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4 Cylinder Diesel Engine 2.0l Common Rail
4 Cylinder Diesel Engine 2.0l Common Rail
4 Cylinder Diesel Engine 2.0l Common Rail
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Workshop Manual
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Engine ID
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Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group n AG. Volkswagen AG do
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15 - Cylinder head, valve gear ir se
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17 - Lubrication auth or
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19 - Cooling
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21 - Turbocharging/supercharging
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26 - Exhaust system
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28 - Glow plug system
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Safety precautions when working on injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Safety precautions when working on charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Safety precautions during road tests in which testing and measuring equipment is used . . 6
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 General notes on the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 General notes on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Rules for cleanliness when working on fuel supply system/injection system . . . . . . . . . . . . 8
3.4 Rules for cleanliness when working on charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Instructions for working on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6 To avoid any risk of injuries to persons and/or the destruction of the injection and glow plug
system, the following must be noted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.7 Instructions for hose connections with screw-type clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
13 - Crankshaft group
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1 Cylinder
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1.1 thoAssembly
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overview - cylinder block . . . . .te.e o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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1.2ss a Assembly overview - sealing flange, belt pulleyacend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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1.4 Assembly overview - poly V-belt drive, vehicles without A/C system . . . . . . . . . . . . . . . . . . 39
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Contents i
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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1.4 Removing and installing oil pump, vehicles with balancer shaft module . . . . . . . . . . . . . . 146
1.5 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
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1.6 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 147
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2.1 Assembly overview - oil filter housing with engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . 150
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2.2 Removing and installing oil filter housing with engine oil cooler . . . . . . . . . . . . . . . . . . . . . . 151
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2.3 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.4 Checking oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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2.5 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
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ii Contents
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.1 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.2 Assembly overview - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.4 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.1 Assembly overview - coolant pump/ball thermostat (4/2-way valve) . . . . . . . . . . . . . . . . . . 187
2.2 Assembly overview - Continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . . . . . 188
2.3 Assembly overview - circulation pump V55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2.4 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.5 Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
2.6 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 196
2.7 Removing and installing coolant temperature sender at radiator outlet G83 . . . . . . . . . . 197
2.8 Removing and installing continued coolant . Vocirculation
lkswagen AG pump V51 . . . . . . . . . . . . . . . . . . 198
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2.9 Removing and installing Y-thermostat
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2.10 Removing and installingiserecirculation
db pump V55 . . . . . . . . .ua. r.an. . . . . . . . . . . . . . . . . . . . . 200
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3 Radiator, radiator fan ho
aut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a. . . . . . . . . . . . . . . . . . 202
3.1 Assembly overview ss - radiator/ radiator fan V7 . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . 202
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3.4 Removing and installing radiator cowl with radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . 207
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3.4 Removing and installing filler neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
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4 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
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4.1 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.2 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
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Contents iii
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.3 Removing and installing intake air temperature sender G42 with charge air pressure sender
G31 . . . . . . . . . . . . . . . . . . . . . . . . k.s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
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1.4 Removing and installinglkexhaust swage gas flap valve N220 es n ............................ 255
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1.5 Checking charge air ed
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yV for leaks . . . . . . . . . . . . .
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2 Turbocharger uth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e.e o.r . . . . . . . . . . . . . . . . . . . . . . .
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2.1 Assembly overview
ss - turbocharger, 120 kW and 132 kW engines .................... 260
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2.3 Removing and installing turbocharger - 120 kW and 132 kW engines . . . . . . . . . . . . . . . . 267
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2.4 Removing and installing turbocharger - 90 kW and 103 kW engines . . . . . . . . . . . . . . . . . . 272
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2.6 Removing and installing regulating flap potentiometer G584 and vacuum unit for
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2.7 Removing and installing regulating flap potentiometer G584 and vacuum unit for
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turbocharger, 132 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
2.8 Removing and installing charge pressure control solenoid valve N75 . . . . . . . . . . . . . . . . rrectness of i 300
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2.2 Testing vacuum system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3 Injectors and high-pressure accumulator (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
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3.1 Overview of injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
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3.2 Injector delivery calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
3.3 Removing and installing injectors (piezo injectors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
3.4 Removing and installing injectors (solenoid valves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
3.5 Removing and installing high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
3.6 Removing and installing high-pressure accumulator (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . 340
3.7 Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 343
4 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
4.1 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
4.2 Checking high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
5 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
5.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
5.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
5.3 Removing and installing throttle valve module J338 with throttle valve potentiometer G69 and
intake manifold flap motor V157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
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6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
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6.1 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
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6.2 Removing and installing exhaust pressure sensor 1 G450 . . . . . . . . . . . . . . . . . . . . . . . . 360
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6.3 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 362
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7.1 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
7.2 Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
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8 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
8.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
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1 Exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
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2.1 Assembly overview - emission control (diesel particulate filter) . . . . . . . . . . . . . . . . . . . . . . 377
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2.2 Assembly overview - emission control (catalytic converter) . . . . . . . . . . . . . . . . . . . . . . . . 379
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2.3 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.4 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
3 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
3.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
3.2 Assembly overview - exhaust gas recirculation, 132 kW engine . . . . . . . . . . . . . . . . . . . . 391
3.3 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 392
3.4 Removing and installing exhaust gas recirculation cooler, 132 kW engine . . . . . . . . . . . . 398
3.5 Removing and installing exhaust gas recirculation valve N18 , 132 kW engine . . . . . . . . 400
3.6 Removing and installing changeover valve for exhaust gas recirculation cooler N345 . . . . 401
3.7 Checking exhaust gas recirculation cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Contents v
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
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vi Contents
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”,
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of the engine. They are stamped onto the engine. The fourth digit
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gine control unit. The four digit engine code can be found on the
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The engine number (“engine code” and “serial number”) can be
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In addition, there is a sticker attached to the toothed belt guard
showing the “engine code” and “serial number”.
The engine code is also included on the vehicle data sticker.
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The engine number consists of up to nine characters (alphanu‐ s
meric). The first part (maximum 4 characters) makes up the
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same code letters, the first of the six digits is replaced by a letter.
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Emissions fulfil yri
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EU 4 standard EU 4 standard EU 4 standard
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EU 5 standard EU 5 standard EU 5 standard
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Capacity l 2.0 2.0 2.0
Output kW at 120/4000 90/3750 90/3750
rpm
Torque Nm at 400/ 340/ 340/
rpm 1500 - 2000 1750 - 2250 1600 - 2000
Capacity cm3 1968 1968 1968
Bore ∅ mm 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5
Valves per cylinder 4 4 4
Compression ratio 16.5 16.5 16.0
Fuel accord‐ DIN EN 590 DIN EN 590 DIN EN 590
ing to
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Balancer shaft module no no no
Catalytic converter yes yes yes
Exhaust gas recirculation yes yes yes
Turbocharging/supercharg‐ yes yes yes
ing
Charge air cooler yes yes yes
Particulate filter yes, in the case of EU 5 yes, in the case of EU 5 yes, in the case of EU 5
1. Identification 1
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
AG. Volkswagen AG d
agen oes
Engine code y Volksw CDCA notCDBA
gu CNFA
d b ara
Particulate filter orise No; on vehicles compli‐ No; on vehicles nte compli‐
eo No; on vehicles compli‐
auth
ant with EU 3 and EU 4 ant with EU 3 andr a EU 4 ant with EU 3 and EU 4
c
ss
standards. standards. standards.
ce
e
nl
Selective catalytic reduction no no no
pt
du
an
(SCR system)
itte
y li
erm
ab
ility
1) Present in the case of engines compliant with EU 5 standard and/or in conjunction with dual clutch gearboxes.
ot p
wit
, is n
h re
hole
spec
Engine codes CNEA CSHA CNFB
es, in part or in w
t to the co
Manufactured from 01.10 ►
to
rrectness of i
Emissions fulfil EU 4 standard EU 4 standard EU 4 standard
EU 5 standard EU 5 standard EU 5 standard
l purpos
nform
ercia
rpm
m
at
Torque Nm at 400/ 420/ 340/
om
io
rpm 1500 - 2250 1750 1600 - 2250
n
c
in t
or
his
ate
do
riv
cum
for
en
g
t.
yi Co
op
Valves per cylinder 4 4 4
C py
t. rig
gh ht
yri
Compression ratio 16.5 16.0 16.0
p by
co Vo
by lksw
cted
Fuel accord‐ DIN EN 590 DIN EN 590 DIN EN 590
agen
Prote AG.
ing to
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Balancer shaft module no yes no
Catalytic converter yes yes yes
Exhaust gas recirculation yes yes yes
Turbocharging/super‐ yes yes yes
charging
Charge air cooler yes yes yes
Particulate filter yes, in the case of EU 5 yes, in the case of EU 5 yes, in the case of EU 5
Particulate filter No; on vehicles compli‐ No; on vehicles compli‐ No; on vehicles compli‐
ant with EU 3 and EU 4 ant with EU 3 and EU 4 ant with EU 3 and EU 4
standards. standards. standards.
Selective catalytic reduc‐ no no no
tion
(SCR system)
2) Present in the case of engines compliant with EU 5 standard and/or in conjunction with dual clutch gearboxes.
2 Safety instructions
⇒ “2.1 Safety precautions when working on fuel supply system”,
page 3
⇒ “2.2 Safety precautions when working on injection
AG. Vosystem”,
lkswagen AG
agen does
page 4 Volksw not
g y ua
db ran
⇒ “2.3 Safety precautions when working
ris
e
on charge air system”, tee
ho
page 5 au
t or
ac
ss
⇒ “2.4 Safety precautions when working on cooling system”, page
ce
e
nl
pt
5
du
an
itte
y li
erm
ab
ility
measuring equipment is used”, page 6
ot p
wit
, is n
h re
hole
spec
fuel supply system
es, in part or in w
t to the co
Caution
rrectness of i
When doing any repair work, especially in the engine compart‐
l purpos
nf
ercia
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
or
vated charcoal filter system, coolant and refrigerant, brake
m
m
atio
fluid and vacuum) and electrical wiring in their original po‐
om
n in
sitions.
or c
thi
te
sd
♦ Ensure that there is sufficient clearance to all moving or
iva
o
r
hot components.
rp
cu
o
m
f
en
ng
♦ Fuel and fuel lines in fuel system can become very hot
t.
yi Co
op
(danger of scalding)!
C py
ht. rig
rig ht
py by
♦ The fuel system is also under pressure! Before opening co Vo
by lksw
the system, place cloths around the connections. Then
cted agen
Prote AG.
carefully loosen connection to release the pressure!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!
2. Safety instructions 3
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
WARNING
Note
pt
du
an
itte
ab
equipment leads.
wit
, is n
h re
anti-theft coding.
spec
es, in part or in w
with the ignition switched off, as otherwise the control unit for
diesel direction injection system could become damaged.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
WARNING
ce
le
pt
an
d
y li
scalding. Cover cap with cloth and open carefully.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
rrectness of i
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
l purpos
sitions.
m
tio
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Safety instructions 5
Amarok 2011 ➤ n AG. Volkswagen AG do
wage es n
4-cylinder diesel engine (2.0 l engine, common
yV
o rail) - Edition 04.2013
lks ot g
b ua
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Note
nform
ercia
a
com
tio
work.
n in
r
te o
thi
♦ Hoses are secured with spring-type clips. In case of repair,
s
iva
do
only use spring-type clips.
r
rp
cum
fo
en
g
t.
yi Co
using spring-type clip pliers - VAS 6340- or Cop py
t. rig
gh ht
yri
♦ … hose clip pliers - VAS 6362- recommended. p by
co Vo
by lksw
cted agen
♦ When installing coolant hoses, route stress-free so that they Prote AG.
do not come into contact with other components (observe
markings on coolant connection and hose).
♦ Arrows on the coolant pipes and on the ends of the hoses must
be aligned with each other.
♦ Only demineralised / distilled water to standard VDE-0510
may be used for mixing. Tap water does not have the required
quality to ensure the coolant's function.
ce
3 Repair instructions
le
un
pt
an
d
itte
y li
⇒ “3.1 General notes on the lubrication system”, page 7
erm
ab
ility
ot p
wit
is n
h re
⇒ “3.3 Rules for cleanliness when working on fuel supply system/
ole,
spec
injection system”, page 8
urposes, in part or in wh
t to the co
⇒ “3.4 Rules for cleanliness when working on charge air system”,
page 8
⇒ “3.5 Instructions for working on fuel system”, page 9
rrectne
⇒ “3.6 To avoid any risk of injuries to persons and/or the destruc‐
s
tion of the injection and glow plug system, the following must be
s o
noted”, page 10
cial p
f inform
⇒ “3.7 Instructions for hose connections with screw-type clips”,
mer
atio
page 11
om
n
c
i
3.1 General notes on the lubrication system
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
Note
t.
yi Co
Cop py
t. rig
The oil level must not be above the max. mark - danger of damage
gh ht
pyri by
to catalytic converter!
co Vo
by lksw
cted agen
Prote AG.
Caution
Caution
3. Repair instructions 7
Amarok 2011 ➤ n AG. Volkswagen AG do
wage es n
4-cylinder diesel engine (2.0 l engine, common yrail)
Vo - Edition 04.2013
lk s ot g
b ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Note
nform
ercia
at
om
io
work.
n
c
in t
or
his
e
do
riv
cum
for
en
g
t.
yi Co
using spring-type clip pliers - VAS 6340- or Cop py
t. rig
gh ht
yri
♦ … hose clip pliers - VAS 6362- recommended. p by
co Vo
by lksw
cted agen
♦ When installing coolant hoses, route stress-free so that they Prote AG.
do not come into contact with other components (observe
markings on coolant connection and hose).
♦ Arrows on the coolant pipes and on the ends of the hoses must
be aligned.
ce
e
nl
pt
du
an
pressure pump are removed or renewed, initial fuel filling must
itte
y li
be carried out.
erm
ab
ility
ot p
♦ If a fuel pump, fuel line (between fuel tank and fuel high-pres‐
wit
, is n
spec
♦ Fuel system must be bled before starting engine for first time.
es, in part or in w
t to the co
connecting.
m
m
atio
m
n in
or c
sd
iva
cu
m
f
en
ng
3. Repair instructions 9
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
ce
e
nl
pt
• Never attempt to reshape high-pressure fuel lines.
du
an
itte
y li
erm
ab
ility
tools may only be used for loosening and tightening pipe un‐
ot p
wit
ions. All other components must always be removed and
, is n
h re
installed by hand without using tools or other equipment.
hole
spec
• Disassembling individual common rail components is not per‐
es, in part or in w
t to the co
mitted.
• The components should be replaced as complete units if faul‐
ty.
rrectness of i
• Never attempt to bleed the common rail system by loosening
l purpos
nf
ercia
o
whilst engine is running.
rm
m
atio
m
n in
c
electrical connectors.
or
thi
te
sd
a
• All cable ties which were opened or cut open during removal
iv
o
r
rp
cu
must be replaced with new ties in same position during instal‐
o
m
f
lation. en
ng
t.
yi Co
op py
• When the fuel system is open: do not work with compressed t. C rig
gh ht
air if this can be avoided. Do not move vehicle unless abso‐ yri
p by
o Vo
lutely necessary.
c by lksw
cted agen
Prote AG.
• Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
Caution
Caution
AG. Volkswagen AG d
agen oes
lksw not
• Do not loosen d by Vthese screw-type clips and pull
o gback
ua over
the delivery rise hose. Risk of damage to the hose! ante
r
ho eo
ut ra
• If a sclip
s a has been removed, it must be renewed together c
with the hose.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
move hoses.
es, in part or in w
t to the co
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Repair instructions 11
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
ce
le
un
pt
♦ Lifting tackle - 3033-
an
d
itte
y li
erm
ab
♦ Support bracket - 10 - 222
ility
ot p
A-
wit
is n
h re
♦ Hook - 10 - 222 A /10-
ole,
spec
urposes, in part or in wh
t to the co
♦ Adapter - 10 - 222 A /16-
♦ Adapter - 10 - 222 A /20-
qty. 2 rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
Procedure:
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Before carrying out further work, remove the battery. Check
whether a coded radio is fitted. Obtain anti-theft coding be‐
l purpos
forehand if necessary.
♦ The engine is removed upwards.
nform
ercia
at
om
io
♦ All cable ties that are opened or cut through when the engine
n
c
in t
or
do
priv
cum
or
♦ Seal open lines and unions with clean plugs from engine bung
f
en
ng
Caution
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
– Release connector -2- on circulation pump - V55- -3- and pull wit
, is n
off. h re
hole
spec
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
– Pull latch -1- back. ir se
d ran
tee
tho
or
– Press retaining lever -2- down and pull connector off.s au ac
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Open clip -1- and remove hose -2- from turbocharger.
l purpos
WARNING
nform
ercia
♦ The fuel and the fuel lines in the fuel system can become
m
a
very hot (danger of scalding)!
com
tion in
r
thi
the system, place cloths around the connections. Then
s
iva
do
carefully loosen connection to release the pressure!
r
rp
cum
fo
en
g
t.
yi Co
op
of repair work on the fuel system! C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
– Release and pull off connector -3-.
hole
spec
– Remove bolt -4-.
es, in part or in w
t to the co
Caution
rrectness of i
• Do not loosen screw-type clips and pull back over pres‐
l purpos
nform
mercia
a
com
t
– Remove hose/pipe -1- completely. To do this, loosen clips
ion in
-2- and -5- sufficiently to enable hose/pipe -1- to be pulled off.
r
te o
thi
s
iva
do
r
– Open clip -2- and remove coolant hose -1-. Guide coolant hose
rp
cum
fo
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Open clips -2- and -4- and remove coolant hoses -1- and -3-.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
o Vo
– Pull off hose -2- from turbocharger. by c lksw
cted agen
Prote AG.
– Open clip -3- and remove coolant hose -6-.
– Pull hose -4- off union -5- and detach from clip -7-.
– Lay clip -1- aside with lines.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
pt
an
d
itte
y li
– Open clips -arrows- and remove toothed belt guard -1-.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
-2- slightly.
es, in part or in w
t to the co
– Remove radiator cowl -2- with assistance of a 2nd mechanic.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Unscrew bolts -1- from left engine mounting -A-.
– Detach gearbox breather line -1- from clip -2- (on coolant hose
on rear right of engine).
– Unscrew bolt -1- for fuel lines -2- from bracket through wheel
housing.
– Install support bracket - 10 - 222 A- .
. Volkswagen AG
– Secure adapter - 10 - 222 A /16- and hook - 10 - 222ksA
wa/10-
gen Ato
G does
not
support bracket - 10 - 222 A- . by
Vol
gu
ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
– Engage hook - 10 - 222 A /2- in transport eye -arrow-.
ce
le
un
pt
an
– Engage shackle - 10 - 222 A /12- with hook - 10 - 222 A /2- on
d
itte
y li
adapter - 10 - 222 A /16- .
rm
ab
pe
ility
– Raise engine until left engine mounting is raised approx. 15
ot
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
Raise engine only sufficiently to allow a square timber to be in‐
rrectness of i
serted between chassis and gearbox.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
– Insert square timber -1-.
fo
en
ng
t.
yi Co
– Lower engine using support bracket - 10 - 222 A- until gearbox Cop py
t. rig
-2- rests completely on square timber -1- and support bracket yri
gh by
ht
- 10 - 222 A- is relieved.
op Vo
by c lksw
cted agen
Prote AG.
Caution
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
– Install retainer - T10014- to front right of engine. s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
com
t
retainer - T10014- and secure with retaining clip.
ion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
Caution
an
d
itte
y li
erm
ab
♦ Only a few millimetres of space are available between
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
a second mechanic.
♦ The workshop hoist - VAS 6100- must also be guided
rrectne
carefully when raising and lowering the engine.
ss o
cial p
f
– When raising and lowering engine, make sure that neither
inform
vacuum hose -1- nor union -2- on vacuum pump are damaged.
mer
atio
m
– Guide vacuum hose -1-, union -2- and vacuum pump past ple‐
o
n
c
i
or
n thi
te
sd
a
o
pr
c
belt drive and turbocharger do not damage radiator.
um
r
fo
en
ng
t.
– When raising and lowering engine, pay attention to lines and
yi Co
op py
hoses to prevent these from being damaged. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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spec
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spec
urposes, in part or in wh
t to the co
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– Secure engine in engine and gearbox support - VAS 6095- .
o
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f inform
mer
atio
om
n
c
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t.
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Cop py
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by
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Prote AG.
Caution
ce
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un
pt
– When raising and lowering engine, make sure that rollers of
an
d
itte
belt drive and turbocharger do not damage radiator.
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– When raising and lowering engine, pay attention to lines and
ot p
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hoses to prevent these from being damaged.
is n
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spec
urposes, in part or in wh
t to the co
moved).
– Check clutch release bearing for wear and, if necessary, re‐
place (gearbox removed).
rrectne
Caution
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• Bring engine and gearbox together in longitudinal direc‐
form
mer
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n
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that needle bearing -arrow- is not damaged.
