Removing
WARNING
Risk of burns.
Parts of the exhaust system may be hot.
Allow exhaust system to cool before removing.
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damage to lines, ensure sufficient clearance from
all moving or hot components.
♦ Cut through cable ties carefully and install new ones in the
same position.
– Detach vacuum hose -2- from upper toothed belt guard -1-.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
pe
rm
itte
d
ility
ab
y li
an
pt
ce
AG.
Rep. gr.26 - Exhaust system
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
382
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– Remove pipe -arrow- from cylinder head cover.
ht
rig
py
Co
t.
un
le
– Open clips -arrows- and remove toothed belt guard -1-.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Detach hoses from intake hose -3- bracket -arrow-.
– Release and pull off wiring harness connector -2-. Detach wir‐
ing harness -2- from intake hose -3-.
– Open clips -1- and -4- and remove intake hose -3- together
with pipe -5-.
– Remove air filter ⇒ page 368 .
– Disconnect connectors -1, 2 and 3- for exhaust gas tempera‐
ture sender 1 - G235- (black connector), exhaust gas temper‐
ature sender 3 - G495- (brown connector) and exhaust gas
temperature sender 4 - G648- (orange connector) at coupling
point (in front of air filter).
– Loosen cable ties -3-, free lines -1 and 2- from fittings, and lay
them to one side.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Clamp off coolant hose -2- with hose clamps up to 25 mm 3094- .
– Open spring-type clip -1- for coolant hose -2- and pull coolant
hose off.
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
2. Cleansing exhaust emissions
383
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Open spring-type clips -1- and pull hoses -2 and 3- off control
lines for particulate filter.
– Undo and remove bolt -2- for coolant pipe -1- at wheel housing
and tie on coolant hose somewhere at a slightly higher point.
Note
Do not bend coolant pipe.
– Undo screw -1- of screw-type clamp -2- between particulate
filter and turbocharger and remove clamp -2-.
– Undo and remove bolts -3- for particulate filter bracket -4-.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
– Undo screw -1- of clamp -2-.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Rep. gr.26 - Exhaust system
do
c
um
en
384
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Undo and remove bolts -3- for exhaust pipe bracket -4-.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– When removing particulate filter, push -1- the coolant pipe
-2- a little to one side.
– Carefully remove particulate filter -1- upwards out of the en‐
gine compartment.
Installing
Installation is carried out in the reverse order; note the following:
Caution
Ensure particulate filter is not stressed when installed.
The particulate filter could be damaged.
Follow installation sequence.
Use new clips and gaskets.
Assembly sequence for installation of particulate filter must be
adhered to during installation to ensure stress-free installation.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
thi
sd
o
cu
m
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
•
2. Cleansing exhaust emissions
385
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
♦ When installing particulate filter, push -1- the coolant pipe -2a little to one side.
♦ Install particulate filter -1- carefully.
♦ Screw in bolts -3- for particulate filter bracket -4- a few turns.
♦ Position particulate filter with new gasket
⇒ Item 2 (page 377) and new screw-type clip
⇒ Item 1 (page 377) .
♦ Fit exhaust pipe bracket -4- and tighten bolts -3- hand-tight.
♦ Fit clamp -2- and tighten screw -1- slightly.
♦ Tighten bolts ⇒ Item 18 (page 378) -3-.
c
o
p
yri
gh
t
.
C
op
yi
♦ Tighten bolts ⇒ Item 18 (page 378) -3-.
Prote
cted
by
386
Rep. gr.26 - Exhaust system
AG.
– Fasten lines -1 and 2- with new cable ties -3-.
agen
lksw
Vo
by
♦ Tighten screw -1- for clamp -2-.
ht
rig
py
Co
t.
r
fo
ng
♦ Tighten screw -1- for screw-type clip ⇒ Item 1 (page 377) -2-.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Connect connectors -1, 2 and 3- for exhaust gas temperature
sender 1 - G235- (black connector), exhaust gas temperature
sender 3 - G495- (brown connector) and exhaust gas temper‐
ature sender 4 - G648- (orange connector) at coupling point
(in front of air filter), and make sure they engage securely.
– Install air filter ⇒ page 368
Note
If a new particulate filter was installed, connect ⇒ Vehicle diag‐
nostic tester and carry out “Ash mass comparison”.