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Cop py
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spec
urposes, in part or in wh
t to the co
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cial p
f inform
mer
atio
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n
c
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t.
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Cop py
t. rig
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Prote AG.
Note
AG. Volkswagen AG d
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Only reuse drained coolant if neither cylinder head nor cylinder
o
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V gu
ara
block have been renewed. orise nte
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♦ Soiled coolant must not be reused. ss a c ce
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nl
pt
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– Replenish coolant ⇒ page 182 .
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– Carry out road test and read event memory ⇒ Vehicle diag‐
ility
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nostic tester.
wit
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Specified torques
hole
spec
t to the co
page 31
♦ ⇒ “2.2 Assembly overview - emission control (catalytic con‐
verter)”, page 379
rrectness of i
at
om
ion
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ate
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mountings
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Caution
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• Nut -2- must not be loosened.
rrectness of i
• If nut -2- is loosened, engine mounting must subsequently
be renewed.
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– Secure engine support -1- to crankcase with bolts -3-.
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Specified torque
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Component Specified torque
Co
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Bolts -3- 50 Nm +180°
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Left 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
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Gearbox mounting to gearbox
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– Secure gearboxs aumounting -A- to gearbox with bolts -1-.
t or
ac
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– Bolts -1- must always be renewed.
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Specified torque
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spec
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Specified torque
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13 – Crankshaft group
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⇒ “1.9 Renewing crankshaft oil seal - belt pulley end”,
rm
ab
page 46
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page 48
hole
spec
es, in part or in w
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1 - Cylinder block
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❑ Removing and installing
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⇒ page 55 .
com
tion in
thi
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cum
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crankshaft
Co
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⇒ page 73 .
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❑ Dismantling and assem‐
op Vo
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bling pistons and con‐
cted agen
Prote AG.
rods ⇒ page 66
2 - Guide tube
❑ Renew O-ring.
3 - Spreader clip
4 - Gaskets
❑ Renew after removing
5 - Oil filter bracket
❑ Oil filter bracket and en‐
gine oil cooler
⇒ page 151 .
6 - Bolt
❑ Renew after removing
❑ First fit upper left and
lower right bolts and
then tighten all four bolts
diagonally.
❑ 14 Nm +180°
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 . n AG. Volkswagen AG do
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❑ Removing and installing ⇒ page 43 yV
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12 - Bolt ir se tee
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❑ Observe different prescribed torques sand
s a tightening sequence ⇒ page 43 . ac
ce
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nl
13 - Bolt
pt
du
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❑ 25 Nm
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14 - Oil sump
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15 - Bolt
❑ 15 Nm
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1 - Bolt
❑ Renew after removing
❑ Loosen and tighten with
counterhold - 3415-
❑ Do not additionally oil
the thread and shoulder.
❑ 120 Nm + 90°
2 - Crankshaft toothed belt pul‐
ley AG. Volkswagen AG d
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❑ Contact surface be‐ olksw not
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tween toothed belt pul‐ ed b ara
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ley and crankshaft must tho r eo
be free from oil ss au ra
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❑ Fitting possible in one
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position only.
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3 - Crankshaft oil seal for belt
pe
ility
pulley end
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hole
spec
ing lip.
es, in part or in w
t to the co
❑ Before installing, re‐
move oil residue from
crankshaft journal using
rrectness of i
a clean cloth.
❑ Renewing ⇒ page 46 .
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com
Catalogue (ETKA) .
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⇒ page 48 . t. Cop py
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5 - Cylinder block yri
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6 - Dowel pin
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7 - Bolt
❑ Specified torque and tightening sequence ⇒ page 36 .
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
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6 - Dowel sleeve olks
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❑ Check for correct seat‐ sed b ua
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❑ Inserted in hole forss the
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pt
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8 - High-pressure pump
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t to the co
10 - Bolt
❑ When reusing bolt, tighten to 20 Nm plus 90° further.
nform
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tion in
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❑ 40 Nm + 90°
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12 - Bolt
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t.
❑ Observe tightening sequence ⇒ page 38 .
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❑ 40 Nm + 90°
t. rig
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13 - Bolt
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Prote AG.
❑ 25 Nm
ce
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❑ Before installing, push vane pump back slightly.
un
pt
an
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15 - Bracket
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16 - Nut
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❑ For bracket of Hall sender - G40- .
h re
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❑ 25 Nm
spec
urposes, in part or in wh
17 - Bolt
t to the co
❑ Observe tightening sequence ⇒ page 38 .
❑ 40 Nm +180°
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18 - Vane pump
s
❑ Removing and installing ⇒ Running gear, axles and steering; Rep. gr. 48 .
s o
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19 - Bolt
form
mer
❑ 25 Nm
atio
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n
20 - Belt pulley
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21 - Bolt
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❑ 25 Nm
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22 - Bolt
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❑ 23 Nm
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23 - Bolt
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Prote AG.
❑ Renew after removing
❑ 20 Nm + 90°
24 - Idler roller
❑ For poly V-belt.
25 - Air conditioner compressor
❑ Removing and installing ⇒ Heating, air conditioning system; Rep. gr. 87 .
26 - Bolt
❑ Prescribed torque ⇒ Electrical system; Rep. gr. 27 .
27 - Poly V-belt tensioning element
❑ Swing with ring spanner to slacken ribbed belt ⇒ page 40
ce
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nl
pt
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itte
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1 - Poly V-belt
ab
ility
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❑ Mark direction of rota‐
wit
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tion before removing.
h re
hole
❑ Check for wear.
spec
es, in part or in w
❑ Do not kink.
t to the co
❑ Removing and installing
⇒ page 40
rrectness of i
2 - Bolt
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❑ Renew after removing
❑ 10 Nm + 90°
nform
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damper
at
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ion
❑ Installation position:
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ate
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for
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❑ Can only be installed in C py
ht. rig
one position. Holes are rig ht
py by
offset.
co Vo
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Prote AG.
4 - Bolt
❑ 20 Nm
5 - Idler roller
❑ For toothed belt
6 - Dowel sleeve
❑ Check for correct seat‐
ing in ancillary bracket.
❑ Inserted in hole for the
left-hand (direction of
travel) bolt -11- on the
rear side of the bracket.
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
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
19 - Bolt ksw
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❑ 25 Nm ed by gu
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20 - Belt pulleyauth eo
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21 - Bolt
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❑ 25 Nm
an
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ab
22 - Bolt
pe
ility
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h re
23 - Poly V-belt tensioning element
hole
spec
❑ Swing with ring spanner to slacken ribbed belt ⇒ page 40
es, in part or in w
t to the co
tion in
r
thi
-1 … 6- in 2 stages as follows:
s
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ng
t.
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2. Tighten all bolts to 40 Nm. t. Cop py
rig
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3. Turn bolts -1, 2, 5 and 6- 90° further.
p by
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4. Turn bolts -3- and -4- 180° further.
Prote AG.
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nl
pt
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ility
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hole
spec
es, in part or in w
t to the co
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l purpos
Removing
nform
ercia
at
om
ion
– Mark direction of rotation of poly V-belt.
c
in t
or
his
te
do
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cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
ce
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un
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6- Poly V-belt
an
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7- Idler roller
erm
ab
ility
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spec
urposes, in part or in wh
t to the co
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1.6 Removing and installing tensioner for
poly V-belt ss o
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f inform
mer
Removing
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Removing
spec
es, in part or in w
WARNING
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at
om
his
ate
cum
for
en
ng
t.
– Screw off vane pump for power assisted steering together with
yi Co
op
connected lines and fasten to body ⇒ Running gear, axles,
C py
t. rig
gh
steering; Rep. gr. 48
ht
pyri by
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co lksw
by
cted agen
Prote AG.
– Unscrew deflection rolls -1- and -2- and screw out bolt of
toothed belt guard -arrow-.
ce
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un
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an
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ab
pe
ility
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wit
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hole
spec
es, in part or in w
t to the co
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Installing
a
com
tion in
thi
s
iva
– Make sure that the dowel sleeve ⇒ Item 6 (page 37) on the
do
r
rp
rear of the bracket is in the hole for the bolt. If the dowel sleeve
um
fo
t.
yi Co
op py
– Installing the generator ⇒ Electrical system; Rep. gr. 27 . t. C rig
gh ht
pyri by
– Installing high-pressure pump ⇒ page 347 .
co Vo
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cted agen
Prote AG.
Specified torques
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 105
♦ ⇒ “1.3 Assembly overview - poly V-belt drive”, page 37
♦ ⇒ “1.4 Assembly overview - poly V-belt drive, vehicles without
A/C system”, page 39
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:
n AG. Volkswagen AG do
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Assembly of the vibration damper is only possible in one position:
ss
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ab
ility
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spec
es, in part or in w
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om
Specified torques
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un
pt
an
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ility
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ole,
spec
urposes, in part or in wh
t to the co
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f inform
mer
atio
om
n
c
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or
n thi
te
sd
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cum
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t.
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Cop py
t. rig
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Removing
Prote AG.
ce
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un
pt
Installing
an
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ab
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Note
ole,
spec
urposes, in part or in wh
The oil seal sealing lip must not be additionally oiled or greased.
t to the co
– Remove oil residues from crankshaft journal with a clean cloth.
rrectne
– Fit guide sleeve - T10053/1- onto crankshaft journal.
ss
– Slide seal over guide sleeve - T10053/1- onto crankshaft jour‐
o
cial p
f i
nal.
nform
mer
atio
om
n
c
i
or
n thi
te
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote
– Press oil seal in as far as stop with press sleeve - T10053- and
AG.
central bolt.
– Install crankshaft toothed belt pulley.
– Install toothed belt ⇒ page 107 .
Specified torques
♦ ⇒ “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
n AG. Volkswagen AG do
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ab
ility
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hole
spec
es, in part or in w
Removing
t to the co
orm
m
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om
n in
or c
thi
te
sd
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cu
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f
en
ng
t.
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Cop py
t. rig
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pyri by
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Prote AG.
Note
ce
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nl
pt
du
an
♦ Before applying sealant bead, cover sealing surface of oil seal
itte
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erm
wit
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3 mm). spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
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ion
c
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or
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cum
for
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ng
t.
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Cop py
t. rig
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co lksw
by
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Prote AG.
AG. Volkswagen AG d
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– Thinly coat lowerthosealing
ris surface -shaded area- on sealing ntee
flange with sealant.
au
or
ac
ss
ce
– Fit sealing flange immediately and lightly tighten all bolts.
le
un
pt
an
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itte
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Note
pe
ility
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, is n
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♦ When fitting sealing flange with oil seal installed use the guide
hole
sleeve - T10053/1- .
spec
es, in part or in w
t to the co
♦ Sealing compound must dry for approx. 30 minutes after in‐
stallation. Only then fill with engine oil.
rrectness of i
– Tighten sealing flange securing bolts diagonally and alternate‐
ly.
l purpos
– Install toothed belt and adjust the valve timing ⇒ page 107 .
com
tion in
r
Specified torques
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thi
s
iva
do
cum
fo
en
t.
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op py
♦ ⇒ “1.4 Assembly overview - poly V-belt drive, vehicles without t. C rig
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A/C system”, page 39 pyri by
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♦ ⇒ “1.1 Assembly overview - sump, oil pump”, page 137 Prote AG.
2 Ancillary drive
⇒ “2.1 Assembly overview - ancillary drive”, page 51
⇒ “2.2 Retrofitting preparation for ancillary drive”, page 51
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
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Special tools and workshop equipment required
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2. Ancillary drive 51
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
AG. Volkswagen AG d
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Procedure
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– Remove poly V-belt ⇒ page 40 .
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Always use the original TDC mark for all adjustments to the
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♦ Set engine to TDC.
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The hub fits in only one position. If incorrectly positioned, the bolt
holes will be offset.
– 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.
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Prote AG.
2. Ancillary drive 53
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
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 .
2 - Sealing flange
❑ Must sit on dowel
sleeves.
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⇒ page 48 . s
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3 - Cylinder block
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❑ Removing and installing
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crankshaft
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⇒ page 73 .
, is n
spec
bling pistons and con‐
es, in part or in w
rods ⇒ page 66 .
t to the co
4 - Bolt
❑ Renew after removing
rrectness of i
❑ 60 Nm + 90°
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5 - Dual-mass flywheel
❑ To loosen securing
nform
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6 - Intermediate plate
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Vol gr. 34 ; Re‐
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moving and installing gearbox . ise
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– Mark position of dual-mass flywheel in relation to engine.
urposes, in part or in wh
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f inform
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♦ 3 hexagon bolts M6 x 35 mm
♦ 2 hexagon bolts M7 x 35 mm
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.
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– Unscrew bolts of sealing flange.
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Sealing flange and sender wheel are pressed off the crankshaft t to the co
together using 3 M6 x 35 mm bolts. rrectness of i
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Assembly tool - T10134-
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A - Clamping surface
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B - Hexagon nut
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– Screw on nut -B- until just before it touches the clamping sur‐
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– Press assembly housing -C- downwards until it lies on nut
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– Remove safety clip -arrow- of the new sealing flange.
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The sender wheel must not be taken out of the sealing flange or
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– Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
– Place sealing flange with front side facing down on a clean
level surface.
Note
– 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
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Note
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
prox. 5 full turns).
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– Push assembly housing -C-orby is hand in direction of arrow until
ed
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sealing lip support ring -B-aut touches crankshaft flange -A-.
h eo
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– Push guide pin for diesel engines (black knob) -D- into hole in
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crankshaft. This ensures that the sender wheel reaches its fi‐
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Note
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The guide pin for petrol engines (red knob) -F- must not be inser‐
es, in part or in w
tool hand-tight.
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– Screw nut -E- onto threaded spindle by hand until it lies against
assembly housing -C-.
nf
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Tighten nut of assembly tool - 35 Nm
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After hexagon nut is tightened to 35 Nm, a small air gap must still
es, in part or in w
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E - Checking sender wheel installation position on crankshaft
rrectness of i
– Screw nut -E- on until it reaches end of threaded spindle.
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– 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-.
– Screw nut -E- onto threaded spindle by hand until it lies against
assembly housing -C-.
AG. Volkswagen AG d
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do
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t.
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Cop py
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T10134-
nl
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– Check the sender wheel installation position on crankshaft
erm
ab
again ⇒ page 63
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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 .
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❑ With combustion ss cham‐
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allocation of piston to
hole
spec
cylinder ⇒ page 68 .
es, in part or in w
t to the co
clamp.
❑ If piston skirt is cracked,
renew piston.
nf
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or
atio
tion at TDC
om
n in
⇒ page 70 .
or c
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te
3 - Piston pin
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❑ If difficult to remove,
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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
6 - Bearing shell
❑ Note installation position ⇒ page 71 .
❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi‐
cation: Black line on bearing surface in area of joint.
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
❑ Check for secure seating.
❑ Axial clearance, wear limit: 0.37 mm
❑ Check radial clearance with Plastigage; wear limit: 0.08 mm.
❑ Do not rotate crankshaft when checking radial clearance.
7 - Cylinder block
❑ Checking cylinder bores ⇒ page 69 .
❑ Piston and cylinder dimensions ⇒ page 69 .
8 - Conrod bearing cap
❑ Note installation position.
9 - Oil spray jet
❑ For piston cooling.
10 - Bolt
❑ Insert without sealant.
❑ 25 Nm n AG. Volkswagen AG do
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❑ Renew afterthremoving
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❑ Oil threads
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❑ 30 Nm + 90°
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spec
urposes, in part or in wh
t to the co
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cial p
f inform
mer
atio
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n
c
i
or
n thi
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sd
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♦ Feeler gauges
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r
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t.
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– Push piston ring at right angle from above down into lower
Co
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cylinder bore to approx. 15 mm from bottom end of cylinder.
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Piston ring New Wear limit
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dimensions in mm
AG.
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4.2 Checking piston and cylinder bore
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Checking piston
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Cop py
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Note
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Piston must be renewed if piston shaft reveals cracking.
AG.
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mension
spec
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t to the co
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cial p
f inform
mer
atio
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n
c
i
or
n thi
te
sd
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pr
cum
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t.
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Cop py
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AG. Volkswagen AG d
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Test procedure h re
hole
spec
♦ The piston projection in the genuine part must be measured
es, in part or in w
gasket size.
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Holes/notches
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0.91 mm … 1.00 mm 1
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1.01 mm … 1.10 mm 2
hole
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1.11 mm … 1.20 mm 3
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c
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Special tools and workshop equipment required
ate
do
priv
♦ Plastigage
um
for
en
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t.
Procedure
yi Co
Cop py
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– Remove conrod bearing cap. Clean bearing cap and bearing
gh ht
pyri by
journal.
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by c lksw
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Prote AG.
– Place a Plastigage corresponding to the width of the bearing
on the journal or into the bearing shells.
– Fit conrod bearing cap and tighten to 30 Nm without turning
further angle and without rotating crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
Radial clearance:
• Wear limit: 0.08 mm
– Renew conrod bolts.
Note
AG. Volkswagen AG d
– Using a plastic hammer, carefully knock against conrod bear‐ agen oes
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ab
ility
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es, in part or in w
t to the co
rrectness of i
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mercia
at
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c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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t. rig
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Prote AG.
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
ce
le
❑ Do not interchange
un
pt
used bearing shells
an
d
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(mark).
rm
ab
pe
ility
2 - Bolt
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wit
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hole
spec
❑ To measure radial clear‐
es, in part or in w
ance, tighten to 65 Nm
t to the co
but not further.
❑ 65 Nm + 90°
rrectness of i
3 - Bearing cap
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tion in
❑ Bearing shell retaining
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4 - Thrust washer
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❑ Note fixing arrange‐
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ment.
Prote AG.
5 - Bearing shell 3
❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove.
❑ Do not interchange used bearing shells (mark).
6 - Needle bearing
❑ 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
AG. Volkswagen AG d
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♦ Dial gauge - VAS 6079- horise nte
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Procedure
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– Fit dial gauge - VAS 6079- with universal dial gauge holder -
VW 387- to cylinder block as shown in the illustration and set
nform
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com
do
– Push crankshaft away from dial gauge and read off measured
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Axial clearance: C py
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• Wear limit: 0.37 mm
AG.
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– Compare width of Plastigage with the measurement scale.
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Radial clearance:
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• New: 0.03 … 0.08 mm
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spec
urposes, in part or in wh
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cial p
f inform
mer
atio
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c
i
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by c lksw
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Prote AG.
5. Crankshaft 75
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
ce
le
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d
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Prote AG.
Removing
• Gearbox is separated from engine.
– Pull needle bearing out using commercially available internal
puller, e.g. KUKKO 21/2 and KUKKO 22/1, -A-.
Installing
Note
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Prote AG.
5. Crankshaft 77
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
ce
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erm
Note
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♦ The plastic packing pieces for protecting the open valves must
h re
not be removed until immediately before fitting cylinder head.
ole,
spec
urposes, in part or in wh
t to the co
must also be renewed.
rrectness o
cial p
f inform
mer
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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 .
4 - Oil pressure switch - F1-
❑ Identification: green wage
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❑ 0.5 bar d by V ua
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❑ If sealthis leaking, nip
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or
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and renew. ac
❑ Checking ⇒ page 156 .
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⇒ page 154 .
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❑ 22 Nm
wit
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spec
❑ 25 Nm
es, in part or in w
t to the co
6 - Lifting eye
7 - Glow plug
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❑ 18 Nm
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8 - Gasket
❑ Renew after removing
nf
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9 - Vacuum pump
rm
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c
DANGER!
or
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vacuum part could other‐
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wise malfunction. This
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would result in the failure
p by
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of the brake servo.
by
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Prote AG.
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 .
21 - Bolt AG. Volkswagen AG d
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❑ 10 Nm ed byV gu
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Observe tightening sequence of cylinder head bolts.
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pt
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erm
ab
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, is n
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hole
spec
es, in part or in w
t to the co
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l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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Cop py
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rig ht
py by
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Prote AG.
Note
Note
1 - High-pressure accumulator
(fuel rail)
❑ Do not attempt to re‐
shape high-pressure
lines.
AG. Volkswagen AG d
❑ Observe rules for clean‐ agen oes
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liness ⇒ page 7 . d byV gu
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❑ Removing and installing hor eo
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high-pressure lines ss a ra
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⇒ page 338 .
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2 - Bolt
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❑ 22 Nm
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❑ Cannot be renewed
ole,
spec
separately
urposes, in part or in wh
t to the co
❑ To fuel tank.
❑ The fuel return line must
not be kinked, damaged
rrectne
or blocked.
❑ The fuel return lines
s
❑ Removing ⇒ page 83
inform
mer
❑ Checking catches
atio
⇒ page 83 .
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❑ Fitting ⇒ page 83
or
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❑ Lock ⇒ page 84
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4 - Injector
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agen
1. Cylinder head 81
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
ce
le
11 - Gasket
un
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12 - Cylinder head cover
erm
ab
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❑ Removing and installing ⇒ page 93 .
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13 - Bolt
h re
ole,
spec
❑ Renew seal if damaged
urposes, in part or in wh
t to the co
❑ 10 Nm
14 - Gasket
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❑ Renew if damaged or leaking.
ss
15 - Vacuum hose
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16 - Pipe assembly
form
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17 - O-ring
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18 - Grommet
Co
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19 - Sealing bush for high-pressure accumulator (fuel rail) rig ht
py by
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❑ Renew if damaged or leaking.
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Prote AG.
20 - Injector seal
❑ Renew if damaged or leaking ⇒ page 99 .
21 - Bracket
22 - Bolt
❑ 10 Nm
AG. Volkswagen AG d
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Check catches uthor eo
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Caution
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pe
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ing as the 4 catches -arrow- can fracture.
ot
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hole
spec
es, in part or in w
t to the co
• A damaged fuel return line that becomes loose when en‐
gine is running causes damage to piezo injector. The
rrectness of i
piezo injector must then be replaced.
l purpos
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return-line connections.
n
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– Connect fuel return line and press the two clips downwards as
t. rig
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far as they will go -arrows-.
p by
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Prote AG.
1. Cylinder head 83
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
AG. Volkswagen AG d
agen oes
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nl
pt
du
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erm
ab
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hole
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es, in part or in w
t to the co
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nform
mercia
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c
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or
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ate
do
priv
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py by
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AG. Volkswagen AG d
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ab
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es, in part or in w
t to the co
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nform
mercia
at
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ion
c
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or
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ate
do
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Cop py
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Prote AG.
1. Cylinder head 85
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
ce
le
un
pt
an
d
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erm
ab
ility
ot p
wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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Cop py
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♦ Hose clip pliers - VAS 6362-
cop Vo
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Note
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tions:
du
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♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
ab
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vated charcoal filter system, coolant and refrigerant, brake
ot p
wit
fluid and vacuum) and electrical wiring in their original po‐
, is n
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sitions.
hole
spec
♦ To avoid damage to lines, ensure sufficient clearance from
es, in part or in w
t to the co
all moving or hot components.
rrectness of i
l purpos
Note
the cylinder head must not be placed on the glow plugs. If nec‐
orm
atio
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n in
or c
Removing
thi
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– Disconnect battery earth strap with ignition switched off ⇒ C py
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Electrical system; Rep. gr. 27 ; Disconnecting and reconnect‐
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ing battery . cop Vo
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cted agen
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– 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
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
c
in t
– Screw off Hall sender - G40- -arrow-.
or
his
ate
cum
for
en
ng
t.
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Cop py
t. rig
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by
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– Remove air filter with attachments ⇒ page 370 .
du
an
itte
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– Remove particulate filter ⇒ page 381 .
erm
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es, in part or in w
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by
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Prote AG.
Note
– 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
Note
pt
an
d
itte
Caution
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erm
ab
ility
ot p
is being lowered.
h re
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spec
sealing surface.
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mer
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c
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or
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pyri by
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Caution
AG. Volkswagen AG d
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Avoid damage to sealing surfaces:
d by Vo gu
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♦ When using abrasive utho paper do not use a grade less than eo
ra
100. ss a c
ce
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♦ Carefully remove any sealant residue from the cylinder
un
pt
an
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scratches are made on the surfaces.
erm
ab
ility
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is n
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ole,
spec
urposes, in part or in wh
Installing
t to the co
Installation is carried out in the reverse order; note the following:
rrectne
Caution
s
Avoid damage to cylinder block.
s o
cial p
f in
♦ No oil or coolant may be contained in hole pockets for cyl‐
form
mer
atio
m
n
c
i
or
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sd
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o
pr
cum
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fo
t.
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damage to the silicone coating or the indented area of the t. Cop py
gasket.
rig
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pyri by
Vo
co
Avoid damage to open valves.
by lksw
cted agen
Prote AG.
♦ When installing an exchange cylinder head, the plastic
protectors fitted to protect the open valves should not be
removed until the cylinder head is ready to be fitted.
Avoid damage to valves and piston crowns after working on
valve gear.
♦ Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.
1. Cylinder head 91
AG. Volkswagen AG d
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ise nte
Amarok 2011 ➤ thor eo
u ra
4-cylinder diesel
ss a engine (2.0 l engine, common rail) - Edition 04.2013
c
ce
e
nl
pt
du
an
itte
y li
Note erm
ab
ility
ot p
wit
♦ Proceed with extreme caution. The assistance of a second
, is n
h re
mechanic is vital.
hole
spec
♦ Always renew cylinder head bolts.
es, in part or in w
t to the co
♦ Renew seals, gaskets, self-locking nuts, bolts tightened
through an additional specified angle and securing clamps.
rrectness of i
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
l purpos
nform
ercia
be oiled.
m
at
om
i
♦ Hose unions and air intake pipes/hoses must be free of oil and
on
c
in t
or
his
ate
do
priv
c
entire coolant ⇒ page 182 and the engine oil must be
um
for
en
changed.
ng
t.
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t. rig
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– To centre, screw guide pins -3070/9- into outer threaded holes cop Vo
by lksw
on intake side.
cted agen
Prote AG.
– 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.
ce
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un
pt
lows:
an
d
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erm
1- Tighten initially with torque wrench:
ab
ility
ot p
Stage I = 35 Nm
wit
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Stage II = 60 Nm
spec
urposes, in part or in wh
t to the co
Stage III = 1/4 turn (90°)
rrectne
Stage IV = 1/4 turn (90°)
ss
– Secure bolt -arrow- of toothed belt guard.
o
cial p
f in
– Install hub and camshaft pulley.
form
mer
atio
– Install toothed belt ⇒ page 107 .
om
n
c
i
– Installing turbocharger ⇒ page 267 .
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pr
cum
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t.
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op
– Install intake manifold ⇒ page 354 .
C py
t. rig
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– Reconnect battery earth strap with ignition switched off ⇒
cop Vo
by lksw
cted
Electrical system; Rep. gr. 27 ; Disconnecting and reconnect‐
agen
Prote AG.
ing battery .
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. Cylinder head 93
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
♦ Socket - T40055-
AG. Volkswagen AG d
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ab
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es, in part or in w
Removing t to the co
Observe safety precautions ⇒ page 3 .
rrectness of i
er connection -4-.
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or c
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rig ht
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by lksw
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Prote AG.
– Pull connector -2- off fuel pressure sender - G247- -1-.
pt
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Caution
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
1. Cylinder head 95
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
n AG. Volkswagen AG do
– Pull all fuel return lines -1- off piezo injectors. lkswage es n
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– Release connectors -2- and pull them off piezo injectors.
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nl
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du
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erm
ab
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spec
es, in part or in w
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– Unscrew union nuts -1- from piezo injectors.
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– Ensure cleanliness. No dirt must be allowed to get into the
l purpos
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– Pull cable guide -3- from high-pressure accumulator (fuel rail). atio
om
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– Unclip connector -2- and pull off from fuel pressure regulating
ht
pyri by
Vo
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valve - N276- -1-.
c by lksw
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– Pull fuel hose -3- from high-pressure accumulator (fuel ail)
-4-.
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un
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– Hand-tighten cylinder head cover in the sequence -1 … 6-.
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erm
ab
ility
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is n
return-line connections.
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f in
– Connect fuel return line and press the two clips downwards as
form
mer
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 97
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
– 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
“Bleeding fuel system” function using the ⇒ Vehiclesdiagnostic
agen
AG. gen AG
does
k w
tester ⇒ page 316 . by Vol not
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ri se
♦ This process takes 130 seconds. Fuel pumps ho are actuated a tee
ut or
total of 3 times in the process. The process
ss a must not be ter‐ ac
minated prematurely.
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nl
pt
du
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Specified torques
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wit
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ab
ility
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es, in part or in w
t to the co
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1. Cylinder head 99
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Caution
AG. Volkswagen AG d
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– With engine switched
rise
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nte
off at piezoutinjectors. To do this, press the two clips downwards
ho eo
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-arrow A- ss a
and, at the same time, pull the release bolt upwards c
-arrow B-.
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Cop py
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Caution
AG. Volkswagen AG d
– Initially position new injector seal by hand. olksw
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– Then carefully push new injector seal in to stoprisedusing assem‐ ara
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– Apply a thin coating of diesel fuel to the new O-rings on the s
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return-line connections.
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– Connect fuel return line and press the two clips downwards as
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Cop py
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Cop py
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Prote AG.
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
pt
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Cop py
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Compression pressures:
New: 25…31 bar
rrectne
f inform
⇒ page 405 .
atio
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i
or
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tester.
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Cop py
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Vo
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Prote AG.
1 - Toothed belt
❑ Mark direction of rota‐
tion before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing and installing
⇒ page 107 .
2 - Bolt
❑ Renew after removing
❑ Use counterhold tool -
3415- to loosen and
tighten.
❑ Do not additionally oil or agen
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3 - Crankshaft toothed belt pul‐
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4 - Nut
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5 - Idler roller
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6 - Nut
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7 - Tensioning roller
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9 - Camshaft pulley
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10 - Bolt
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❑ 50 Nm + 90°
an
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18 - Idler roller
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19 - Hub
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❑ Use counterhold tool - T10051- to loosen and tighten.
hole
spec
❑ To remove, use puller - T40064- . es, in part or in w
t to the co
❑ Removing and installing ⇒ page 347 .
20 - Nut
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❑ 95 Nm
l purpos
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❑ 23 Nm
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23 - Coolant pump
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24 - Bolt
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25 - Toothed belt guard upper part p by
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26 - Toothed belt guard lower part Prote AG.
27 - Bolt
❑ Renew after removing
❑ 10 Nm
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
AG. Volkswagen AG d
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Removing
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Cop py
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Prote AG.
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– Remove lower toothed belt guard. To do this, unscrew bolts
-arrows-.
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Cop py
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Prote AG.
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.
ce
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un
in cylinder head.
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– Loosen bolts -arrows- approx. 90°.
rm
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r
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Cop py
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t.
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Cop py
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111
Prote AG.
2. Toothed belt drive
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
AG. Volkswagen AG d
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ing pin - 3359- . To do this, push locking pin into adjustment
rrectness of i
hole outside toothed belt pulley.
l purpos
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io
toothed belt pulley of high-pressure pump.
n
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– Finally, place toothed belt onto idler roller.
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– Undo the fastening nuts of the tensioning roller and pull out
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Cop py
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by lksw
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Prote AG.
AG. Volkswagen AG d
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Note
h re
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spec
urposes, in part or in wh
operation.
s
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s o
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♦ Camshaft pulley: tighten bolts. Counterhold with counterhold
erm
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- T10172- and adapters - T10172/4- .
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counterhold - T10172- and adapters - T10172/8- .
hole
spec
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– Install vibration damper/belt pulley.
rrectness of i
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– First, fit top part of toothed belt guard to middle -1- of toothed
m
at
om
i
belt guard from the rear.
on
c
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or
– Then, fit toothed belt guard to middle -2- and -3- of toothed belt
his
ate
do
priv
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for
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Cop py
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Prote AG.
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c
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priv
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
1 - Heat shield
❑ For air filter housing.
2 - Bolt
❑ 6 Nm
3 - Air filter bracket
❑ Removing and installing
⇒ page 118 . n AG. Volkswagen AG do
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4 - Bolt byV
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❑ 6 Nm ir se tee
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6 - Spring-type clip
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7 - Hose clip
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8 - Blower
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❑ Removing and installing
hole
spec
⇒ page 117 .
es, in part or in w
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9 - Bracket
10 - Bolt
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❑ 6 Nm
l purpos
11 - Rubber sleeve
❑ Qty. 2.
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❑ To air filter
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12 - Nut
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13 - Bracket
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❑ Removing and installing Cop py
⇒ page 117 .
t. rig
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❑ ⇒ ETKA (Electronic
co Vo
by lksw
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Parts Catalogue)
agen
Prote AG.
15 - Bolt
❑ 6 Nm
AG. Volkswagen AG d
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– Loosen screw-type clip -1- and then remove bolts -arrows-
ot
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from bracket.
h re
hole
spec
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t to the co
Installing
Installation is carried out in the reverse order; note the following:
rrectness of i
♦ ⇒ “3.1 Assembly overview - fresh air supply system”,
page 116
l purpos
nform
mercia
a
com
tion in
thi
do
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fo
Removing
en
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t.
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op
– Unscrew bolts -arrows- and remove heat shield -1-. C py
t. rig
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pyri by
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Prote AG.
AG. Volkswagen AG d
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spec
es, in part or in w
t to the co
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l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
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t.
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Cop py
t. rig
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pyri by
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Prote AG.
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⇒ “4.2 Measuring axial clearance of camshaft”, page 121
an
itte
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⇒ “4.3 Measuring radial clearance of camshafts”, page 122
ility
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⇒ “4.4 Removing and installing camshafts”, page 123
, is n
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⇒ “4.5 Removing and installing camshaft oil seal”, page 129 hole
spec
es, in part or in w
t to the co
⇒ “4.7 Renewing valve stem seals”, page 132
rrectness of i
4.1 Assembly overview - valve gear
l purpos
Note
nform
ercia
at
om
i
used without reducing engine life, provided the cracks are
on
c
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small and not more than 0.5 mm wide.
or
his
ate
♦ The plastic packing pieces for protecting the open valves must
do
priv
c
not be removed until immediately before fitting cylinder head.
um
for
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t.
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♦ When cylinder head is renewed, the coolant must be com‐
Co
op py
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t. C rig
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Prote AG.
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
clean cloth. y Volk not
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❑ To install, mask
horis off nte
eo
groove onaucamshaft
t tap‐ ra
c
er (e.g. using
ss
Sellotape)
ce
le
un
pt
an
d
itte
⇒ page 129 .
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2 - Bolt
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❑ Observe sequence
h re
when loosening and
ole,
spec
tightening ⇒ page 121 .
urposes, in part or in wh
t to the co
❑ 10 Nm
3 - Retaining frame
rrectne
❑ Seal with silicone seal‐
ant ⇒ Electronic Parts
Catalogue (ETKA) .
ss o
cial p
4 - Exhaust camshaft
f inform
❑ Removing and installing
mer
⇒ page 123 .
atio
om
n
c
5 - Inlet camshaft
i
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⇒ page 123 .
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n AG. Volkswagen AG do
4.2 Measuring axial clearance of camshaft
Vol
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Special tools and workshop equipment required oris tee
th or
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♦ Universal dial gauge bracket - VW 387- ss
ac
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un
pt
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rm
ab
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l purpos
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mercia
a
com
tion in
r
te o
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
Procedure
– Remove retaining frame ⇒ page 121 .
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nl
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Special tools and workshop equipment required
du
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♦ Plastigage
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ility
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Procedure
wit
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– Remove roller rocker finger.
hole
spec
es, in part or in w
t to the co
– Place a length of Plastigage corresponding to the width of the
bearing on the journal to be measured or into the bearings.
rrectness of i
• Plastigage must lie in the middle of the bearing.
l purpos
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at
om
ion
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or
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priv
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for
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Cop py
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Cop py
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123
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Prote
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agen 4. Valve gear
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
olksw
♦ Silicone adhesive sealant ⇒ Electronic PartswagCatalogue
en AG. V (ET‐
agen AG
does
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Removing ris
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– Remove fuel filter ⇒ page 239
ss .
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– Removed toothed belt from camshaft and high-pressure pump
an
d
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⇒ page 107 .
rm
ab
pe
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– Remove cylinder head cover ⇒ page 93 .
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wit
, is n
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– Unscrew and remove bolts -arrows- for toothed belt and cam‐
hole
shaft.
spec
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t to the co
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l purpos
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mercia
a
com
tion in
r
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thi
do
cum
fo
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t.
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Cop py
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Prote AG.
Note
Note
n AG. Volkswagen AG do
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Seal contact surface between retaining frame and cylinder yV
o head
lks es n
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using silicone adhesive sealant ⇒ Electronic Parts Catalogue
ir se
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(ETKA) . tho tee
or
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ss
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Caution
an
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Camshafts may only be installed with camshaft fitting tool -
ility
ot p
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is n
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ole,
must be replaced.
spec
urposes, in part or in wh
Make sure that no sealant residues get into the cylinder head
t to the co
or the bearings.
rrectne
– Remove remaining sealant and from cylinder block and re‐
taining frame using, for example, a rotating plastic brush. ss o
f inform
atio
m
n
c
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Cop py
Note
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If the supports of the camshaft fitting tool - T40094- are not yet
cted agen
Prote AG.
marked, mark the removed supports, e.g. with number stamps,
so they can be fitted in the original positions later.
Caution
The exhaust camshaft tensioning roller has been discontinued n AG. Volkswagen AG do
⇒ Electronic Parts Catalogue (ETKA) . olks
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In the case of exhaust camshafts with tensioning roller,risensure
ed
ara
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that the clamping jaw marked with an arrow is seated tho on the eo
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wider gear. ss c
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un
pt
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spanner to assist.
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t to the co
f inform
mer
atio
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Cop py
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126
by lksw
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Rep. gr.15 - Cylinder head, valve gear Prote AG.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
n AG. Volkswagen AG do
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Sealant beads must not be thicker than specified, otherwise ex‐
hole
spec
cess sealant could enter the camshaft bearings.
es, in part or in w
t to the co
– Install new cap ⇒ Item 14 (page 120) flush on cylinder head.
– Remove camshafts from camshaft fitting tool - T40095- to‐
rrectness of i
gether with retaining frame and camshaft fitting tool - T40094- .
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Cop py
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Note
on top.
ss
ley.
inform
mer
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n
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Cop py
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Removing
at
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c
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⇒ page 107 .
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129
by lksw
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Prote 4. Valve gear
AG.
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Note
The oil seal sealing lip must not be additionally oiled or greased.
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es, in part or in w
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– Press in oil seal with press piece of fitting tool - 10 - 203- and
rrectness of i
Specified torques
rm
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Cop py
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Prote AG.
Note
Procedure:
– Start engine and run until the radiator fan has switched on
once.
– Increase engine speed to about 2500 rpm for 2 minutes (per‐
form road test if necessary).
– If the hydraulic compensation elements are still noisy, find out
which is the defective compensation element as follows:
AG. Volkswagen AG d
agen
– Remove cylinder head cover ⇒ page 93 . olksw
oes
not
byV gu
ara
d
– Turn crankshaft by the bolt for the toothed belt wheel until
oris cam
e nte
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of supporting element to be tested is facing upwards. aut
h
ra
ss c
– Press roller rocker finger downwards -arrow- to check clear‐
ce
le
un
pt
ance between cam and roller rocker finger.
an
d
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roller rocker finger, replace hydraulic compensation element.
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rrectness of i
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nform
mercia
a
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Cop py
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ce
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3220-
un
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♦ Valve stem seal puller -
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3364-
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♦ Valve stem seal fitting tool -
, is n
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3365-
hole
spec
♦ Removal and installation
es, in part or in w
t to the co
device for valve cotters -
VAS 5161 A- with guide
plate - VAS 5161/23- and
rrectness of i
spacer ring - VAS
5161/23-1-
l purpos
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mercia
a
com
tion in
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cum
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Cop py
t. rig
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pyri by
Vo
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by
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Prote AG.
Procedure
– Remove all glow plugs using jointed spanner - 3220- .
⇒ page 405
– Remove camshafts ⇒ page 123 .
– Place guide plate - VAS 5161/23- onto cylinder head.
– Secure guide plate on intake manifold side with knurled screw
- VAS 5161/12- and tighten it hand-tight to studs using M6
collarless nuts -1-.
– Screw sealing bolts - VAS 5161/10- into the guide plate.
– Insert punch - VAS 5161/3- in the guide plate and use a plastic
hammer to knock loose the firmly seated valve cotters.
n AG. Volkswagen AG do
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– Remove assembly cartridge with spacer ring, valve plate and Cop py
valve spring.
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– Pull off valve stem seals using valve stem seal puller - 3364- . Prote AG.
Note
A plastic sleeve -A- is included with the new valve stem oil seals.
Note
ce
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nl
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du
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– Insert assembly cartridge - VAS 5161/8- into guide plate again.
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– Press pressure fork downwards and pull knurled screw up‐
ility
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spec
– Reduce pressure on pressure fork whilst pulling on knurled
es, in part or in w
screw.
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Installation is carried out in the reverse order; note the following: rrectness of i
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Valve seats must not be reworked due to the very small toleran‐
hole
spec
ces.
es, in part or in w
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5.2 Checking valve guides
Special tools and workshop equipment required
rrectness of i
♦ Universal dial gauge bracket - VW 387-
l purpos
nform
mercia
a
com
tion in
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fo
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t.
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.
♦ Dial gauge - VAS 6079-
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.
Note
AG. Volkswagen AG d
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olksw not
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aut ra
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spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
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c
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Cop py
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Prote AG.