Specified torques
Volkswagen AG
AG.(diesel
♦ ⇒ “2.1 Assembly overview - emission
control
particu‐
does
agen
ksw
not
l
o
late filter)”, page 377
V
gu
y
b
ara
nte
e
ed
♦ ⇒ “7.1 Assembly overviewtho-risair filter”, page 368
pe
rm
itte
d
un
le
Removing and installing catalytic con‐
verter
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Special tools and workshop equipment required
or
ac
ility
ab
y li
an
pt
ce
2.4
au
ss
♦ Lambda probe open ring spanner set - 3337-
do
c
um
en
r
te o
iva
r
rp
fo
g
n
♦ Torque wrench (5…50 Nm) - V.A.G 1331-
ht
rig
py
Co
t.
2. Cleansing exhaust emissions
387
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Removing
– Remove pipe -arrow- from cylinder head cover.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
– Detach hoses from intake hose -3- bracket -arrow-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Release and pull off wiring harness connector -2-. Detach wir‐
ing harness -2- from intake hose retainer -3-.
– Open clips -1- and -4- and remove intake hose -3- together
with pipe -5-.
– Remove air filter ⇒ page 368
– Pull vacuum hose -2- off vacuum unit of exhaust gas recircu‐
lation cooler and vacuum hose -1- off regulating flap potenti‐
ometer - G584- .
AG.
Prote
cted
by
Rep. gr.26 - Exhaust system
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
388
ht
rig
py
Co
t.
– Loosen clamp -3- on exhaust pipe -1- and pull exhaust pipe
-1- off a little.
do
c
um
en
– Loosen screw -2- for clamp -1- between exhaust pipe -4- and
turbocharger.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Undo and remove bolts -3- holding exhaust pipe -2- on gear‐
box bracket -1-.
– Release and detach connector -1- of exhaust gas temperature
sender 1 - G235- on front right wheel housing -3- at the cou‐
pling point -2-. Then, free wiring nharness
from
agen fittings
AG. Volksw
AG do and lay
es n
wage
it to one side.
o
olks
t gu
a
V
by
ran
ed
– Carefully remove front
tee
ris exhaust pipe upwards out of the engine
o
h
or
compartment. ut
a
a
ss
Installation is carried out in the reverse order; note the following:
– Use new clips and gaskets.
– Secure front exhaust pipe with all brackets, and fit screw-type
clip ⇒ Item 1 (page 374) at bottom.
– Install air filter ⇒ page 368
Specified torques
♦ ⇒ “2.2 Assembly overview - emission control (catalytic con‐
verter)”, page 379
♦ ⇒ “7.1 Assembly overview - air filter”, page 368
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Install front exhaust pipe and first fasten the top screw-type
clamp for the exhaust pipe on turbocharger
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
c
ility
ab
y li
an
pt
ce
Installing
2. Cleansing exhaust emissions
389
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
3
Exhaust gas recirculation
⇒ “3.1 Assembly overview - exhaust gas recirculation”,
page 390
⇒ “3.2 Assembly overview - exhaust gas recirculation, 132 kW
engine”, page 391
⇒ “3.3 Removing and installing exhaust gas recirculation cooler”,
page 392
⇒ “3.4 Removing and installing exhaust gas recirculation cooler,
132 kW engine”, page 398
⇒ “3.5 Removing and installing exhaust gas recirculation valve
N18 , 132 kW engine”, page 400
⇒ “3.6 Removing and installing changeover valve for exhaust gas
recirculation cooler N345 ”, page 401
olkswagen AG
en AG. V
ag
ksw
Vol leaks”, page
⇒ “3.7 Checking exhaust gas recirculation cooler
yfor
db
e
402
ris
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Assembly overview - exhaust gas recirculation
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
1 - Exhaust gas recirculation
valve - N18- with exhaust gas
recirculation potentiometer G212-
ility
ab
y li
an
pt
ce
3.1
tho
au
s
s
does
not
gu
ara
nte
eo
ra
c
2 - Vacuum unit for exhaust
flap
3 - Exhaust gas recirculation
cooler
❑ Removing and installing
⇒ page 392 .
4 - Connection
❑ Coolant hose schematic
diagram ⇒ page 175 .
6 - Gasket
❑ Renew after removing
7 - Bolt
❑ 20 Nm
8 - Lower pipe
9 - Gasket
❑ Renew after removing
390
Rep. gr.26 - Exhaust system
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
❑ First, fit bolts on turbo‐
charger side and screw
them in hand-tight.
❑ 8 Nm
agen
lksw
Vo
by
For better accessibility and to en‐
sure the correct torque for the bolts
of the exhaust gas recirculation
cooler on the turbocharger side,
hexagon bolts with part number »N
107 188 01« can be used.
do
c
um
en
Note
ht
rig
py
Co
t.
5 - Bolt
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
10 - Bolt
❑ 20 Nm
un
le
14 - Bolt
❑ Renew after removing
❑ 8 Nm
AG.
3 - Bolt
❑ Renew after removing
❑ 8 Nm
agen
lksw
Vo
by
2 - Bracket
❑ For exhaust gas recircu‐
lation cooler.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
1 - Exhaust gas recirculation
cooler
❑ Removing and installing
⇒ page 398 .
r
fo
ng
Assembly overview - exhaust gas recirculation, 132 kW engine
ht
rig
py
Co
t.
3.2
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
13 - Gasket
❑ Renew after removing
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
12 - Upper pipe
ility
ab
y li
an
pt
ce
11 - Bolt
❑ 8 Nm
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
4 - Gasket
5 - Connecting pipe
❑ To exhaust gas recircu‐
lation valve - N186 - Exhaust gas recirculation
valve - N18❑ Removing and installing
⇒ page 400 .
7 - Connecting pipe
❑ From exhaust gas recir‐
culation cooler
8 - Bolt
❑ 20 Nm
3. Exhaust gas recirculation
391
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
3.3
Removing and installing exhaust gas recirculation cooler
Special tools and workshop
equipment required
♦ Torque wrench (5…50 Nm)
- V.A.G 1331♦ Torque wrench (40…200
Nm) - V.A.G 1332♦ Torque wrench - V.A.G
1410♦ Drip tray for workshop hoist
- VAS 6208-
ility
ab
y li
an
pt
ce
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
♦ Hose clip pliers - VAS
6362-
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
Rep. gr.26 - Exhaust system
Prote
cted
by
392
AG.
♦ Flexible magnet
agen
lksw
Vo
by
♦ Small hand-held mirror
c
o
p
yri
gh
t
.
C
op
yi
♦ Hose clamps up to 25 mm - 3094-
do
c
um
en
Special tools and workshop equipment required
ht
rig
py
Co
t.
♦ Hose clip pliers - VAS
6340-
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Removing
Note
♦ Exhaust gas recirculation cooler is removed upwards. Conta‐
minated areas must be cleaned thoroughly after installing.
♦ To facilitate removal of the exhaust gas recirculation cooler,
remove the air filter housing and the exhaust pipe.
♦ For better accessibility and to ensure the correct torque for the
bolts of the exhaust gas recirculation cooler, hexagon bolts
with part number »N 107 188 01« can be used.
♦ Some connectors are difficult to see. A small hand-held mirror
is required to unscrew and insert the threaded connection.
♦ Note different bolt lengths for pipes.
♦ Renew gaskets and seals.
– Detach vacuum hose -2- from upper toothed belt guard -1-.
– Open clips -arrows- and remove toothed belt guard -1-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
do
c
um
en
ht
rig
py
Co
t.
– Remove pipe
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
-arrow- afrom
cylinder head cover.
u
ac
ss
3. Exhaust gas recirculation
393
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Detach hoses from intake hose -3- bracket -arrow-.
– Release and pull off wiring harness connector -2-. Detach wir‐
ing harness -2- from intake hose retainer -3-.
– Open clips -1- and -4- and remove intake hose -3- together
with pipe -5-.
– Remove air filter ⇒ page 368
ility
ab
y li
an
pt
ce
un
le
–
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut hose off vacuum unit of exhaust gas recirculation
ra
Pull vacuum
a
c
s
s and vacuum hose from regulating flap potentiometer
cooler -1-
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
- G584- -2-.
– Detach connectors -1- from exhaust gas recirculation valve N18- -2- and regulating flap for potentiometer - G584- -3-.
ht
rig
py
Co
t.
r
fo
ng
Vehicles with particulate filter
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
– Undo and remove bolt -2- for coolant pipe -1- at wheel housing
and tie on coolant hose somewhere at a slightly higher point.
– Remove particulate filter ⇒ page 381 .