17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump, oil pump”, page 137
Volkswa gen AG AG.
agen
does
⇒ “1.2 Removing and installing oil sump”,
Vol
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⇒ “1.3 Removing and installing
horisoil pump”, page 146 nte
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⇒ “1.4 Removing and installing
ss oil pump, vehicles with balancer c
shaft module”, page 146
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⇒ “1.6 Removing and installing oil level and oil temperature send‐
ility
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Prote AG.
1 - Bolt
❑ 15 Nm
2 - Sealing flange
❑ With seal.
❑ Must seat on dowel
sleeves.
❑ Insert with silicone seal‐
ant ⇒ Electronic Parts
Catalogue (ETKA) . AG. Volkswagen AG d
agen
❑ Do not apply additional Volksw
oes
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oil or grease the sealing d by ara
lip of the oil seal. rise nte
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❑ Before installing, re‐ ss a c
move oil residue from
ce
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un
pt
crankshaft journal using
an
d
itte
a clean cloth.
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⇒ page 48 .
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3 - Toothed belt for oil pump
hole
spec
❑ Check for damage.
es, in part or in w
t to the co
❑ Replace if necessary.
Note
rrectness of i
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placing.
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4 - Bolt
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❑ 10 Nm
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fo
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5 - Oil dipstick
t.
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Cop py
❑ The oil level must not be above the max. mark!
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❑ Markings ⇒ page 147 . cop Vo
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Prote AG.
6 - Guide tube
7 - Clip
8 - Dowel sleeves
9 - O-ring
❑ 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
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
ce
le
pt
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d
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❑ 30 Nm
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21 - Bolt
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❑ 10 Nm
spec
urposes, in part or in wh
t to the co
❑ Only for vehicles compliant with emission standard EU 5.
❑ Black 3-pin connector
rrectne
❑ Removing and installing ⇒ page 147 .
s
23 - Seal
s o
cial p
f
❑ Only for vehicles compliant with emission standard EU 5.
inform
mer
n
c
i
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sd
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25 - Bolt
p
cum
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fo
en
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AG. Volkswagen AG d
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Eye protection Cop py
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Flat scraper p by
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Prote AG.
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
– 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
pt
du
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itte
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ility
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es, in part or in w
– Unscrew bolts -arrows- and remove bracket -1- for final drive.
t to the co
nf
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orm
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Cop py
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rig ht
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by lksw
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Prote AG.
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– Unscrew bolts -3- for coolant pipe -2- at left assembly mount‐
ility
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ing and remove coolant pipe -2- from coolant hose -1-.
wit
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
– Unscrew bolts -3- for engine support -1- on left and right -1-.
om
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Caution
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• If nut -2- is loosened, engine mounting must subsequently
C py
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be renewed.
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♦ Engine mounting connection to engine support may only
cted agen
Prote AG.
be loosened if engine mounting is to be renewed.
ce
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un
pt
– Unscrew bolts -1- from right engine mounting -A-.
an
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Note
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trical connection off air condition compressor otherwise it may be
es, in part or in w
t to the co
damaged.
rrectness of i
l purpos
nform
ercia
a
com
tio
– Remove front anti-roll bar with coupling rods ⇒ Rep. gr. 40
n in
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fo
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t.
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Cop py
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by
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Prote AG.
– 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
WARNING
Note
Caution
nl
pt
du
an
itte
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ab
ility
ot p
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hole
spec
es, in part or in w
t to the co
rrectness of i
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c
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ate
do
priv
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t.
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Cop py
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Vo
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by c lksw
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Prote
144
AG.
Rep. gr.17 - Lubrication
AG. Volkswagen AG d
agen oes
Volksw Amarok
not
gu
2011 ➤
y
4-cylinder diesel engine
rised b
(2.0 l engine, common rail) - Edition ara04.2013
nte
utho eo
ra
a
– Apply bead of sealant onto clean sealing surface
ss of sump as c
illustrated.
ce
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nl
pt
du
an
itte
• Thickness of sealant bead: 2…3 mm.
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ility
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Note
h re
hole
spec
♦ Take particular care when applying sealant bead at front and
es, in part or in w
rear of sealing flange -arrows-.
t to the co
♦ Oil sump must be installed within 5 minutes after applying
sealant.
rrectness of i
♦ When installing sump with engine removed, ensure that sump l purpos
is flush with crankcase at flywheel end.
nf
ercia
or
gearbox connecting bolts and all the oil sump bolts. Ensure
m
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atio
m
n in
c
flange.
or
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– Tighten sump bolts.
iva
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– Tighten bolts between sump and gearbox.
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– Secure anti-roll bar to subframe. Use new bolts. Tighten bolts Cop py
t. rig
when vehicle is standing on its wheels in an unloaded condi‐ yri
gh by
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tion or when vehicle is raised and wheels are also in the empty cop Vo
by lksw
weight position ⇒ front suspension; Rep. gr. 40 .
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Prote AG.
Note
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Note erm
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Renew O-ring.
wit
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spec
es, in part or in w
– Insert new dowel sleeves when oil pump has no dowel sleeves
t to the co
-arrows- for centring oil pump.
– Check oil pump for ease of movement, turn toothed belt pulley
rrectness of i
with one finger for this.
l purpos
Note
nf
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♦ Renew sluggish oil pump.
rm
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♦ The toothed belt can sag after long use, this is not a fault.
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– Check toothed belt for oil pump.
f
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op
– Fit oil pump with toothed belt pulley into toothed belt and tight‐ C py
t. rig
en along with baffle.
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– Install sump ⇒ page 140 . cted agen
Prote AG.
Caution
Note
♦ Renew O-ring.
♦ Renew damaged or over-tensioned circlip.
♦ Circlip must lie in base of groove.
pt
du
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itte
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Oil capacities:
erm
ab
ility
ot p
h re
Without oil filter change: 6.7 l
hole
spec
t to the co
⇒ Maintenance ; Booklet 11
Markings on oil dipstick
rrectness of i
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Note
nform
ercia
The oil level may be in area -d- due to the infiltration of fuel in the
engine oil as a result of unfavourable driving conditions after fill‐
m
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ion
in t
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his
ate
do
riv
1 - Min. mark
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for
en
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2 - Max. mark
n
t.
yi Co
Cop py
a - Oil level in min. mark area: replenish engine oil!
t. rig
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b - Oil level in middle range: can be topped-up with engine oil.
c by lksw
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Prote AG.
c - Oil level in max. mark area: Do not replenish engine oil!
d - The oil level may be in this area as a result of particular driving
conditions.
ce
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un
pt
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d
itte
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ility
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wit
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hole
spec
Specified torques
es, in part or in w
t to the co
♦ ⇒ “1.1 Assembly overview - sump, oil pump”, page 137
rrectness of i
l purpos
nform
mercia
a
com
ti
1.7 Removing and installing dipstick tube
on in
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Removing
s
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Observe general notes on the lubrication system ⇒ page 7
fo
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ng
t.
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Observe rules for cleanliness when working on charge air system Cop py
⇒ page 8 ht. rig
rig ht
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– Release and pull off connector -1- for intake air temperature
by lksw
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Prote
sender - G42- together with charge air pressure sender - G31-
AG.
-1-.
– Remove charge air pipe. Loosen clip -arrow- and pull hose
connection with charge air pipe -1- off throttle valve module -
J338- -2-.
– Loosen clip -1- and pull charge air hose off charge air pipe.
Then remove bolt -2- and remove pipe -arrow-.
– Remove nut -2-. Move wiring harness retainer aside. Then re‐
move bolt -1- and remove dipstick tube -arrow- .upwards.
Volkswag AG en AG
agen does
Installing yV
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Installation is carried out in rise
the hreverse order; note the following: nte
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Note
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pt
an
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erm
ab
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Specified torques
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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Vo
co lksw
by
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Prote AG.
ce
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nl
pt
du
Do not lubricate rubber seals (11 and 14) with oil. Oil would
an
itte
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make the coolant seals swell up.
erm
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ility
ot p
wit
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hole
1 - O-ring
spec
es, in part or in w
t to the co
2 - Cap
❑ 25 Nm
rrectness of i
3 - O-ring
l purpos
4 - O-ring
❑ Renew after removing
m
at
om
ion
in t
or
his
e
do
riv
cum
or
tem ⇒ page 7
f
en
ng
t.
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6 - Guide tube Cop py
t. rig
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❑ Renew O-ring.
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7 - Bolt
agen
Prote AG.
❑ 10 Nm
8 - Spreader clip
9 - Engine oil cooler
❑ Observe general notes
on the lubrication sys‐
tem ⇒ page 7
❑ Ensure clearance to ad‐
jacent components.
❑ Coolant hose schematic
diagram ⇒ page 175 .
❑ Checking engine oil
cooler for leaks
⇒ page 159
❑ Removing and installing
engine oil cooler
⇒ 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.
Note
pt
an
itte
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erm
h re
spec
quence
es, in part or in w
t to the co
WARNING
nf
ercia
Do not lubricate rubber seals (8 and 11) with oil. Oil would
rm
atio
om
n in
or c
thi
te
sd
iva
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cu
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f
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ng
t.
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Cop py
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rig ht
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- G69- and intake manifold flap motor - V157- .
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– 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:
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♦ Renew gaskets, seals and O-rings. orise
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Hose unions and air intake pipes/hoses mustssbe
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grease when installing.
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Specified torques
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Removing
– Unscrew securing bolt -1- from right engine mounting -A- and
remove engine mounting.
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– Unscrew oil pressure switch - F1- -B- from cylinder head using
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Installation is carried out in the reverse order; note the following:
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– Tighten oil pressure switch - F1- . cted agen
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Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 78
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Test procedure opyri
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Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
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– Connect brown wire -1- of tester to earth (-).
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– Connect voltage tester - V.A.G 1527 B- to battery positive (+)
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and oil pressure switch using cables from auxiliary test set - ot p
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V.A.G 1594 C- .
hole
spec
• LED must not light up.
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If the LED lights up:
– Replace oil pressure switch - F1-
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If LED does not light up:
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oil pressure switch - F1- .
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Prerequisite
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3 Engine oil cooler
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⇒ “3.1 Checking engine oil cooler for leaks”, page 159
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3.1 Checking engine oil cooler for leaks
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spec
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Special tools and workshop
equipment required
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♦ Refractometer - T10007 A-
♦ Hose clamps up to 25 mm - l purpos
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V.A.G 1274-
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♦ Adapter for cooling system
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♦ Drip tray - V.A.G 1306- or
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Prerequisites:
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Test procedure ot p
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– Remove underbody guard, if fitted ⇒ General body repairs,
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spec
exterior; Rep. gr. 66 ; Underbody guard .
es, in part or in w
t to the co
– Drain coolant ⇒ page 182 .
– Loosen hose clip on engine oil cooler with spring-type clip pli‐
ers - VAS 5024- .
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– Remove engine oil cooler with housing ⇒ page 151 .
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Note
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♦ Collect escaping coolant with drip tray - VAS 6208- .
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screw clamp.
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⇒ “4.3 Installing a new balancer shaft module”, page 165
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⇒ “4.4 Installing a previously used balancer shaft module again”,
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page 168
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4.1 Assembly overview - balancer shaft module
spec
urposes, in part or in wh
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1 - Oil sump
❑ Tightening sequence
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⇒ page 163 .
❑ Removing and installing
ss
⇒ page 140 .
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2 - Bolt
form
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❑ 10 Nm
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3 - Suction hose
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6 - Oil pump
❑ Before installing, check
that both dowel sleeves
for centring oil pump on
balancer shaft module
are fitted.
7 - Drive shaft for oil pump
8 - Circlip
❑ Must lie in base of
groove.
❑ Renew damaged or
over-tensioned circlip.
9 - Spur gear for balancer shaft
10 - Bolt
❑ 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 .
Caution
When installing the inter‐
mediate gear wheel, en‐
sure that the thrust
washer is seated cor‐
rectly ⇒ page 163 .
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18 - Bolt
itte
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❑ Note tightening sequence: installing new balancer shaft module ⇒ page 165 , reinstalling previously run
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❑ M7 = 13 Nm + 90°
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❑ M8 = 20 Nm + 90°
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20 - Bolt
❑ 10 Nm
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21 - Bolt
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❑ 40 Nm
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22 - Bolt
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❑ Initial tightening torque: 5 Nm
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24 - Seal
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❑ Permanently attached to drain plug.
25 - Oil drain plug
❑ Renew after removing
❑ With seal.
❑ 30 Nm
Caution
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Removing
– Pull oil dipstick out.
– Remove sump ⇒ page 140 . AG. Volkswagen AG d
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– Remove vibration damper ⇒ page d by 44 .
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– Rotate crankshaft to TDCutand lock in position with crankshaft
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stop - T10050- . ss a c
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The markings on the crankshaft toothed belt pulley -2- and the
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crankshaft stop - T10050- -1- must align. At the same time, the
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the sealing flange.
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stalled with correct tooth backlash.
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♦ A coating is applied to the new intermediate gear wheel to set
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the correct tooth backlash.
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♦ Intermediate gear wheels that have a white point are partly
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coated around the circumference. Intermediate gear wheels
spec
without a white spot are fully coated around the circumference
es, in part or in w
t to the co
♦ The coating is quickly worn away, as a result of which the tooth
backlash is set.
rrectness of i
♦ For this reason a new balancer shaft module must always be
installed with a new intermediate gear wheel with special coat‐
l purpos
ing.
♦ A white spot is positioned only on partly coated intermediate
nf
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gear wheel to ensure correct installation position.
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• Crankshaft locked in position with crankshaft stop - T10050- .
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Note
Note
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4. Tighten bolts -1 … 2-, -4- and -6- to 20 Nm.
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5. Turn bolts -1 … 2-, -4- and -6- 90° further with rigid spanner.
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– Lock balancer shaft with locking device - T10255- . To do this,
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• Locking tool pin must engage in groove in balancer shaft when
doing this.
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Note
Note
No backlash may be perceptible after installing intermediate gear agen AG. Volkswagen AG do
wheel. This can be checked by hand using light force. yV
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Further installation is carried out in the reverse order.au
t In the proc‐
h or
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ess, note the following: ss
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– Install sump ⇒ page 140 .
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– Install belt pulley/vibration damper (replace securing bolts)
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⇒ page 44
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spec
Specified torques
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t to the co
♦ ⇒ “1.1 Assembly overview - sump, oil pump”, page 137
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 105
rrectness of i
4.4 Installing a previously used balancer
l purpos
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Caution
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If the bolt for the intermediate wheel has been removed, a new
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ment of the drive gear wheel on the crankshaft and to removal
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Note
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3. Turn bolts -3- and -5- 90° further with rigid spanner.
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4. Tighten bolts -1 … 2-, -4- and -6- to 20 Nm.
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wit
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– Remove crankshaft stop - T10050- .
ole,
spec
urposes, in part or in wh
t to the co
ess, note the following:
– Install sump ⇒ page 140 .
rrectne
– Install belt pulley/vibration damper (replace securing bolts)
⇒ page 44
ss
Specified torques
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♦ ⇒ “1.1 Assembly overview - sump, oil pump”, page 137
form
mer
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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
The securing bolts for the assembly mountings may only be re‐
nl
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– Unbolt bracket -2- for oil supply line -1- from turbocharger.
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Vo oil supply line on upper turbocharger
– Loosen banjo bolt -2- d byfor ua
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– Loosen banjo bolt -2- for oil supply line on lower turbocharger
rrectness of i
-1-.
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– Unscrew bolt -2- for oil supply line bracket -1- through opening
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on assembly mounting -3-.
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Procedure must be adhered to, this ensures that the oil supply
hole
spec
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– Renew seals, gaskets and self-locking nuts.
rrectness of i
– Fit new double seal -2- onto the respective line connection
-1- and secure by screwing in the corresponding banjo bolt
l purpos
-3-.
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Removing and
nform
ercia
installing starter .
m
a
– Install right engine support ⇒ page 31 .
com
tion in
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– Install air filter housing ⇒ page 368 .
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Specified torques
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♦ ⇒ “2.1 Removing and installing assembly mountings”, t. C rig
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page 31 yri
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♦ ⇒ “1.1 Assembly overview - charge air system”, page 250
agen
Prote AG.
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 .
AG. Volkswagen AG d
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– Remove bolts -1- and remove oil pressure line. aut ra
c
ss
– Collect escaping oil with a cloth.
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Installing
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Installation is carried out in the reverse order; note the following:
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hole
Note
spec
es, in part or in w
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Procedure must be adhered to, this ensures that the oil pressure
line is installed stress-free.
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Prote AG.
– 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 . n AG. Volkswagen AG do
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– Install air filter housing ⇒ page 368 . d byV ua
ran
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Specified torques autho
or
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ss
♦ ⇒ “2.1 Removing and installing assembly mountings”,
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page 31
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♦ ⇒ “1.1 Assembly overview - charge air system”, page 250 erm
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♦ ⇒ “2.2 Assembly overview - turbocharger, 90 kW and 103 kW
hole
spec
engines”, page 264
es, in part or in w
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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
1.1.1 Coolant hose schematic diagram for vehicles with supplementary heater,
engine codes CDCA and CDBA
1 - Expansion tank
2 - Heat exchanger for heater
unit
3 - Union on rear of cylinder
head
❑ With coolant tempera‐
ture sender - G62-
4 - Cylinder head
5 - Engine oil cooler
6 - 4/2-way valve
❑ With thermostat.
❑ Can only be renewed AG. Volkswagen AG d
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❑ Removing and installing ised b ara
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⇒ page 191 . ut
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7 - Circulation pump - V55- s
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❑ Assembly overview
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⇒ page 189 .
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⇒ page 200 .
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8 - Auxiliary heater
hole
spec
❑ Depending on equip‐
es, in part or in w
t to the co
ment.
9 - Radiator
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10 - Coolant pump
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1.1.2 Coolant hose schematic diagram, vehicles with auxiliary heater, engine co‐
an
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des CSHA and CNEA (emission standards EU 4 and EU 5)
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1 - Expansion tank
hole
spec
es, in part or in w
t to the co
unit
3 - Union on rear of cylinder
rrectness of i
head
❑ With coolant tempera‐
l purpos
nf
ercia
orm
5 - Engine oil cooler
m
atio
om
n in
6 - 4/2-way valve
or c
thi
e
❑ With thermostat.
t
sd
iva
o
r
rp
cu
❑ Can only be renewed
o
m
f
complete.
en
ng
t.
yi Co
op
7 - Circulation pump - V55-
C py
t. rig
gh ht
yri by
8 - Coolant pump
op Vo
by c lksw
cted agen
Prote AG.
9 - Auxiliary heater
❑ Depending on equip‐
ment.
10 - 2-way valve for coolant
shut-off valve - N147-
11 - Radiator
❑ Renew coolant after re‐
placing
12 - Exhaust gas recirculation
cooler changeover valve -
N345-
13 - Continued coolant circula‐
tion pump - V51-
14 - Radiator outlet coolant
temperature sender - G83-
15 - Exhaust gas recirculation cooler
16 - Thermostat (Y-piece)
17 - Coolant temperature sender - G62-
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 - G62-
4 - Cylinder head
AG. Volkswagen AG d
agen
5 - Engine oil cooler Volksw
oes
not
gu
by ara
d
6- Circulation pump orise- V55- nte
eo
th
u ra
7- 4/2-way valve
ss a c
ce
e
❑ With thermostat.
nl
pt
du
an
itte
y li
erm
ab
complete.
ility
ot p
8 - Coolant pump
wit
, is n
h re
hole
9 - Auxiliary heater
spec
es, in part or in w
❑ Depending on equip‐
t to the co
ment.
10 - 2-way valve for coolant
shut-off valve - N147- rrectness of i
11 - Radiator
l purpos
at
om
cooler
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
er - V.A.G 1274/8-
an
d
itte
y li
⇒ page 180 . erm
ab
ility
❑ With coolant tempera‐
ot p
wit
ture display sender -
is n
h re
G32- .
ole,
spec
urposes, in part or in wh
2 - Spring-type clip
t to the co
❑ Hose clip pliers - VAS
6340- or hose clip pliers
- VAS 6362- are recom‐
rrectne
mended for installation
of spring-type clips.
ss
3 - Coolant line
o
cial p
f in
❑ Coolant hose schematic
form
mer
atio
m
4 - Retaining clip
o
n
c
i
or
n thi
e
5 - T piece
t
sd
iva
o
r
❑ To heat exchanger
p
cum
r
fo
en
ng
6 - Connection
t.
yi Co
op py
❑ Removing and installing
t. C rig
gh ht
yri
with coolant tempera‐ p by
co Vo
ture sender - G62-
by lksw
cted agen
Prote
⇒ page 196
AG.