Vehicles with engines compliant with EU 4 and EU 3 standards
394
Rep. gr.26 - Exhaust system
Amarok 2011 ➤
common rail) - Edition 04.2013
ility
ab
y li
an
pt
ce
-4- at turbocharger.
un
le
–
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
guengine (2.0 l engine,
y
b
4-cylinder
diesel
ara
d
nte
ise
r
o
eo
h
t
u
r a pipe
a
Loosen
bolt
-2in
screw-type
clip
-1for
front
exhaust
c
s
s
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
– Loosen screw-type clip -3- for front exhaust pipe -1-.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
– Unscrew and remove bolts -3- in bracket for front exhaust pipe
-4-.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
– Undo and remove bolts -3- for front exhaust pipe -2- at bracket
-1-.
– Release and detach connector -1- of exhaust gas temperature
sender 1 - G235- on front right wheel housing -3- at the cou‐
pling point -2-. Then, free wiring harness from fittings and lay
it to one side.
– Carefully remove front exhaust pipe upwards out of the engine
compartment.
Continuation for all vehicles
3. Exhaust gas recirculation
395
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Clamp off coolant hose -2- with hose clamps up to 25 mm 3094- .
– Loosen spring-type clip -3- and remove coolant hose -2- at
exhaust gas recirculation cooler -1-.
– Undo and remove bolts -2- for pipe -1- and remove pipe from
exhaust gas recirculation cooler.
Note
The bolts -3- for the pipe -4- are not undone.
– Clamp off coolant hose -2- with hose clamps up to 25 mm 3094- .
pe
rm
itte
d
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– Undo and remove bolts -2- and -3- for pipe -1- and remove
pipe.
ility
ab
y li
an
pt
ce
un
le
– Open spring-type clip -1- for coolant hose -2- and pull coolant
hose off.
Note
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Rep. gr.26 - Exhaust system
ht
rig
py
Co
t.
396
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Bear in mind the differences between the types of bolt!
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Unclip connector -2- on oil pressure switch - F1- .
– Undo and remove bolts -2- at exhaust gas recirculation cooler
-1-.
– Undo and remove bolts -2- at exhaust gas recirculation cooler
-1-.
– Carefully remove exhaust gas recirculation cooler upwards.
– Clean contaminated areas thoroughly.
Installing
AG. Volkswagen A
G do
gen
Installation is carriedlkout
enote
s no the following:
swa in the reverse order;
t gu
ara
nte
eo
ra
c
seals.
ility
ab
y li
an
pt
ce
Note
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
–
o
yV
d b and
e
Renew gaskets
s
ri
ho
ut
a
ss
For better accessibility and to ensure the correct torque for the
bolts -2- of the exhaust gas recirculation cooler on the turbo‐
charger side, hexagon bolts with part number N 107 188 01 can
be used.
– Replace both bolts -2- at exhaust gas recirculation cooler on
right with hexagon bolts (part number »N 107 188 01«), and
tighten hexagon bolts.
Note
♦ Note different bolt lengths for pipes.
ht
rig
py
Co
t.
r
fo
ng
♦ Only screw pipe bolts in loosely at first, then tighten.
3. Exhaust gas recirculation
397
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Replace screw-type clamp -1- for front exhaust pipe -4-.
– Replenish coolant ⇒ page 182 .
Specified torques
♦ ⇒ “3.1 Assembly overview - exhaust gas recirculation”,
page 390
♦ ⇒ “2.1 Assembly overview - emission control (diesel particu‐
late filter)”, page 377
♦ ⇒ “2.2 Assembly overview - emission control (catalytic con‐
verter)”, page 379
3.4
Removing and installing exhaust gas re‐
circulation cooler, 132 kW engine
Special tools and workshop equipment required
ility
ab
y li
an
pt
ce
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
♦ Hose clamps up to 25 mm -
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
3094by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
♦ Drip tray for workshop hoist - VAS 6208-
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Rep. gr.26 - Exhaust system
ht
rig
py
Co
t.
398
do
c
um
en
♦ Hose clip pliers - VAS 6362-
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Note
♦ The exhaust gas recirculation cooler is removed upwards.
Contaminated areas must be cleaned thoroughly after instal‐
ling.
♦ Renew gaskets and seals.
Removing
– Clamp off coolant hose -2- leading to input to exhaust gas re‐
circulation cooler -1- with hose clams up to 25 mm - 3094- .
– Loosen clamp -3- and pull coolant hose -2- off exhaust gas
recirculation cooler -1-.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
– Loosen clamp -2- and pull coolant hose -1- off output of ex‐
haust gas recirculation cooler -3-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
– Clamp off coolant hose -1- coming from output of exhaust gas
recirculation cooler -3- with hose clams up to 25 mm - 3094- .
– Unscrew bolts -3-.
do
c
um
en
– Undo and remove bolts -1 and 4- and remove connecting pipe
-5-.
3. Exhaust gas recirculation
399
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
AG. Volkswagen AG d
– Unscrew bolts -arrows- and remove bracket -1- of exhaust
gas
agen
oes
ksw
not
l
recirculation cooler.
o
V
g
by
ed
ua
ran
tee
is
– Carefully remove exhaust gas recirculationhcooler
upwards.
or
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
Installation is carried out in the reverse order; note the following:
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Note
or
ac
ility
ab
y li
an
pt
ce
t
au
ss
Installing
First, screw in all pipe bolts loosely and then tighten them to
specified torque.
Specified torques
♦ ⇒ “3.2 Assembly overview - exhaust gas recirculation, 132 kW
engine”, page 391
3.5
Removing and installing exhaust gas re‐
circulation valve - N18- , 132 kW engine
Removing
Prote
cted
by
400
Rep. gr.26 - Exhaust system
AG.
– Undo and remove bolts -2 and 3- and remove pressure pipe
-1-.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
– Detach connector -3- from throttle valve control module J338- .
ht
rig
py
Co
t.
– Remove bolt -1- for dipstick guide tube.
thi
sd
o
cu
m
en
– Loosen clip -2- and pull pressure hose off throttle valve control
module - J338- .
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Release oil dipstick again. To this, force expanding clip -2- off,
using removal lever - 80 - 200- .
– Remove throttle valve module - J338- ⇒ page 357 .
– Undo and remove bolts -1 and 3- from connecting pipe -2-.
– Remove connecting pipe -2-.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
– Undo and remove bolts -arrows- and remove exhaust
gu
y V gas re‐
b
ara
d
e
circulation valve - N18- -1- from intake manifold.
nte
is
r
o
eo
h
ut
ra
a
Installing
c
s
s
Installation is carried out in the reverse order; note the following:
Specified torques
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
♦ ⇒ “3.2 Assembly overview - exhaust gas recirculation, 132 kW
engine”, page 391
♦ ⇒ “5.1 Assembly overview - intake manifold”, page 354
3.6
Removing and installing changeover
valve for exhaust gas recirculation cool‐
er - N345-
Special tools and workshop equipment required
do
c
um
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
3. Exhaust gas recirculation
401
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Torque wrench - V.A.G 1410-
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
ility
ab
y li
an
pt
ce
un
le
♦ Socket set 1/4", 22-piece - VAS 5528-
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Removing
– Pull connector -3- and vacuum lines and pull off changeover
valve for exhaust gas recirculation cooler - N345- -1-.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
– Unclip locking lug for changeover valve for exhaust gas recir‐
culation cooler - N345- -1- and remove changeover valve for
exhaust gas recirculation cooler - N345- .
Installing
Installation is carried out in the reverse order; note the following:
Caution
Do not kink, twist or crush the vacuum lines when routing. This
may cause breakdowns.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
Exhaust gas recirculation cooler is removed ⇒ page 398 .
Prote
cted
by
402
Rep. gr.26 - Exhaust system
AG.
•
Checking exhaust gas recirculation
cooler for leaks
ht
rig
py
Co
t.
3.7
r
fo
ng
Connect all hoses to stop or at least 10 mm on the relevant
connection piece.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– The cooler connection which will be immersed in the water
must be sealed watertight.
– Using a clamp, secure a hose to the cooler connection at which
compressed air is supplied.
un
le
♦ Supply compressed air at connection where coolant is sup‐
plied.
♦ The cooler should remain immersed in the water for at least
30 minutes in order to obtain a significant result.
♦ Using a commercially available immersion heater , heat water
to approx. 60-80 °C.
♦ Perform the pressure test with the cooler in vertical position.