7 - Y-thermostat
8 - Coolant pipe
9 - Coolant line
❑ 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.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
equipment required
erm
ab
ility
ot p
wit
V.A.G 1274 B-
, is n
h re
hole
spec
tester - V.A.G 1274/8-
es, in part or in w
t to the co
♦ Adapter for cooling system
tester - V.A.G 1274/9-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Test prerequisite
• Engine is at operating temperature
• Perform leakage test of cooling system using cooling system
tester - V.A.G 1274- and adapters adapter - V.A.G 1274/8- and
adapter - V.A.G 1274/9- .
Test sequence:
WARNING
DANGER!
If pressure drops:
AG. Volkswagen AG d
agen oes
– Find leaks and rectify. olksw not
byV gu
ara
d
Check pressure relief valve in filler cap horise nte
eo
aut ra
– Screw cap into adapter for cooling system tester
s - V.A.G
s c
1274/9- .
ce
e
nl
pt
du
an
itte
y li
erm
ab
system tester - V.A.G 1274/9- .
ility
ot p
wit
, is n
h re
tester - V.A.G 1274 B- using connecting hose supplied.
hole
spec
– Using hand pump on cooling system tester, build up a pres‐
es, in part or in w
t to the co
The pressure relief valve must not open.
rrectness of i
If the pressure relief valve opens prematurely:
l purpos
– Renew cap.
– Increase pressure to over 1.6 bar.
nf
ercia
o
The pressure relief valve must open.
rm
m
atio
m
n in
or c
thi
– Renew cap.
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
Draining ility
ot p
wit
, is n
h re
WARNING
hole
spec
es, in part or in w
t to the co
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Remove spring-type clip -2- and pull lower coolant hose -1- off
radiator -3-.
rrectness
Note
o
cial p
f inform
Observe environmental regulations for disposal.
mer
atio
om
n
Filling
c
i
or
n thi
te
sd
iva
o
r
Caution
p
cum
r
fo
en
ng
t.
yi Co
Only distilled water may be used for mixing with coolant addi‐ Cop py
tives. The use of distilled water ensures optimum protection
t. rig
gh ht
yri
against corrosion.
p by
co Vo
by lksw
cted agen
Prote AG.
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ The coolant concentration must not be reduced by adding wa‐
ility
ot p
wit
, is n
h re
hole
spec
weather conditions, the coolant additive content can be in‐
es, in part or in w
t to the co
creased. But only to 60 %, or the antifreeze protection will be
reduced again and the cooling effect will be impaired.
♦ ONLY refractometer - T10007 A- may be used for determining
rrectness of i
current anti-freeze density.
l purpos
atio
om
n in
c
thi
te
sd
a
o
r
rp
cu
m
f
en
ng
t.
yi
-25 °C 40 % 5.0 l 7.5 l
Co
op py
-36 °C 50 % 6.25 l 6.25 l
t. C rig
gh ht
pyri by
Vo
co
3) The quantity of coolant can vary depending upon vehicle equipment. by lksw
cted agen
Prote AG.
Procedure:
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
186
AG.
Rep. gr.19 - Cooling
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
3 - Bolt
un
pt
an
d
itte
❑ 15 Nm
y li
erm
ab
valve)
wit
is n
h re
spec
⇒ page 191 .
urposes, in part or in wh
t to the co
5 - O-ring
❑ Renew after removing
rrectne
6 - Coolant pump
❑ Removing and installing
s
⇒ page 190 .
s o
cial p
f in
7 - Bolt
form
mer
❑ 15 Nm
atio
om
8 - Oil sump
c
i
or
n thi
te
9 - Bolt
sd
iva
o
pr
❑ 15 Nm
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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- .
❑ For continued coolant AG. Volkswagen AG d
agen oes
ksw
circulation pump - V51-
by
Vol not
gu
ara
wiring harness. rised
nte
tho eo
6 - Continued coolant
ss
au circula‐ ra
c
tion pump - V51-
ce
le
un
pt
❑ Removing and installing
an
d
itte
y li
⇒ page 198 .
rm
ab
pe
ility
7 - Coolant hose
ot
wit
, is n
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
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.
7 - Coolant hose
❑ From cylinder head
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
– Remove underbody guard, if fitted ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody guard .
– 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.
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
ility
Coolant pump sealing plug faces downwards.
ot p
wit
, is n
h re
– Install toothed belt ⇒ page 107 .
hole
spec
es, in part or in w
– Replenish coolant ⇒ page 182 .
t to the co
– Install underbody guard, if fitted previously ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody guard .
rrectness of i
Specified torques
l purpos
nf
ercia
o
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 105
rm
m
atio
om
n in
2.5 Removing and installing 4/2-way valve with thermostat
or c
thi
te
sd
iva
o
r
rp
cu
Special tools and workshop
o
m
f
en
ng
equipment required
t.
yi Co
Cop py
t.
♦ Refractometer - T10007 A-
rig
gh ht
pyri by
Vo
co
♦ Torque wrench (5…50 Nm)
by lksw
cted agen
Prote
- V.A.G 1331-
AG.
Removing
– Remove underbody guard, if fitted ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody guard .
Note
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
t to the co
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Caution
Note
– 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
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
– Detach connector -1- for Hall sender - G40- . s
ce
e
nl
pt
du
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐
an
itte
y li
ing and installing alternator .
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
– Remove coolant hoses -1- at coolant pipe branch-off -2-.
for
en
ng
t.
yi Co
– Remove oil filter bracket ⇒ page 151 . . Cop py
rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Loosen clamp for coolant hose -1- and pull off coolant hose
-1-.
– Loosen clamp for coolant pipe -4- and pull coolant pipe -4- out
at union -2-.
– Unscrew securing bolt -3- for coolant pipe bracket.
Note
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
h re
ole,
– Pull valve out of cylinder block and then to the left to separate
connection -C- from coolant pipe.
rrectne
Installing
s
f inform
mer
Note
atio
om
n
c
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
pt
an
d
y li
erm
ab
– Install underbody guard, if fitted previously ⇒ General body
ility
ot p
wit
is n
h re
ole,
Specified torques
spec
urposes, in part or in wh
t to the co
way valve)”, page 187
♦ ⇒ “5.1 Assembly overview - intake manifold”, page 354
rrectne
2.6 Removing and installing coolant temper‐
ss
ature sender - G62-
o
cial p
f inform
Special tools and workshop equipment required
mer
atio
m
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
– Briefly open filler cap for coolant expansion tank in order to
reduce pressure in cooling system.
– Remove underbody guard, if fitted ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody guard .
– Drain coolant ⇒ page 182 .
Note
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Hose clamps up to 25 mm - 3094-
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– 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.
n AG. Volkswagen A
2.8 Removing and installing continued
Vol
ksw
age coolant circulation
G do
es n
ot g pump - V51-
by ua
ed ran
oris tee
th
Special tools and workshop au
or
ac
equipment required ss
ce
le
un
pt
♦ Hose clamps up to 25 mm -
an
d
itte
y li
3094-
rm
ab
pe
ility
♦ Torque wrench (5…50 Nm)
ot
wit
, is n
- V.A.G 1331-
h re
hole
spec
es, in part or in w
6362-
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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- .
pt
y li
rm
ab
ility
ot
wit
Specified torques
, is n
h re
hole
t to the co
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
199
cted agen
Prote AG.
2. Coolant pump, regulation of cooling system
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
AG. Volkswagen AG d
agen
♦ Hose clip pliers - VAS 6340- Volksw
oes
not
by gu
d ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
– Briefly open filler cap for coolant expansion tank in order to
l purpos
a
com
tion in
– Remove spring-type clip -1- with hose clip pliers - VAS 6340- .
r
te o
thi
do
r
rp
cum
en
ng
t.
yi Co
Installing t. Cop py
rig
gh ht
Installation is carried out in the reverse order; note the following: pyri by
Vo
o
by c lksw
cted agen
– Check coolant level ⇒ page 182 . Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
Removing
ab
ility
ot p
spec
escaping coolant.
t to the co
– Unscrew bolt -4- and remove circulation pump - V55- -1- with
bracket.
m
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io
Installing
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Cop py
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pe
ility
V.A.G 1274/9- .
ot
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es, in part or in w
7 - Connector
8 - Bolt t to the co
❑ 5 Nm
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9 - Expansion tank
l purpos
er - V.A.G 1274/8-
com
tion in
⇒ page 180 .
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te o
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10 - Bolt Cop py
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❑ 5 Nm
ht
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11 - Radiator cowl with radiator fan - V7-
agen
Prote AG.
14 - Spring-type clip
❑ Hose clip pliers - VAS 6340- or hose clip pliers - VAS 6362- are recommended for installation of spring-
type clips.
15 - Bolt
❑ 1.2 Nm
16 - Bracket
❑ For continued coolant circulation pump - V51- .
17 - Bolt
❑ 4.5 Nm
18 - Continued coolant circulation pump - V51-
19 - Coolant hose
❑ Coolant hose schematic diagram ⇒ page 175 .
20 - Bracket
21 - Radiator outlet coolant temperature sender - G83- agen
AG. Volkswagen AG d
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❑ Coolant hose schematic diagram ⇒ page 175 . d by
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22 - Bracket ut
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23 - Spring-type clip
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24 - Radiator lower mounting
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Prote AG.
1 - Radiator
2 - Radiator fan
3 - Bolt
❑ 5 Nm
4 - Bolt
❑ 5 Nm
5 - Locking lug
❑ Must be engaged in ra‐
diator.
6 - Radiator cowl
AG. Volkswagen AG d
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pt
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ab
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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 .
Caution
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• Do not bend oredstretch the refrigerant lines excessively.
by ua
ran
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o
• During further
auth removal work, make sure that the refriger‐e or a
ant linesssare not bent or stretched excessively. c
ce
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un
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itte
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ab
ility
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spec
cooler. When doing so, take the radiator -2- past the refrigerant
urposes, in part or in wh
lines.
t to the co
rrectne
Note
s
f inform
♦ Undo and remove bolt -2- on right and left (not shown in illus‐
mer
tration) at radiator.
atio
om
n
c
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or
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Installing
te
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fo
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t.
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Cop py
t. rig
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pyri by
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co lksw
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Prote AG.
Note
– Insert radiator mounting into lock carrier -2- at bottom -1-, do‐
ing so transversely to the direction of travel, and then turn it
90".
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tho
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un
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an
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itte
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erm
ab
ility
ot p
– Insert top radiator mountings -1- on right and left into the
wit
is n
h re
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
– When installing the radiator, make sure that the catches -1- of
or
n thi
e
the radiator mounting on the left and right at the top have en‐
t
sd
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cum
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fo
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t.
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Caution Cop py
t. rig
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pyri by
The screw-type clips on the charge air lines must always be
co Vo
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cted agen
tightened to 5.5 Nm. If the torque is too low or too high, the Prote AG.
charge air hose may slip off the charge air pipe during vehicle
operation.
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nl
Caution
pt
du
an
itte
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erm
ab
• Do not bend or stretch the refrigerant lines excessively.
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
50 ; Lock carrier .
rrectness of i
Specified torques
l purpos
nf
ercia
or
♦ ⇒ “3.2 Assembly overview - radiator cowl and radiator fan V7
m
m
atio
”, page 204
om
n in
or c
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sd
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t.
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Removing t. Cop py
rig
gh ht
– Remove underbody guard, if fitted ⇒ General body repairs, yri
p by
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exterior; Rep. gr. 66 ; Underbody guard .
c by lksw
cted agen
Prote AG.
– Unclip coolant hose -1- from brackets -2-.
– Unscrew securing bolts -3- for radiator cowl -4-.
AG. Volkswagen AG d
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un
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ab
wit
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spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
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t.
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Cop py
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rig ht
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co Vo
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208
Prote AG.
Rep. gr.19 - Cooling
Amarok 2011 ➤
AG.4-cylinder diesel
Volkswagen AG do engine (2.0 l engine, common rail) - Edition 04.2013
agen es n
olksw ot g
y V ua
– Unscrew bolts ris
ed -arrows- and remove radiator fan -1-.
b ran
tee
tho
or
Installing s au ac
s
ce
e
pt
du
an
itte
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erm
ab
repairs, exterior; Rep. gr. 66 ; Underbody guard .
ility
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wit
Specified torques
, is n
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hole
spec
”, page 204
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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t.
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Cop py
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rig ht
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ab
⇒ “1.3 Engine is running”, page 211
pe
ility
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hole
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es, in part or in w
Caution
t to the co
Irreparable damage to high-pressure components, especially
the high-pressure pump, due to lack of lubrication though die‐
rrectness of i
sel can occur when filling fuel tank with incorrect fuel. Damage
l purpos
nform
mercia
a
com
tio
Here are the solutions for two different cases of filling with incor‐
n in
r
rect fuel:
te o
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♦ 1. 1st case: filling with incorrect fuel was detected BEFORE
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⇒ page 210 .
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Cop py
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♦ 2. 2nd case: filling with incorrect fuel was detected AFTER
rig
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starting the engine. Impurities or incorrect type of fuel has en‐ op Vo
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tered the fuel system and has reached the high-pressure cted agen
Prote AG.
system ⇒ page 211 .
– Thoroughly clean area around filler neck -1- on fuel tank -4-.
– Loosen clamp -2- for connecting hose -1- of filler neck on fuel
tank -4- and pull connecting hose off.
– Extract fuel with fuel extractor - VAS 5190- via the opening.
– Re-attach connecting hose -1- of filler neck to fuel tank, using
clamp -2-. wage
n AG. Volkswagen AG do
es ks not
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d by ara
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ris
tho eo
au ra
c
ss
ce
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nl
pt
du
an
itte
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erm
ab
– Press the circlip to release the fuel line and then detach the
ility
ot p
wit
, is n
h re
hole
line -3-.
spec
es, in part or in w
t to the co
– Connect ⇒ Vehicle diagnostic tester and carry out “Check
electric fuel pump(s)”.
rrectness of i
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Note
nf
ercia
orm
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or c
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– Fill fuel tank with 5 litres of diesel fuel. Then, carry out “Guided
t
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ty the tank. cu
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– Reconnect fuel supply line. Cop py
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– Fill fuel tank completely with diesel fuel. p by
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by c lksw
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– Perform road test. Prote AG.
ce
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– Extract fuel with fuel extractor - VAS 5190- via the opening. un
pt
an
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itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Press the circlip to release the fuel line and then detach the
rrectne
fuel supply line -3-.
s
– Connect pressure gauge pipe -VAS 6550/1- to the fuel supply
s o
line -3-.
cial p
f inform
– Guide open end of line into a suitable container.
mer
atio
m
n
c
i
electric fuel pump(s)”.
or
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sd
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Note
en
ng
t.
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op py
Fuel pump is now activated for 30 seconds.
t. C rig
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pyri by
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co lksw
by
cted
– Repeat this procedure until fuel tank is completely empty.
agen
Prote AG.
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pt
du
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itte
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erm
ab
ility
Note
ot p
wit
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♦ The adapter lines/leads 1 to 4 listed below are not required for
hole
spec
the test.
es, in part or in w
t to the co
♦ Hose - VAS 6551/1-
♦ Hose - VAS 6551/2-
rrectness of i
♦ Test lead - VAS 6551/3-
l purpos
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Note
atio
om
n in
or c
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Test prerequisites
• Fuses must be OK.
• Battery voltage at least 12 V
• Ignition switched off
• There must be at least 10 l of fuel in the fuel tank.
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
AG. Volkswagen AG d
• The fuel lines must not be kinked or damaged. lksw
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WARNING uthor eo
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Fuel supply lines are under pressure! Wear eye protection and
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pt
du
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itte
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fore loosening hose connections, wrap a cloth around the
erm
ab
connection. Then release pressure by carefully pulling hose off
ility
ot p
connection.
wit
, is n
h re
hole
Procedure spec
es, in part or in w
t to the co
WARNING
rrectness of i
at
io
in t
r
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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by
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Prote AG.
ce
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un
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erm
ab
ility
ot p
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is n
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ole,
spec
– Connect pressure tester - VAS 6551- -1- with hoses from
urposes, in part or in wh
t to the co
– Connect hose -VAS 6551/2- as well as connection fitting -VAS
6551/5-1- from adapter set - VAS 6551/5- to fuel supply line
rrectne
-3- and connection -A - of pressure tester - VAS 6551- .
– Open shut-off tap -A-.
ss o
– Connect hose »-2« from adapter set - VAS 6551/5- to open
cial p
f in
connection on high-pressure pump -2- and connection -B- of
form
mer
atio
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n
c
i
or
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– Switch on pressure tester - VAS 6551- by pressing on/off
te
sd
va
pushbutton.
i
o
pr
cum
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fo
en
t.
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op py
– Connect ⇒ Vehicle diagnostic tester to test instrument box -
. C rig
ht ht
rig
VAS 6356- . py by
co Vo
by lksw
cted agen
– Activate fuel pump using guided function “Fuel pump activa‐
Prote AG.
tion”.
– The fuel pump is activated.
• Specification: ≥ 3.5 bar.
If the specified value is not reached: check fuel low-pressure
ahead of fuel filter ⇒ page 218 .
♦ If the pressure ahead of fuel filter is “OK”:
♦ Renew fuel filter ⇒ page 239 .
Note
Note
AG. Volkswagen AG d
agen oes
olksw not
To perform test, ⇒ Vehicle diagnostic tester d b may be used in con‐
y V gu
ara
junction with test instrument box - VAS horis6356-
e
. nte
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s a c
s
Special tools and workshop equipment required
ce
le
un
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an
♦ Pressure gauge - VAS 6551- d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
Fuel supply lines are under pressure! Wear eye protection and
itte
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protective clothing to avoid eye injuries and skin contact. Be‐
erm
ab
fore loosening hose connections, wrap a cloth around the
ility
ot p
connection. Then release pressure by carefully pulling hose off
wit
is n
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connection.
ole,
spec
urposes, in part or in wh
t to the co
Procedure
rrectne
WARNING
ss
on the fuel system ⇒ page 8 .
o
cial p
f inform
♦ Always follow these rules for cleanliness and instructions
mer
atio
om
n
c
i
or
n thi
the fuel system, then carefully loosen the connection to
te
sd
a
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note p by
co Vo
by lksw
cted agen
Prote AG.
Collect escaping fuel with a cleaning cloth.
– 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
pt
y li
rm
Specification: ≥ 550 ml
ab
pe
ility
ot
wit
, is n
spec
fuel filter
es, in part or in w
t to the co
Note
rrectness of i
the test.
♦ Hose - VAS 6551/1-
nform
ercia
a
com
tio
thi
do
r
rp
cum
fo
en
ng
t.
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op
Note C py
t. rig
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pyri by
Vo
To perform test, use ⇒ Vehicle diagnostic tester in conjunction
co lksw
by
cted agen
with test instrument box - VAS 6356- . Prote AG.
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Adapter set - VAS 6551/5-
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
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f
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Cop py
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rig ht
py by
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by lksw
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♦ Vehicle diagnostic tester Prote AG.
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
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
pt
an
itte
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erm
ab
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.
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nl
pt
– Open shut-off tap -A- of pressure tester - VAS 6551- .
du
an
itte
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– Connect hose »-4« from adapter set - VAS 6551/5- to open
erm
ab
ility
connection on fuel filter and connection -B- of pressure tester
ot p
wit
- VAS 6551- .
, is n
h re
hole
– Open shut-off tap -B- of pressure tester - VAS 6551- .
spec
es, in part or in w
– Close shut-off tap -C- of pressure tester - VAS 6551- .
t to the co
– Switch on pressure tester - VAS 6551- by pressing on/off
pushbutton.
rrectness of i
– Connect ⇒ Vehicle diagnostic tester or laptop, vehicle diag‐
l purpos
nf
ercia
orm
tion”.
m
atio
om
n in
– The fuel pump is activated.
or c
thi
te
sd
iva
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cu
o
m
f
en
ng
t.
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Note
Co
Cop py
t. rig
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♦ If the specification has been reached and the fuel low-pressure cop Vo
by lksw
on the high-pressure pump has not been checked yet, the fuel cted agen
Prote AG.
low-pressure downstream of fuel filter must be checked.
♦ If the fuel low-pressure on the high-pressure pump has already
been checked and the specification has not been reached, re‐
new fuel filter ⇒ page 239 .
Note
ce
le
un
pt
• Specification: ≥ 3.5 bar.
an
d
itte
ab
pe
ility
ot
h re
hole
spec
t to the co
Note
rrectness of i
the test.
♦ Hose - VAS 6551/1-
nform
ercia
a
com
tio
thi
do
r
rp
cum
fo
en
ng
t.
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op
Note C py
t. rig
gh ht
pyri by
Vo
o
To perform test, ⇒ Vehicle diagnostic tester may be used in con‐ by c lksw
cted agen
junction with test instrument box - VAS 6356- . Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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au ra
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un
pt
♦ Vehicle diagnostic tester
an
d
itte
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erm
ab
♦ Laptop, vehicle diagnosis (remote head) - VAS 6150 A-
ility
ot p
wit
♦ Instrument box - VAS 6356-
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
sd
iva
o
pr
Test prerequisites
um
r
fo
en
ng
t.
• Fuses must be OK.
yi Co
Cop py
t. rig
• Battery voltage at least 12 V
gh ht
pyri by
Vo
co lksw
by
• Ignition switched off Prote
cted AG.
agen
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
ce
e
nl
pt
du
an
itte
y li
– Collect escaping fuel with a cleaning cloth.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– 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
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3 Fuel tank
⇒ “3.1 Assembly overview - fuel tank”, page 226
AG. Volkswagen AG d
⇒ “3.2 Assembly overview - fuel lines”, page 228 lkswagen oes
not
o
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⇒ “3.3 Removing and installing fuel tank”,ripage
se d b 229 ara
nte
tho eo
⇒ “3.4 Removing and installing filler neck”,
au page 232 ra
c
ss
ce
e
3.1 Assembly overview - fuel tank nl
pt
du
an
itte
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erm
ab
Caution
ility
ot p
wit
, is n
h re
The fuel pump must not be allowed to run when the fuel tank
hole
spec
is empty, as this may cause deflagrations.
es, in part or in w
t to the co
The fuel tank must contain at least 5 litres of fuel.
rrectness of i
1 - Seal
l purpos
❑ Renew if damaged.
❑ Moisten with fuel when
nf
ercia
o
installing
rm
m
atio
m
2 - Union nut
o
n in
or c
thi
te
sd
a
o
r
rp
3217- .
cu
o
m
f
en
ng
❑ 110 Nm
t.
yi Co
Cop py
3 - Supply line ht. rig
rig ht
py by
❑ For vehicles with addi‐
co Vo
by lksw
cted
tional heater ⇒ Rep. gr.
agen
Prote AG.
82 .
❑ Check for secure seat‐
ing.
4 - Spring-type clip
❑ Check for secure seat‐
ing.
5 - Connecting hose
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 .
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
wage es n
21 - Protective cover Vol
ks ot g
d by ua
❑ For bottom oforfuel ise tank.
ran
tee
th or
❑ Depending s a on equipment.
u ac
s
ce
e
22 - Supply line
nl
pt
du
an
y li
erm
ab
wit
h re
hole
or
atio
m
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
line are marked with arrows on fuel gauge sender flange.
un
pt
an
d
itte
y li
erm
ab
ility
Note ot p
wit
is n
h re
After installing fuel gauge sender, check whether fuel supply and
ole,
spec
return lines are still clipped onto fuel tank.
urposes, in part or in wh
t to the co
3.2 Assembly overview - fuel lines
rrectne
1 - Supply line
ss o
❑ To high-pressure pump
cial p
f inform
❑ Check for secure seat‐
mer
ing.
atio
om
n
c
2 - Return line
i
or
n thi
e
❑ From high-pressure
t
sd
iva
o
pump.
pr
cum
r
fo
en
ng
t.
yi Co
ing. t. Cop py
rig
gh ht
3 - Fuel temperature sender - yri
p by
o Vo
G81-
c by lksw
cted agen
Prote AG.
❑ Fitting location
⇒ page 307
4 - Bracket
5 - Return line
❑ From the injectors
❑ Check for secure seat‐
ing.
6 - Return line
❑ Check for secure seat‐
ing.
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.
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
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.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
229
cop Vo
by lksw
Prote
cted AG.
agen 3. Fuel tank
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
ce
e
pt
du
an
itte
y li
– Extract fuel with fuel extractor - VAS 5190- via the opening.
erm
ab
ility
ot p
wit
, is n
h re
– Unbolt protective cover on bottom of fuel tank
hole
spec
es, in part or in w
t to the co
Continuation for all vehicles:
– Support fuel tank with engine and gearbox jack - V.A.G 1383
A- .
rrectness of i
l purpos
Note
m
at
om
io
in t
or
his
ate
do
riv
– Unscrew bolt -arrow- for securing fuel tank -1- on left cross
p
cum
or
member.
f
en
ng
t.
yi Co
– Loosen securing straps in succession: . Cop py
rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Unscrew bolt -arrow- for front securing strap -2- for fuel tank
-1-.
– 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:
ce
le
un
pt
an
d
itte
– Loosen clamp -2- for connecting hose -1- of filler neck on fuel y li
rm
ility
ot
wit
, is n
spec
es, in part or in w
Note
t to the co
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
– Unclip fuel lines -2 and 3- from fuelodelivery
lksw
age unit -1-. es n
ot g
yV ua
– Carefully lower fuel tank. db ran
ir se tee
ho
ut or
Installing ss
a ac
ce
le
pt
an
d
itte
y li
rm
ab
Caution
pe
ility
ot
wit
, is n
The fuel pump must not be allowed to run when the fuel tank
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Push hose -1- of filler neck onto connection on fuel tank -3-.
l purpos
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Push on breather line -3- and engage securely. cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Removing
urposes, in part or in wh
t to the co
– Remove fuel tank ⇒ page 229 .
– Unscrew bolt -2- for filler neck -1- on underbody.
rrectne
– Open tank flap and clean inside tank flap unit thoroughly.
– Unscrew cap.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
– Unscrew bolt -2- from tank flap unit. opyri
gh by
Vo
ht
c
– Unclip tank flap unit and remove completely.
by lksw
cted agen
Prote AG.
– Unscrew nuts -2- from filler neck -1- at top of tank flap unit cut-
out.
– Remove filler neck -1- from below; filler neck must be turned
when doing this.
Installing
Installation is carried out in the reverse order; note the following:
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Installing fuel tank:
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
– Push hose -1- of filler neck onto connection on fuel tank -3-.
te
sd
iva
o
r
cum
r
fo
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
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.
Continuation for all vehicles:
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
h re
spec
urposes, in part or in wh
Installing
t to the co
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
spec
es, in part or in w
Installing
Installation is carried out in the reverse order; note the following:
rrectness of i
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
⇒ “5.2 Removing and installing fuel filter”, page 239
pt
du
an
itte
y li
⇒ “5.3 Checking fuel filter”, page 239
erm
ab
ility
ot p
5.1 Assembly overview - fuel filter
wit
, is n
h re
hole
spec
1 - Supply line es, in part or in w
t to the co
❑ From fuel tank
❑ Check for secure seat‐
ing.
rrectness of i
2 - Supply line
l purpos
❑ To high-pressure pump
nform
ercia
at
om
io
3 - Fuel filter
n
c
in t
or
his
ate
complete.
do
priv
cum
or
en
g
⇒ page 239 .
n
t.
yi Co
op py
❑ Checking ⇒ page 239 .
t. C rig
gh ht
pyri by
Vo
4 - Gasket
co lksw
by
cted agen
Prote
❑ Renew if damaged.
AG.
Note
Installing
Install in reverse order.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
♦ Hose - VAS 6551/3-
hole
spec
es, in part or in w
atio
n in
thi
te
sd
iva
WARNING
r
rp
cu
o
m
f
en
ng
t.
yi
Fuel supply lines are under pressure! Wear eye protection and
Co
Cop py
protective clothing to avoid eye injuries and skin contact. Be‐ ht. rig
rig ht
fore loosening hose connections, wrap a cloth around the py by
co Vo
connection. Then release pressure by carefully pulling hose off
by lksw
cted agen
Prote
connection.
AG.
Procedure
ce
le
un
pt
before starting work and while working on the fuel system.
an
d
itte
y li
♦ Wrap a clean cloth around the connection before opening
rm
ab
pe
ility
the fuel system, then carefully loosen the connection to ot
wit
release the pressure.
, is n
h re
hole
spec
es, in part or in w
t to the co
– Collect escaping fuel with a cleaning cloth.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
line -VAS 6551/3- to open end of fuel filter.
Co
Cop py
t. rig
gh ht
– Connect connection -B- of pressure tester - VAS 6551- to‐ yri
p by
o Vo
gether with line -VAS 6551/4- to open line of high-pressure
c by lksw
cted agen
pump.
Prote AG.
ce
le
un
pt
– Connect connection -B- of pressure tester - VAS 6551- to‐
an
d
itte
y li
gether with line -VAS 6551/4- to open line of fuel tank.
rm
ab
pe
ility
– Switch on pressure tester - VAS 6551- by pressing On/Off
ot
wit
, is n
button.
h re
hole
spec
– Close shut-off tap “C” of pressure tester - VAS 6551- .
es, in part or in w
t to the co
– Carefully open shut-off valves -A- and -B-.
– Start engine.
rrectness of i
• Take specification reading: at least 3.5 bar on pressure tester
- VAS 6551-
l purpos
If specification is attained:
nform
ercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
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
Note
ce
le
un
pt
Special tools and workshop equipment required
an
d
itte
y li
♦ Pressure tester - VAS 6551-
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
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
AG. Volkshose
wagenoff
AG do
agen
connection. Volksw es n
ot
by gu
ara
ed nte
oris eo
th
Procedure ss
au ra
c
ce
e
nl
pt
du
an
WARNING
itte
y li
erm
ab
ility
♦ Read rules for cleanliness and the instructions for working
ot p
wit
on the fuel system ⇒ page 8 .
, is n
h re
hole
spec
before starting work and while working on the fuel system.
es, in part or in w
t to the co
♦ Wrap a clean cloth around the connection before opening
the fuel system, then carefully loosen the connection to
release the pressure.
rrectness of i
l purpos
nf
ercia
Note
orm
m
atio
m
n in
vehicle.
or c
thi
te
sd
iva
cu
o
m
f
en
ng
t.
yi Co
op py
Note
. C rig
ht ht
rig by
copy Vo
by lksw
To do this, press catches on hose couplings. Prote
cted AG.
agen
– 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
Fuel pump is now activated for 30lkseconds.
swa
gen A oes
not
Vo gu
d by ara
e nte
– Carefully open shut-off horvalve
is
-C- completely. eo
aut ra
– Slowly close the shut-off
ss tap -C- again while reading the pres‐ c
ce
e
pt
du
y li
erm
ab
wit
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Test prerequisites
Volkswa
• At RT = room temperature or a fuel stemperature
agen
AG. of Tge=n (20
AG do+-
es n
k w
5) °C . by
Vol ot g
ua d ran
ise
• At a pressure of 5 ± 0.2 bar
tho at flange output
r tee
or
au ac
• ss
During the checking process, there must be voltages of 11 to
ce
e
pt
du
an
the delivery unit.
itte
y li
erm
ab
• If these voltages are not achieved, the fuel pump must be
ility
ot p
wit
, is n
h re
– Carry out in the guided function “Checking electronic fuel
hole
spec
pump(s)”
es, in part or in w
t to the co
*) Amount of fuel delivered in ml/30 s.
**) Voltage across fuel delivery unit (V) with engine at a standstill
and with pump running.
rrectness of i
Example:
l purpos
nf
ercia
orm
m
atio
m
n in
or c
sd
o
r
rp
cu
m
f
en
ng
Note
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
♦ Vehicle diagnostic tester auth or
ac
ss
Test prerequisites
ce
e
nl
pt
du
an
• Fuses must be OK.
itte
y li
erm
ab
• Battery voltage must be at least 12 V, if necessary connect a
ility
ot p
battery charger.
wit
, is n
t to the co
• Visual check of cables OK.
Procedure:
rrectness of i
l purpos
Note
connector from the flange of the fuel pump unit ⇒ page 229
rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
247
Prote AG.
6. Fuel pump
Amarok 2011 ➤
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 AG. gen AG
agen does
7.1 Function db
yV
olksw not
gu
ara
rise nte
With the EPC system, the throttle valve is unot
tho operated by a cable eo
ra
from the accelerator There is no mechanical
ss a connection between c
the accelerator and the throttle valve.
ce
le
un
pt
an
d
Position of accelerator is transmitted to engine control unit by two
itte
y li
accelerator position senders (variable resistors together in one
erm
ab
ility
housing) connected to accelerator.
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
sitioner) in throttle valve module over full range of engine speeds
and load conditions.
rrectne
Throttle valve is operated by throttle valve positioner which is
controlled by engine control unit .
ss
When the engine is not running and the ignition is switched on,
o
cial p
f
the engine control unit moves the throttle valve exactly as pre‐
inform
scribed by the accelerator position sender . This means that when
mer
atio
m
opens the throttle valve to the same extent. The throttle valve is
o
n
c
i
then approx. half open.
or
n thi
te
sd
va
When the engine is running (under load), the engine control unit
i
o
pr
c
can open or close the throttle valve independently of the accel‐
um
r
fo
en
ng
1 - Bearing bracket
❑ Removing and instal‐
ling: ⇒ Rep. gr. 46 .
2 - Connector
❑ 6-pin
3 - Nut
❑ 9 Nm
4 - Accelerator position sender
- G79-
❑ Not adjustable.
❑ The accelerator position
sender - G79- transmits
the driver's input to the
engine control unit
❑ Remove footwell cover
to remove sender. gen AG. Volkswagen AG
wa does
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
21 – Turbocharging/supercharging
1 Charge air system
⇒ “1.1 Assembly overview - charge air system”, page 250
⇒ “1.2 Removing and installing charge air cooler”, page 251
. Volkswagen AG
a gen AG does
⇒ “1.3 Removing and installing intake air temperature sender
Vol
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gu
with charge air pressure sender G31 ”, page 254 ed by ara
nte
is
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⇒ “1.4 Removing and installing exhaust gas aflap
ut
h
valve N220 ”, ra
page 255 ss c
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un
pt
⇒ “1.5 Checking charge air system for leaks”, page 256
an
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ility
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Caution
ole,
spec
urposes, in part or in wh
t to the co
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.
rrectne
Assembly of hose connections ⇒ page 11 .
ss o
cial p
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mer
atio
om
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or
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pyri by
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Prote AG.
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1 - Clamp
un
pt
an
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itte
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ab
structions ⇒ page 11 .
ility
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2 - Bolt
is n
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ole,
❑ 2 Nm
spec
urposes, in part or in wh
t to the co
sender - G42- with charge air
pressure sender - G31-
❑ Removing and installing
rrectne
⇒ page 254 .
s
4 - O-ring
s o
cial p
f
❑ Renew if damaged or
inform
leaking.
mer
atio
5 - Connecting hose
om
n
c
i
❑ Note installation posi‐
or
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sd
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6 - Connecting hose
um
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fo
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ng
t.
❑ Note installation posi‐
yi Co
op
tion ⇒ page 251 .
C py
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7 - Charge air cooler
op Vo
by c lksw
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❑ Removing and installing
Prote AG.
⇒ page 251 .
8 - Connecting hose
❑ Note installation posi‐
tion ⇒ page 251 .
9 - Turbocharger
10 - Intake manifold
ce
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nl
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du
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ab
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hole
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es, in part or in w
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♦ Socket set 1/4", 22-piece - VAS 5528-
rrectness of i
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at
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ion
c
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ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
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Removing
ht
pyri by
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co lksw
by
cted
– Remove bolts -2- for securing radiator to lock carrier -1-.
agen
Prote AG.
– Unclip right catch as well and pull condenser -3- off radiator
-1-.
Caution
Note
Installing
Installation is carried out in the reverse order; note the following:
Note
AG. Volkswagen AG d
agen oes
olksw no
Before installing radiator,
ed by Vcheck that radiator mountings t-1- gu are
ara
correctly seated on horfront
is part of car -2- and, if necessary, reposi‐
nte
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tion: s aut ra
c
s
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le
un
pt
an
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erm
ab
ility
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ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Insert radiator mounting into lock carrier -2- at bottom -1-, do‐
ing so transversely to the direction of travel, and then turn it
90".
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
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ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
– When installing the radiator, make sure that the catches -1- of
t to the co
the radiator mounting on the left and right at the top have en‐
gaged completely in the lock carrier.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Insert top radiator mountings -1- on right and left into the
f
en
ng
t.
yi
mounting on radiator -2- appropriately.
Co
Cop py
t. rig
gh
– Install radiator cowl ⇒ page 207 .
ht
pyri by
Vo
o
by c lksw
– Filling with coolant ⇒ page 182 cted agen
Prote AG.
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.
n AG. Volkswagen AG do
Installing olkswage es n
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Installation is carried out in the reverse order; note the ir sefollowing:
d ran
tee
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or
Specified torques ss
au ac
ce
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pt
du
an
itte
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erm
ab
1.4 Removing and installing exhaust gas
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
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ng
t.
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♦ Socket set 1/4", 22-piece - VAS 5528-
Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
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.
AG. Volkswagen AG d
agen oes
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♦ Adapter - V.A.G 1687/10- ised b ara
nte
or eo
h
♦ Engine bung set - VAS aut6122- ra
ss c
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nl
pt
du
an
itte
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erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
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l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
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f
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
256
cted agen
Prote AG.
Rep. gr.21 - Turbocharging/supercharging
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-.
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
f inform
mer
Note
atio
om
n
c
To turn the pressure regulating valve -2- the knob must be pulled
i
or
n thi
upwards.
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Connect compressed air hose -1- (compressed air supply) toagen AG. Volkswagen AG d
charge air system tester - V.A.G 1687- , using a standard Vocon‐
lksw
oes
not
gu
necting piece. ed by ara
n ris tee
utho or
a ac
ss
Note
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nl
pt
du
an
itte
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erm
ab
ility
ot p
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, is n
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hole
spec
Caution
es, in part or in w
t to the co
The pressure must not exceed 0.5 bar! If the pressure is too
high, this can cause damage to the charge air system.
rrectness of i
l purpos
at
ion
c
in t
r
♦ By listening
o
his
ate
do
riv
♦ By feeling
p
cum
for
en
g
t.
yi Co
Cop py
♦ or with ultrasonic tester - V.A.G 1842- .
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
259
agen
Prote AG.
2. Turbocharger
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
AG. Volkswagen AG d
agen oes
2.1 Assembly overview - turbocharger, 120 kW and 132 kW engines byV
olksw not
gu
ara
ed
ris nte
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aut ra
Note ss c ce
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un
pt
an
d
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ab
ility
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wit
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t to the co
♦ Before screwing on oil pressure line, fill turbocharger with engine oil through union.
♦ After installing turbocharger, allow engine to run at idling speed for about 1 minute to ensure that oil is
supplied to turbocharger.
rrectness of i
l purpos
1 - Heat shield
2 - Bolt
nform
ercia
❑ 9 Nm
m
a
com
3 - Vacuum unit
ion in
r
thi
⇒ page 321 .
s
iva
do
r
rp
cum
en
ng
eter - G584-
t.
yi Co
op py
❑ Removing and installing
. C rig
ht ht
rig
⇒ page 278 . py by
co Vo
by lksw
cted agen
5 - Nut Prote AG.
❑ 9 Nm
6 - Exhaust gas temperature
sender 1 - G235-
❑ Grease thread of sender
using high-temperature
paste ⇒ Electronic
Parts Catalogue (ET‐
KA) .
ce
le
un
pt
an
d
itte
8 - Gasket
y li
erm
ab
❑ Renew after removing
ility
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is n
h re
ole,
spec
urposes, in part or in wh
t to the co
❑ Always renew oil return line when it has been removed or opened in area of hose connection.
❑ Check oil supply lines for damage before installing them ⇒ Item 16 (page 261) .
rrectne
❑ Note tightening sequence and installation procedure ⇒ page 263 .
❑ When turbocharger and connecting pipes are being assembled, it is essential that the correct repair kit
ss
f i
10 - Bracket
n
c
i
or
n thi
e
11 - Bolt
t
sd
iva
o
pr
en
ng
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
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.
AG. Volkswagen AG d
agen
23 - Bolt olksw
oes
not
byV gu
❑ 11 Nm rised ara
nte
ho eo
ut
24 - Gasket ss a ra
c
❑ Renew after removing
ce
le
un
pt
an
d
itte
25 - Bolt
y li
rm
ab
❑ 15 Nm
pe
ility
ot
wit
, is n
27 - Clip
t to the co
28 - Bolt
❑ 9 Nm
rrectness of i
29 - Pulsation damper
l purpos
30 - O-ring
nform
ercia
a
com
tion in
31 - Banjo bolt
r
te o
thi
❑ 30 Nm
s
iva
do
r
rp
32 - Seal
um
fo
en
ng
t.
❑ Renew after removing
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Installation position
horis of connecting hose at turbocharger nte
eo
aut ra
– Fit connecting
ss hose in such a way that the “rib” -1- of the con‐ c
necting hose is aligned with the middle of the nameplate -2-.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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r
rp
cu
o
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Turbocharger 263
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Note
ce
e
nl
pt
du
an
itte
y li
1 - Turbocharger
erm
ab
ility
❑ Renew complete only.
ot p
wit
, is n
h re
be removed before re‐
hole
spec
moving ⇒ page 250 .
es, in part or in w
t to the co
❑ Check oil pressure lines
for damage before in‐
stalling them.
rrectness of i
❑ Note tightening se‐
quence and installation
l purpos
nform
ercia
at
om
ion
c
in t
or
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e
do
riv
logue) is used.
p
cum
or
❑ Installation position of
f
en
ng
t.
yi
connecting hose at tur‐
Co
op py
bocharger ⇒ page 264 t. C rig
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❑ Removing and installing cop Vo
by lksw
⇒ page 272 . cted agen
Prote AG.
2 - Bolt
❑ No replacement part
available
3 - Position sender for charge
pressure positioner - G581-
4 - Heat shield
5 - Bolt
❑ 9 Nm
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
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
❑ Supply and return. lkswage es n
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yV ua
❑ Oil pressure line must be
ir serenewed after removing turbocharger. ant
d b r
ee
ho
aut or
ac
Note ss
ce
e
nl
pt
du
y li
ab
ility
ot p
after removing.
h re
hole
spec
ling turbocharger.
♦ Removing and installing
rrectness of i
⇒ page 170 .
l purpos
17 - Bolt
18 - Seal
nform
ercia
at
om
io
19 - Banjo bolt
n
c
in t
or
❑ 32 Nm
his
ate
do
riv
20 - Seal
p
cum
for
en
g
t.
yi Co
op py
21 - O-ring t. C rig
gh ht
yri by
❑ Renew after removing cop Vo
by lksw
cted agen
Prote AG.
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
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Installation position of connecting hose at turbocharger
hole
spec
es, in part or in w
– Fit connecting hose in such a way that the “rib” -1- of the con‐
t to the co
necting hose is aligned with the middle of the nameplate -2-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
Caution Cop
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py
t. rig
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When a mechanical fault is found on the turbocharger, e.g. a pyri by
Vo
co
destroyed compressor impeller, it is not only sufficient to renew
by lksw
cted agen
Prote
the turbocharger. To avoid subsequent damage, the following
AG.
2. Turbocharger 267
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
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.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Loosen screw-type clip -3- for front exhaust pipe -1-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
– Undo and remove bolts -3- for front exhaust pipe -2- at bracket
for
en
g
-1-.
n
t.
yi Co
Cop py
– Carefully remove front exhaust pipe upwards out of the engine
t. rig
gh ht
yri
compartment.
p by
co Vo
by lksw
cted agen
Prote AG.
– Loosen screw-type clip -2- for connecting hose -1- and detach
connecting hose from pulsation damper.
Note
Note
pt
du
an
itte
ab
G447- -1-.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Remove bolts -2 and 3- for pipe -1- from exhaust gas recircu‐
m
at
lation cooler.
om
ion
c
in t
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his
ate
do
riv
cum
for
en
ng
t.
yi Co
Caution
t. Cop py
rig
gh ht
yri by
• Avoid damage to oil supply line. Observe notes.
cop Vo
by lksw
cted agen
Prote AG.
• When doing this, ensure that no pressure is exerted on the
rod.
• Do not hold onto the rod when removing the turbocharger.
• When carrying the turbocharger, always hold it by the
pipes and not by the rods.
Bent rods impair the functioning of the turbocharger.
2. Turbocharger 269
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - oEdition
lksw
04.2013
AG. V agen AG
agen does
lksw not
– Undo and remove bolts -2- for oil return line db
yat
V bottom of tur‐
o gu
ara
bocharger -1-. rise nte
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c
s
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Undo and remove bolt -2- for turbocharger -1- at lower bracket.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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– Release and detach connector -1- of exhaust gas temperature
op Vo
by c lksw
sender 1 - G235- on front right wheel housing -3- at the cou‐
cted agen
Prote AG.
pling point -2-. Then, free wiring harness from fittings and lay
it to one side.
– Undo and remove bolts -1- to -8- for exhaust manifold with
turbocharger.
– Remove turbocharger with exhaust manifold upwards.
– 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
olksw not
byV gu
ar
d
– Check oil supply risline -arrow- for damage after installing ante
e
o
th 261) . eo
⇒ Item 16 (page
au ra
c
ss
– Install connecting pipes ⇒ page 250 .
ce
e
nl
pt
du
an
itte
y li
erm
Caution
ab
ility
ot p
wit
, is n
spec
es, in part or in w
t to the co
Specified torques
♦ ⇒ “2.1 Removing and installing assembly mountings”,
rrectness of i
page 31
l purpos
at
om
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Turbocharger 271
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Caution
atio
m
♦ Check the whole charge air path and charge air cooler for
o
n in
c
foreign objects.
or
thi
te
sd
a
If foreign objects are found in the charge air system, the charg‐
iv
o
r
rp
cu
ed air routing must be cleaned and the charge air cooler must
o
m
f
en
be renewed, if necessary.
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
“Turbocharger” is removed upwards.
cop Vo
by lksw
cted agen
Prote AG.
For removal of the “turbocharger”, the following parts must first
be removed:
ce
le
⇒ page 11 .
un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
♦ After lines and hoses have been removed, the open connec‐
hole
spec
tions are to be sealed immediately with a plug from the engine
es, in part or in w
t to the co
♦ Only use clean plugs.
rrectness of i
– Remove air filter with attachments ⇒ page 368
l purpos
nform
ercia
-4- at turbocharger.
m
a
com
– Unscrew and remove bolts -3- in bracket for front exhaust pipe
-4-. tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– 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
– 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
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
– Remove bolts -2 and 3- for pipe -1- from exhaust gas recircu‐
wit
, is n
h re
lation cooler.
hole
spec
t to the co
Caution
rrectness of i
a
com
thi
s
iva
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Loosen clamp -2- on oil pressure line pipe -1- and separate oil
pressure line.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Turbocharger 275
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
– Remove nuts -1- to -8- for exhaust manifold with turbocharger.
ility
ot p
wit
is n
h re
ole,
wards.
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
m
– Undo and remove bolts -1- in bracket for coolant pipe -2- and
o
n
c
i
remove exhaust manifold gasket -3-.
or
n thi
te
sd
a
Installing
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
op
– Renew all gaskets, O-rings and self-locking nuts.
C py
t. rig
gh ht
yri by
– Install turbocharger with new oil pressure line. cop Vo
by lksw
cted agen
Prote AG.
– Fit new seals -2- onto the respective line connection -3- and
secure by screwing in the corresponding banjo bolt -1-.
– Install connecting pipes ⇒ page 250 .
Caution
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
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
Note
l purpos
at
io
nently to vehicle.
n
c
in t
or
his
ate
do
priv
cum
or
Note
f
en
ng
t.
yi Co
Cop py
♦ After lines and hoses have been removed, the open connec‐
t. rig
gh ht
yri
tions are to be sealed immediately with a plug from the engine
p by
co Vo
by lksw
bung set - VAS 6122- . cted agen
Prote AG.
2. Turbocharger 277
olkswagen AG
en AG. V
Amarok 2011 ➤ ksw
ag does
not
Vol
4-cylinder diesel engine (2.0 l engine,
ed by common rail) - Edition 04.2013gu
ara
ris nte
utho eo
– Release and pull connector -4-ss aoff charge air pressure sender ra
c
2 - G447- -1-.
ce
e
nl
pt
du
an
– Unscrew bolts -2- on bracket for charge air pressure sender 2
itte
y li
- G447- .
erm
ab
ility
ot p
– Remove banjo bolt -3- from turbocharger and remove charge
wit
, is n
air pressure sender 2 - G447- complete.
h re
hole
spec
Installing
es, in part or in w
t to the co
Install in reverse order.
rrectness of i
l purpos
nf
ercia
or
for turbocharger, 120 kW engine
m
m
atio
om
n in
or c
thi
e
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Special tools and workshop Cop py
equipment required
t. rig
gh ht
pyri by
Vo
o
♦ Hand vacuum pump - VAS
c by lksw
cted agen
6213- or hand vacuum
Prote AG.
Note
Removing
– Detach vacuum hose -2- from upper toothed belt guard -1-.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
– Detach hoses from connecting hose -3- bracket -arrow-.
erm
ab
ility
ot p
– Release and pull off wiring harness connector -2-. Detach wir‐
wit
, is n
h re
hole
spec
– Open clips -1- and -4-.
es, in part or in w
t to the co
– Remove connecting hose -3-.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Turbocharger 279
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
s a ac
– Detach connector -2- from charge air pressure sender 2 -
s
ce
e
G447- -1-.
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Undo and remove bolts -2- securing bracket for charge air
pressure sender 2 - G447- -1- and place charge air pressure
nform
ercia
at
om
in t
or
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Undo and remove bolts -2- securing heat shield -1- and re‐
move heat shield.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
– Working from below, undo and remove nuts securing regulat‐
n
c
in t
or
cum
or
en
ng
t.
gether with bracket. Cop
yi Co
py
t. rig
Installing gh ht
pyri by
Vo
co lksw
by
Installation is carried out in the reverse order; note the following: Prote
cted AG.
agen
Caution
Use only new bolts and nuts from the spare-parts kit if the reg‐
ulating flap potentiometer - G584- is being replaced complete‐
ly!
New part
– If necessary, remove lower nut securing the control rod of the
new regulating flap potentiometer - G584- .
Note
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
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
– Install regulating flap potentiometer - G584- and guide control
utho eo
ra
a
rod -1- through adjusting lever on turbocharger as shown ss in c
the illustration.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Fit regulating flap potentiometer - G584- on the turbocharger
l purpos
mounting with new nuts from the spare-parts kit -4- and tighten
nuts to 8 Nm.
nf
ercia
o
– Screw nuts -2- onto control rod by hand in direction of vacuum
rm
m
atio
unit.
om
n in
or c
thi
te
sd
a
Note
iv
o
r
rp
cu
o
m
f
en
ng
Make sure that the guiding element -1- of the flap lever moves
t.
yi Co
easily along the control rod. Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
– Attach connector -1- to regulating flap potentiometer - G584-
an
itte
y li
-2-.
erm
ab
ility
ot p
Connect ⇒ Vehicle diagnostic tester.
wit
, is n
h re
Selecting operating mode:
hole
spec
– Press button on display for “Vehicle self-diagnosis”.
es, in part or in w
t to the co
Selecting vehicle system:
– Press button “01 - Engine electronics” on display.
rrectness of i
The display indicates the control unit identification and the coding
l purpos
nform
ercia
at
om
io
– The display shows the individual components.
n
c
in t
or
his
e
do
riv
cum
for
en
g
t.
yi Co
uum pump - VAS 6213- or hand vacuum pump - V.A.G. 1390- Cop py
ht. rig
to vacuum connection -1- of regulating flap potentiometer - py
rig by
ht
G584- using a T-piece to do so. co Vo
by lksw
cted agen
Prote
Switch on turbocharger tester - V.A.G 1397A- and move sliding
AG.
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
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
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
– Tighten securing bolts -2- for heat shield -1-.
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
Note
iva
o
r
rp
cu
o
m
f
t.
yi Co
for replacing the vacuum unit. t. Cop py
rig
gh ht
pyri by
Removing
co Vo
by lksw
cted agen
Prote AG.
– Remove pipe -arrow- from cylinder head cover.
2. Turbocharger 285
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Undo nuts of vacuum unit -1- and remove vacuum unit -2-.
Installing
Installation is carried out in the reverse order; note the following:
Caution
ce
e
nl
pt
du
an
itte
y li
erm
ab
charger.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Fit vacuum unit -2- in place and fit nuts -1-, tighten nuts to 8
t to the co
Nm.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
en
ng
t.
yi
unit.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
Note Prote
cted AG.
agen
Make sure that the guiding element of the flap lever moves easily
along the control rod.
2. Turbocharger 287
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Caution
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
– Screw nut -3- in direction of vacuum unit until it is touching the
an
d
itte
y li
flap lever, while applying a tightening torque of 8 Nm to the
erm
ab
lock nut -2- at the same time.
ility
ot p
wit
is n
h re
ole,
Note
spec
urposes, in part or in wh
t to the co
Make sure that control rod -1- does not turn by counterholding on
the nut -3-.
rrectne
– Reduce vacuum again and apply a vacuum of 390 ± 10 mbar
to vacuum unit again.
ss o
cial p
f in
Note
form
mer
atio
m
Flap lever must now be resting against the stop (closed position).
o
n
c
i
or
n thi
te
sd
a
o
pr
cum
r
fo
en
ng
t.
yi Co
Note t. Cop py
rig
gh ht
yri by
The check must be repeated at least 3 to 5 times in order to ensure cop Vo
by lksw
that the vacuum unit has been set precisely and in order to avoid
cted agen
Prote AG.
possible damage to the turbocharger.
Note
The dial gauge rod and the control rod of the vacuum unit must
be in line with each other.
ce
le
un
pt
and repeat the measurement until the setting agrees with the
an
d
itte
y li
specified values.
erm
ab
ility
ot p
– Secure securing nut and lock nut with sealing paint from the
wit
spare-parts kit.
is n
h re
ole,
spec
urposes, in part or in wh
– Press retaining clip from spare-parts kit onto control rod and
turn 90° in the -direction of the arrow-.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
en
ng
t.
yi Co
Further assembly is carried out in the reverse order of removal. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Turbocharger 289
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
290
Prote AG.
Rep. gr.21 - Turbocharging/supercharging
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Removing
– Remove pipe -arrow- from cylinder head cover.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Release and pull off wiring harness connector -2-. Detach wir‐
ing harness -2- from connecting hose retainer -3-.
rrectness of i
– Open clips -1- and -4-.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
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.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
– Loosen and completely unscrew securing nut -2- for control
du
an
itte
rod.
y li
erm
ab
ility
– Counterhold lock nut -3- with open-end spanner.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
at
charger (3 nuts).
om
ion
c
in t
r
his
te
do
priv
cum
or
Installing
f
en
ng
t.
yi Co
Installation is carried out in the reverse order; note the following: Cop py
t. rig
gh ht
pyri by
Vo
co
Caution
by lksw
cted agen
Prote AG.
Use only new bolts and nuts from the replacement-parts kit if
the regulating flap potentiometer - G584- is being renewed
completely!
New part
– If necessary, remove lower securing nut on control rod of new
regulating flap potentiometer - G584- .
Note
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
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
– Install regulating flap potentiometer - G584- and
aut guide control ra
c
rod -1- through adjusting lever on turbocharger
ss
as shown in
ce
e
illustration.
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
– Screw securing nut -2- onto control rod by hand in direction of
m
atio
m
vacuum unit.
o
n in
or c
thi
te
sd
iva
Note
o
r
rp
cu
o
m
f
en
ng
Make sure that the guiding element -1- of the flap lever moves
t.
yi Co
op
easily along the control rod.
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Turbocharger 293
AG. Volkswagen AG d
agen oes
olksw not
Amarok 2011 ➤ d by
V gu
ara
e nte
4-cylinder diesel engine (2.0 l engine, commonhoris
rail) - Edition 04.2013 eo
aut ra
ss c
– Attach connector -1- to regulating flap potentiometer - G584-
ce
e
nl
-2-.
pt
du
an
itte
y li
Connect ⇒ Vehicle diagnostic tester.
erm
ab
ility
ot p
Selecting operating mode:
wit
, is n
h re
– Press button on display for “Vehicle self-diagnosis”.
hole
spec
es, in part or in w
Selecting vehicle system:
t to the co
– Press button “01 - Engine electronics” on display.
The display indicates the control unit identification and the coding
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of the engine control unit.
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– The display shows the individual components.
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uum pump - VAS 6213- or hand vacuum pump - V.A.G. 1390-
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switch on device to position II.
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Note
Make sure that control rod -1- does not turn by counterholding on
nut -2-.
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.
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– Press
ss a securing clip from replacement-parts kit onto control
c rod
and turn 90° in -direction of arrow-.
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2. Turbocharger 295
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
AG. Volkswagen AG d
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2.7.2 Removing and installing vacuum unit for turbocharger
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Special tools and workshop s
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♦ Universal dial gauge brack‐
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♦ Hand vacuum pump - VAS , is n
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6213- or hand vacuum
hole
spec
pump - V.A.G. 1390- .
es, in part or in w
t to the co
♦ Turbocharger tester -
V.A.G 1397A-
♦ Dial gauge set, 4-part - VAS
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6341-
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Note
Removing
– Remove pipe -arrow- from cylinder head cover.
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– Undo and remove bolts -2- securing heat shield -1-.
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2. Turbocharger 297
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Caution
Note
– Fit vacuum unit -2- in place and fit nuts -1-, tighten nuts to 8
Nm.
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vacuum unit.
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Note
spec
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Make sure that the guiding element of the flap lever moves easily
along the control rod.
rrectness of i
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The following adjusting work must be carried out with extreme erm
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care and precision as, otherwise, there is a risk that the turbo‐
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charger will be damaged.
, is n
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spec
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– Move flap lever -4- on turbocharger in -direction of arrow- to
“Closed” position.
rrectness of i
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– Screw nut -3- in direction of vacuum unit until it is touching the
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Note
The control rod -1- must not turn. Therefore, counterhold on se‐
curing nut -3-.
Note
Flap lever must now be resting against the stop (closed position).
Note
2. Turbocharger 299
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Note
The dial gauge rod and the control rod of the vacuum unit must
align with each other.
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– Secure securing nut and lock nut with sealing paint from re‐
ility
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placement-parts kit.
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spec
– Press securing clip from replacement-parts kit onto control rod
urposes, in part or in wh
t to the co
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Further assembly is carried out in the reverse order of removal.
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♦ Socket set 1/4", 22-piece - VAS 5528-
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Removing
– Pull connector -2- and vacuum lines off charge pressure con‐
trol solenoid valve - N75- -1-.
– Remove spreader rivet -3- and charge pressure control sole‐
noid valve - N75- -1-.
Installing
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
WARNING
pt
total of 3 times in this case. The process must not be termi‐ an
d
itte
nated prematurely.
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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 . AG. Volkswagen AG d
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3 - Fuel temperature sender - d by V gu
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4 - High-pressure pump ss a c
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⇒ page 347 .
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5 - Fuel metering valve - N290-
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DANGER!
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Valve
• must not be re‐
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moved.
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separate part.
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7 - High-pressure accumulator
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(fuel rail)
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ate
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G247-
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❑ Removing and installing
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⇒ page 365 . t. C rig
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9 - Restrictor
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❑ Cannot be renewed separately
AG.
10 - Injectors
❑ Injector, cylinder 1 - N30-
❑ Injector, cylinder 2 - N31-
❑ Injector, cylinder 3 - N32-
❑ Injector, cylinder 4 - N33-
❑ Removing and installing ⇒ page 327 .
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N33-
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❑ Fitting location
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⇒ 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-
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❑ Fitting location ⇒ page
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14 - Engine controlthunit
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❑ Fitting location
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⇒ page 306 ac
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15 - Intake air temperature sender - G42- with charge air pressure sender - G31-
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16 - High-pressure pump
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19 - Exhaust gas recirculation valve - N18- with exhaust gas recirculation potentiometer - G212-
❑ Fitting location ⇒ page 307
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21 - Radiator outlet coolant temperature sender - G83-
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❑ Fitting location ⇒ page 311
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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 Atemperature sender
G. Volkswagen A 2 - G448-
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❑ Installed in exhaust manifold/turbocharger.
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E - Exhaust gas temperature sender t3ho-ri G495- tee
or
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❑ Fitting location ⇒ Item 5 (page
ss 377)
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H - Particulate filter
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2- Glow plug 2 - Q11-
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Mounting locations on top of engine (continued)
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Intake air temperature sender - G42- with charge air pressure
urposes, in part or in wh
sender - G31-
t to the co
1- Intake air temperature sender - G42- with charge air pres‐
sure sender - G31-
rrectne
2- Connector
ss o
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2- Vacuum hose
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Brake light switch on brake master cylinder
aut - F- ra
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Brake light switch - F- with brake pedal switch - F47- -1- is fitted
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1.3 Assembly overview - fuel system ss c
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WARNING
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♦ Read through the rules for cleanliness and the instructions
, is n
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for working on the fuel system ⇒ page 7 .
hole
spec
♦ Always follow these rules for cleanliness and instructions
es, in part or in w
t to the co
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
rrectness of i
still empty.)
♦ The engine must not be run when the fuel return line is
nf
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and to ensure that the engine starts quickly after parts have been
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♦ If components of fuel system between fuel tank and high-pres‐
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sure pump are unbolted, removed or renewed, “Bleeding fuel py by
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system” function must be carried out to bleed fuel system us‐
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ing ⇒ Vehicle diagnostic tester.
AG.
1 - Return line
❑ From high-pressure
pump.
❑ General diagram of fuel
lines leading to engine
⇒ page 228
2 - Supply line
❑ To high-pressure pump.
❑ General diagram of fuel
lines leading to engine
⇒ page 228
3 - Bolt
❑ 10 Nm
4 - Hose
❑ Connection to return
lines of the injectors
5 - Hose
❑ Around high-pressure
accumulator (fuel rail) AG. Volkswagen AG d
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6 - Return line olksw not
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❑ To fuel tank. orise nte
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7 - Supply line ss a c
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❑ To high-pressure pump
nl
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8 - Return line
erm
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❑ To fuel filter
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9 - High-pressure line
h re
hole
❑ Between high-pressure
spec
es, in part or in w
Note
m
at
om
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in t
or
checks:
do
priv
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or
en
ng
t.
sure line for deformation and
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cracks.
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♦ The line hole must not be de‐
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❑ Cannot be re-installed.
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❑ 80 Nm
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❑ Removing and installing ⇒ page 362 .
ility
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15 - O-ring
h re
hole
spec
es, in part or in w
t to the co
❑ Do not interchange!
❑ When removing and installing, always renew the following components and seals/O-rings: “copper seal”
rrectness of i
⇒ Item 17 (page 313) and ⇒ Item 19 (page 313) , “O-ring for injector bore”, ⇒ Item 15 (page 313) , “O-
ring for injector return connection” ⇒ Item 15 (page 313) and “bolt for clamping plate”
l purpos
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e.g. transverse scores or corrosion. Always renew if damaged.
rm
m
atio
❑ If piezo injectors, high-pressure lines ⇒ Item 9 (page 312) and clamping plates ⇒ Item 20 (page 313)
om
which were removed are to be reinstalled, they must always be re-fitted in their original positions (i.e. on
n in
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17 - Copper washer
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❑ Renew after removing C py
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18 - O-ring op Vo
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❑ Renew after removing Prote AG.
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
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26 - High-pressure line
pt
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❑ Secured with 3 clamps ⇒ Item 10 (page 312)
erm
ab
❑ Between high-pressure pump and high-pressure accumulator (fuel rail)
ility
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ole,
spec
urposes, in part or in wh
t to the co
re-used after the following
checks:
rrectne
♦ Check taper seat of high-pres‐
sure line for deformation and
cracks.
ss o
cial p
f
♦ The line hole must not be de‐
inform
formed, constricted or damaged.
mer
atio
♦ Corroded lines should no longer
om
n
be used.
c
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❑ 30 Nm
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❑ With fuel metering valve - N290- (must not be opened). Cop py
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❑ After renewing, initial fuel filling must be carried out (never allow the pump to run while it is still empty)
ht
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⇒ page 316 .
c by lksw
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❑ Removing and installing ⇒ page 347 .
28 - Bolt
❑ Renew after removing
❑ 20 Nm +180°
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-
AG. Volkswagen AG d
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Check locks
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spec
es, in part or in w
Caution
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• Carefully pull fuel return lines upwards when disconnect‐
ing as the 4 catches -arrow- can fracture.
rrectness of i
• After disconnecting, check the 4 catches -arrow- to see
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nf
ercia
orm
• A damaged fuel return line that becomes loose when en‐
m
atio
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c
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• The engine must not be run when the fuel return line is
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urposes, in part or in wh
DANGER!
t to the co
♦ Observe safety precautions when working on the injection
system ⇒ page 4 .
rrectne
♦ Observe rules for cleanliness ⇒ page 8 .
ss
Follow these instructions before starting work and while work‐
o
cial p
f i
ing on system.
nform
mer
atio
om
n
– Allow engine to idle for a few minutes but do not accelerate.
c
i
or
n
Then switch off engine again. (Fuel system will bleed itself au‐
thi
te
sd
a
tomatically).
iv
o
pr
cum
r
fo
t.
yi Co
op
Renew the affected component if leakage still occurs after tight‐ C py
ht. rig
ening to the correct torque. rig ht
py by
co Vo
by lksw
– Then, road-test the vehicle for more than 20 km. Accelerate cted agen
Prote AG.
with full throttle at least once.
Note
If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off engine, erase event memory and then continue
road test.
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.
Note
ce
e
nl
pt
du
an
itte
y li
Proceed as follows to fill high-pressure pump with fuel.
erm
ab
ility
ot p
wit
, is n
h re
– Connect ⇒ Vehicle diagnostic tester, and carry out function
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
This process takes 130 seconds. Fuel pumps are actuated a total
of 3 times in this case. The process must not be terminated pre‐
l purpos
maturely.
nform
ercia
at
om
ion
c
in t
or
his
te
do
priv
cum
or
en
ng
t.
entry. Cop
yi Co
py
t. rig
– Then, road-test the vehicle for more than 20 km. Accelerate gh ht
yri by
with full throttle at least once.
op Vo
by c lksw
cted agen
Prote AG.
Note
♦ If there is any air left in the fuel system, the engine may switch
to the backup mode ('emergency running' mode) during the
road test. Switch off the engine and erase the fault memory.
Then continue road test.
♦ Then check high-pressure part of fuel system again for leak‐
age.
2 Vacuum system
⇒ “2.1 Schematic diagram - vacuum system”, page 318
⇒ “2.2 Testing vacuum system for leaks”, page 321
AG . Volkswage
⇒ “2.2.1 Checking vacuum hoses ksw
leading
agen to non-return
n AG d
ovalve,
es n
l
solenoid valves N220 and N75by V changeover valve N345 ”, ot gu
o
ara
page 322 ris
ed
nte
ho eo
ut
⇒ “2.2.2 Checking svacuum
sa hose leading to changeover valve for ra
c
exhaust gas recirculation cooler N345 ”, page 324
ce
e
nl
pt
du
an
⇒ “2.2.3 Checking vacuum hose to vacuum unit on turbocharger”,
itte
y li
page 324
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
2.1 Schematic diagram - vacuum system
es, in part or in w
t to the co
Caution
rrectness of i
Do not kink, twist or crush the vacuum lines when routing. This
l purpos
nform
ercia
connection piece.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
hose to vacuum unit
an
d
itte
⇒ page 320
y li
erm
ab
ility
6 - T-piece
ot p
wit
is n
h re
ole,
spec
pump.
urposes, in part or in wh
t to the co
❑ Connection of vacuum
hose to T-piece
⇒ page 320
rrectne
7 - Regulating flap potentiom‐
eter - G584-
ss
❑ With vacuum unit with
o
cial p
f
potentiometer
inform
mer
❑ On turbocharger.
atio
m
❑ Connection of vacuum
o
n
c
n thi
te
sd
o
pr
en
ng
t.
yi
8 - Vacuum line
Co
Cop py
ht. rig
❑ Fastened with cable ties rig ht
py by
co Vo
by lksw
9 - Cylinder head cover Prote
cted AG.
agen
❑ Vacuum reservoir is installed in cylinder head cover. Both parts can only be renewed together.
❑ Connection of vacuum hose to cylinder head cover ⇒ page 320
10 - Exhaust gas flap valve - N220-
❑ 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
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
– Fit and tighten bolt holding bracket with valves -1- to top of air
spec
filter housing -2-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
Installation of vacuum lines on engine on right-hand side
or
his
ate
do
riv
cum
gas recirculation.
for
en
ng
t.
yi
2- Connect vacuum hose to regulating flap potentiometer -
Co
Cop py
G584- .
t. rig
gh ht
pyri by
Vo
o
3- Connect vacuum hose of recirculation valve leading to cyl‐ by c lksw
cted agen
inder head cover.
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or
♦ Hand vacuum pump - VAS 6213-
aut
h eo
ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Caution
nform
ercia
Do not kink, twist or crush the vacuum lines when routing. This
m
at
ion
c
in t
r
his
e
connection piece.
at
do
priv
cum
for
en
ng
t.
yi
Checking vacuum hoses to non-return valve, exhaust gas flap
Co
Cop py
valve - N220- , charge pressure control solenoid valve - N75- ,
t. rig
gh ht
yri
changeover valve for exhaust gas recirculation cooler - N345- and p by
o Vo
by c lksw
vacuum reservoir ⇒ page 322 Prote
cted AG.
agen
ce
e
-N75- changeover valve -N345-
nl
pt
du
an
itte
y li
erm
Test procedure
ab
ility
ot p
wit
, is n
h re
hole
spec
– Pull vacuum hose -2- off at outer connection of charge pres‐
es, in part or in w
t to the co
– Pull vacuum hose -6- off at outer connection of changeover
valve for exhaust gas recirculation cooler - N345- -5-.
rrectness of i
– Connect hand vacuum pump - VAS 6213- to the 3 valves one
l purpos
nf
ercia
orm
m
atio
• Vacuum must not drop.
om
n in
or c
If vacuum drops:
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
– Seal vacuum hoses -2, 3 and 6- with clean bungs from engine
Co
op py
bung set - VAS 6122- .
t. C rig
gh ht
pyri by
Vo
– Seal connecting piece -2- with a clean bung from engine bung
co lksw
by
cted agen
set - VAS 6122- . Prote AG.
ce
le
• Vacuum must not drop.
un
pt
an
d
itte
y li
If vacuum drops:
erm
ab
ility
ot p
– Locate damage or leaking vacuum hose connection. To do
wit
this, pull individual vacuum hoses off from relevant connection
is n
h re
and check for leak to connected component.
ole,
spec
urposes, in part or in wh
t to the co
– Pull off vacuum hoses -1- and -2- at connector -arrow- and
check non-return valve and vacuum hose to exhaust gas re‐
circulation cooler changeover valve - N345- .
rrectne
– Locate damage or leaking vacuum hose connection.
– Renew non-return valve or leaking vacuum hose.
ss o
cial p
f
– Reconnect all vacuum hoses to valves and to union -arrow-.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
ce
e
pt
du
an
itte
y li
erm
ab
for approx. 30 seconds.
ility
ot p
wit
• Vacuum must not drop.
, is n
h re
hole
If vacuum drops:
spec
es, in part or in w
t to the co
rrectness of i
– Pull vacuum hose -arrow- off regulating flap potentiometer -
G584- . Seal opening of vacuum hose with clean bung from
l purpos
atio
n in
thi
te
sd
o
r
rp
cu
If vacuum drops:
o
m
f
en
ng
t.
yi Co
– Renew leaking vacuum hose. Cop py
t. rig
gh ht
yri
If pressure does not drop: p by
co Vo
by lksw
cted agen
– Connect hand vacuum pump - VAS 6213- to potentiometer for Prote AG.
regulating flap - G584- and generate a vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213-
for approx. 30 seconds.
• Vacuum must not drop.
If vacuum drops:
– Replace turbocharger ⇒ page 267 .
ce
e
nl
pt
du
control solenoid valve - N75- -1-.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Connect hand vacuum pump - VAS 6213- to removed vacuum
nform
ercia
hose -2- and generate a vacuum of 0.6 bar.
m
at
– Observe pressure gauge of hand vacuum pump - VAS 6213-
om
ion
for approx. 30 seconds.
c
in t
or
his
te
do
priv
cum
or
If vacuum drops:
f
en
ng
t.
yi Co
– Remove underbody guard, if fitted ⇒ Rep. gr. 66 . t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Pull vacuum hose -1- from vacuum unit -2-. Seal opening of
vacuum hose with clean bung from engine bung set - VAS
6122- .
– Connect hand vacuum pump - VAS 6213- to pulled-off vacuum
reservoir and generate a vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213-
for 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 6213-
for approx. 30 seconds.
• Vacuum must not drop.
If vacuum drops:
– Replace turbocharger ⇒ page 267 .
– 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 6213-
for approx. 30 seconds.
• Vacuum must not drop.
If vacuum drops:
AG. Volkswagen AG d
– Renew leaking vacuum hose. agen oes
olksw not
V gu
d by ara
If pressure does not drop: oris e nte
h eo
ut ra
– Connect hand vacuum pump
ss a - VAS 6213- to vacuum unit and c
generate a vacuum of 0.6 bar.
ce
le
un
pt
an
d
y li
ab
ility
ot p
h re
ole,
If vacuum drops:
spec
urposes, in part or in wh
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
⇒ “3.4 Removing and installing injectors (solenoid valves)”, page
pt
an
d
332
itte
y li
rm
ab
⇒ “3.5 Removing and installing high-pressure lines”, page 338 pe
ility
ot
wit
, is n
h re
page 340
hole
spec
es, in part or in w
t to the co
page 343
rrectness of i
Engine codes Solenoid valves with Piezo injectors with
l purpos
nform
ercia
CDBA, CDCA X
m
a
com
CNEA, CNFA, X
tion in
CSHA
r
te o
thi
s
iva
do
r
rp
cum
fo
en
g
t.
yi Co
Cop py
♦ Vehicle diagnostic tester
t. rig
gh ht
pyri by
Vo
o
Check “injector delivery calibration” adaptation
c by lksw
cted agen
Prote AG.
The function “injector delivery calibration” serves to correct the
injection rates for each cylinder of a common rail system individ‐
ually across the entire map range.
The 7-digit adaptation values -1- (details in illustration are only an
example) are marked separately on each piezo injector. They
may consist of letters and/or numbers (ASCII code).
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Puller - T10402-
Caution
ce
e
nl
pt
du
Removing
an
itte
y li
erm
ab
– Pull off connector -1- at piezo injector to be removed.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
ion
c
in t
or
his
e
Caution
at
do
priv
cum
or
en
ng
t.
yi
ing as the 4 catches -arrow- can fracture.
Co
Cop py
t. rig
gh
• After disconnecting, check the 4 catches -arrow- to see
ht
pyri by
Vo
whether they are fractured or have broken off.
co lksw
by
cted agen
Prote AG.
• 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.
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
wit
Ensure cleanliness. It must be assured that no dirt gets into the
, is n
h re
disconnected fuel return lines or the open connections of the pie‐
hole
spec
zo injectors.
es, in part or in w
t to the co
– Unscrew high-pressure line ⇒ Item 9 (page 312) between
high-pressure accumulator (fuel rail) and injectors to be re‐
moved.
rrectness of i
– Remove bolts ⇒ Item 21 (page 313) of the injectors to be re‐
l purpos
moved.
nform
mercia
a
com
tion in
– Place puller - T10055- with adapter - T10055/1- in position as
r
te o
thi
shown and pull injector out downwards with tapping move‐
s
iva
ments.
do
r
rp
cum
fo
Installing
en
ng
t.
yi Co
op
Installation is carried out in the reverse order; note the following:
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Fit new copper seal -1- on piezo injector -2- with help of as‐
sembly sleeve - T10377- . Use “narrow” side of assembly
l purpos
nf
ercia
damaging O-ring.
orm
m
atio
– Clean sealing surface of injector in cylinder head and injector
om
n in
shaft.
or c
thi
te
sd
iva
o
r
WARNING
rp
cu
o
m
f
en
ng
t.
yi Co
Only cleaning set - VAS 6811- may be used for cleaning seal‐
Cop py
ing surface of injector bore.
t. rig
gh ht
pyri by
Vo
o
For detailed information on how to use the cleaning set as well
by c lksw
cted agen
as the order in which its components are applied, refer to the
Prote AG.
– Connect fuel return line and press the two clips downwards as
far as they will go -arrows-.
AG. Volkswagen
– After fuel return line has been pushed won
agecompletely,
n
press
AG do
es n
olks
the locking bolt downwards -arrow-.
d by V ot g
ua
e ran
ris tee
– Install high-pressure linesu⇒
tho page 338 . or
a ac
ss
ce
le
un
pt
Note
an
d
itte
y li
rm
ab
After renewing one or more injectors, the “injector delivery cali‐
pe
ility
ot
bration” values for the new injectors must be written into the
wit
, is n
spec
es, in part or in w
Specified torques
t to the co
nform
mercia
tion in
noid valves)
r
te o
thi
s
iva
do
r
cum
fo
en
ng
♦ Puller - T10055-
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
♦ Puller -T10415-
rm
ab
pe
ility
ot
Removing
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
♦ Read rules for cleanliness and the instructions for working
on the fuel system ⇒ page 8 .
rrectness of i
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
l purpos
nform
ercia
Caution
m
a
com
tion in
♦ Mark allocation of injectors to cylinders. They must always
r
te o
thi
be re-installed on the same cylinders.
s
iva
do
r
rp
c
♦ Observe rules for cleanliness when working on the injec‐
um
fo
en
g
tion system.
n
t.
yi Co
op py
♦ The open connections must be sealed with a suitable cap.
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Pull return line connections off injectors. To do this, press the
catches -1- and -2- downwards and, at the same time, pull the
release pin upwards -arrow-.
Caution
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Fit puller - T10055- with puller -T10415- and pull injector out
upwards using tapping movements.
Note
ce
le
pt
an
d
itte
y li
♦ O-ring for fuel return connection
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec
urposes, in part or in wh
t to the co
sure lines.
♦ The high-pressure lines may be re-used after the following
checks:
rrectne
♦ Check taper seat of respective high-pressure line for defor‐
s
mation and cracks.
s o
cial p
f i
♦ The line hole must not be deformed, constricted or damaged.
nform
mer
atio
om
n
c
i
or
n
Installing used injectors
thi
te
sd
va
o
pr
cum
r
fo
en
ng
♦ Copper seal
t.
yi Co
Cop py
♦ O-ring 3 for shaft of injector
t. rig
gh ht
pyri by
Vo
o
♦ O-ring for fuel return connection by c lksw
cted agen
Prote AG.
– Spray tip of injector with an rust removal spray. Wait approx.
5 minutes and wipe off soot and oil particles with a cloth.
– If an injector is very dirty, the tip of the nozzle should also be
cleaned with a soft brass wire brush to make it easier to re‐
move the copper seal. Do not apply the wire brush to the bores
in the nozzle.
– To remove the old copper seal from the injector, clamp the seal
carefully in a vice so that it is just held between the jaws without
turning. Then carefully pull and twist the injector out of the
copper seal by hand.
– Use a scraper to clean off the deposits under the copper seal.
– Clean sealing surface of injector in cylinder head and injector
shaft.
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- .
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
If any of the seals for injectors in cylinder head cover are dam‐
aged, replace the affected seal .
Note
pt
du
y li
erm
ab
h re
hole
spec
Note
es, in part or in w
t to the co
Note
m
at
om
ion
If there is any air left in the fuel system, the engine may switch to
c
in t
or
en
ng
t.
yi Co
op
Specified torques
C py
t. rig
gh ht
yri by
♦ ⇒ “1.3 Assembly overview - fuel system”, page 311 cop Vo
by lksw
cted agen
Prote AG.
♦ Socket - T40055-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Removing
ot
wit
, is n
h re
hole
Caution
spec
es, in part or in w
t to the co
able cap.
♦ Do not crush or damage fuel return lines during removal
nform
ercia
or installation.
m
♦ The engine must not be run when the fuel return line is
a
com
tio
thi
s
iva
do
r
rp
cum
fo
t.
yi
high-pressure accumulator (fuel rail) and injectors to be re‐
Co
Cop py
moved. ht. rig
rig ht
py by
o Vo
Installing by c lksw
cted agen
Prote AG.
Installation is carried out in the reverse order; note the following:
Caution
Note
ce
e
nl
pt
pressure accumulator (fuel rail) and injector)
du
an
itte
y li
– Remove new injection line from its packaging. Remove seal‐
erm
ab
ility
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– Proceed in the same way with other injection lines.
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♦ 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.
– 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.
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them click into place. Then press the release pin downwards
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– Filling fuel system ⇒ page 316 .
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Specified torques
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♦ ⇒ “1.3 Assembly overview - fuel system”, page 311
es, in part or in w
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3.6 Removing and installing high-pressure
accumulator (rail)
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– Release connectors -2- and pull them off piezo injectors.
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– Ensure cleanliness. No dirt must be allowed to get into the
ion in
disconnected fuel return lines or the open connections on the
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piezo injectors.
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– Unscrew bolts -2- from high-pressure accumulator (fuel rail).
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– Unclip connector -2- and pull off from fuel pressure regulating
valve - N276- -1-.
– Pull fuel hose -3- from high-pressure accumulator (fuel ail)
-4-.
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Installation is carried out in the reverse order; note the following:
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– Install high-pressure lines (without tension).
h re
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– Observe instructions for installing high-pressure lines
es, in part or in w
⇒ page 338 .
t to the co
– The fuel system must first be filled with fuel before the engine
is started ⇒ page 316 .
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Specified torques
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with engine running
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Special tools and workshop equipment required
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♦ Return flow meter - VAS 6684-
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WARNING
Procedure
WARNING
Note
Note
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The hoses of the return flow meter - VAS 6684- must be of the
itte
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same length.
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press tabs -1- and -2- downwards and simultaneously pull re‐
spec
t to the co
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mer
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n
c
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t.
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Cop py
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Caution
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– Start engine and allow to idle for 3.5 minutes.
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– When the engine is warm and running at idling speed the re‐
h re
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turn flow rates at each of the 4 injectors must not differ by more
spec
than a small amount -1-.
es, in part or in w
t to the co
– If the return flow rate of one injector is significantly higher than
the return flow rate of the other injectors -2-, renew the re‐
spective injector, ⇒ page 328 or ⇒ page 332 .
rrectness of i
Installing
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Note
a
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tion in
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– Carefully fit return lines onto injectors and press down tabs on
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pyri by
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side -arrows- until they engage audibly.
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4 High-pressure pump
⇒ “4.1 Removing and installing high-pressure pump”, page 347
⇒ “4.2 Checking high-pressure pump”,
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page
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4.1 Removingrisand
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installing high-pressure ara
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Caution
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♦ Risk of irreparable damage to high-pressure pump if al‐
ility