♦ The pressure must not exceed 3 bar.
ht
rig
py
Co
t.
r
fo
ng
– Immerse cooler in water as shown in illustration. Hose
-arrow- must protrude from water in order to perform pressure
test.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Note
ility
ab
y li
an
pt
ce
n AG. Volkswagen AG do
es n
wage
s
k
l
o
o
The exhaust gas recirculation cooler
y Vis now ready to be immersed t gua
b
d
ran
in the water.
ir se
tee
ho
t
or
u
ac
a
ss
3. Exhaust gas recirculation
403
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
olksw
agen AG
n AG. V
Amarok 2011 ➤
does
wage
not
olks
V
gu
4-cylinder diesel engine
y (2.0 l engine, common rail) - Edition
b
a 04.2013
d
Glow plug system
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
⇒ “1.1 Checking glow plug system”, page 404
⇒ “1.2 Removing and installing glow plugs”, page 405
⇒ “1.3 Removing and installing engine speed sender G28 ”, page
406
⇒ “1.4 Removing and installing Hall sender G40 ”, page 407
1.1
Checking glow plug system
Procedure
Automatic glow period control unit - J179- -A- is located in front
left of engine compartment -arrow- beneath headlight.
Glow plug system is activated via automatic glow period control
unit - J179- . The automatic glow period control unit - J179- is
capable of self-diagnosis.
c
o
p
yri
gh
t
.
C
op
yi
The procedure for checking the glow plug system is described in
⇒ Vehicle diagnostic tester.
agen
lksw
Vo
by
AG.
Prote
cted
by
For faster starting, the vehicle is equipped with electronically con‐
trolled glow plugs and a separate glow period control unit.
Each glow plug is activated and diagnosed separately.
404
Rep. gr.28 - Glow plug system
ht
rig
py
Co
t.
A fault entry is stored in the engine control unit if a fault occurs in
the glow plug system.
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
1
Glow plug system
ility
ab
y li
an
pt
ce
28 –
ran
tee
or
ac
e
ris
tho
u
a
ss
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
1.2
Removing and installing glow plugs
Special tools and workshop
equipment required
♦ Jointed wrench 10 mm 3220♦ Pliers - 3314-
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Removing
– Switch off ignition.
Caution
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
Make sure that no wiring connections are damaged when dis‐
connecting the connectors. Otherwise the whole wiring har‐
ness will need to be renewed. Do not compress the pliers 3314- to firmly to separate the connectors, otherwise the
support sleeve may be damaged.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
♦ Torque wrench - V.A.G
1410-
1. Glow plug system
405
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Position pliers - 3314- with groove -arrow A- on support sleeve
shoulder -arrow B-.
– Carefully pull connector off glow pin plug
-in direction of arrow-.
AG. Volkswagen AG d
agen
o
Note
es n
ot g
ua
ran
tee
or
ac
pe
rm
itte
d
un
le
Detach all the necessary electrical connectors to ensure that the
wiring harness is not damaged.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Note
♦ Cleaning procedure:
♦ Use a vacuum cleaner to remove coarse dirt.
♦ Spray brake cleaner or suitable cleaning agent into glow pin
plug opening, let it work in briefly, and blow out with com‐
pressed air.
♦ Then use an oil-soaked cloth to clean the glow pin plug open‐
– To loosen glow plugs, use special tool U/J extension and
10 mm socket - 3220-
ht
rig
py
Co
t.
c
o
p
yri
gh
t.
C
op
yi
Installing
Installation is carried out in the reverse order; note the following:
agen
lksw
Vo
by
Prote
cted
by
– To tighten the glow plugs use special tool U/J extension and
socket, 10 mm - 3220- with a suitable torque wrench.
AG.
– Tighten glow plugs.
– Fit glow plug connectors to the respective glow plugs and en‐
sure they are firmly seated.
– Delete event memory of engine control unit.
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 78
1.3
Removing and installing engine speed
sender - G28-
Special tools and workshop equipment required
406
Rep. gr.28 - Glow plug system
do
c
um
en
r
te o
iva
r
rp
fo
g
n
ing.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
– Clean glow pin plug opening in cylinder head. It must be as‐
sured that no dirt falls into the cylinder.
ility
ab
y li
an
pt
ce
ksw
Vol
by
d
e
ris
tho
u
a
ss
ility
ab
y li
an
pt
ce
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
4-cylinder
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
Amarok
nte 2011 ➤
is
r
o
eo
h
diesel
ut engine (2.0 l engine, common rail) - Edition 04.2013
ra
a
c
s
s
♦ Hexagon key extension, 4 mm - T10370-
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Removing
– Remove underbody guard, if fitted ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody guard .
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
To release electrical connector without assembly tool - T10118- ,
press connector on engine speed sender - G28- in with a screw‐
driver and at the same time raise release tab with a thin wire hook.
ht
rig
py
Co
t.
Note
do
c
um
en
– Pull the connector -2- off the engine speed sender - G28- be‐
low the oil filter holder -1-.
– Loosen securing bolt -arrow- with socket AF 4 mm - T10370and remove speed sender.
Installing
Installation is carried out in the reverse order; note the following:
Specified torques
♦ ⇒ “3.1 Assembly overview - cylinder block, gearbox end”, page
54
1.4
Removing and installing Hall sender G40-
Removing
– Remove poly V-belt ⇒ page 40 .
1. Glow plug system
407
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Detach vacuum hose -2- from upper toothed belt guard -1-.
– Open clips -arrows- and remove toothed belt guard -1-.
– Unscrew bolt -3- for bracket -1-.
– Detach connector -1- for Hall sender - G40- .
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
Prote
cted
by
Rep. gr.28 - Glow plug system
AG.
408
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
Markings on crankshaft toothed belt pulley -2- and crankshaft stop
- T10050- -1- must align. At the same time, the pin of the crank‐
shaft stop - T10050- must engage in the drilling in the sealing
flange.
ht
rig
py
Co
t.
Note
r
fo
ng
– Turn engine to TDC and lock crankshaft toothed belt pulley in
position with crankshaft stop - T10050- . To do this, push the
crankshaft stop into the teeth of the toothed belt pulley from
the latter's face side. The toothed segment of the camshaft
must be at the »12 o'clock position«.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
– Remove vibration damper ⇒ page 44 .
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Arrow on camshaft pulley must be at almost »12 o'clock«.
– Mark direction of rotation of toothed belt.
– Lock the camshaft hub with locking pin - 3359- . To do this,
insert locking pin through outer free elongated hole into hole
in cylinder head.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
ility
ab
y li
an
pt
ce
un
le
– Loosen bolts -arrows- approx. 90° for camshaft toothed belt
pulley.
pe
rm
itte
d
– Remove bolts of toothed belt pulley of high-pressure pump
-2-.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– Loosen belt tensioner nut -1-.
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
– Turn eccentric of tensioning roller anti-clockwise -arrow- using
socket - T10264- , until the tensioning roller can be locked with
locking tool - T10265- .
agen
lksw
Vo
by
1. Glow plug system
409
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Now turn tensioning roller eccentric clockwise -arrow- onto
stop and tighten securing nut -1- hand-tight.
– Remove toothed belt from idler roller and high-pressure pump.
– Screw off Hall sender - G40- -arrow-.
– Remove guide roller -1- ⇒ Item 18 (page 106) .
– Using a screwdriver, remove webs -arrows- and detach wiring
harness
– Remove cover -2- of repair aperture -arrows-.
n AG. Volkswagen AG do
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
– Unscrew Hall sender - G40- from cylinder head.
– Pull wiring harness -1- out of retainer -2- and separate.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Installing
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
– Pull wiring harness together with Hall sender - G40- out com‐
pletely in direction of normal travel (forwards).
Installation is carried out in the reverse order; note the following:
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Rep. gr.28 - Glow plug system
ht
rig
py
Co
t.
410
do
c
um
en
r
te o
iva
r
rp
fo
g
n
– Seal repair aperture in toothed belt guard with rubber plugs as
specified in ⇒ Electronic Parts Catalogue (ETKA) .
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– Install guide roller -1- ⇒ Item 18 (page 106) .
– Fit toothed belt and adjust the valve timing ⇒ page 107 .
– Install upper toothed belt guard -3- and secure with clips
-arrows-.
– Clip vacuum hose -2- into toothed belt guard -1-.
– Tighten bolt -3- for coolant pipe bracket -1-.
– Install poly V-belt ⇒ page 40 .
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 78
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
un
le
ility
ab
y li
an
pt
ce
ht
rig
py
Co
t.
♦ ⇒ “2.1 Assembly overview - toothed
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V 105
gu
belt drive”, page
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
agen
lksw
Vo
by
1. Glow plug system
411
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi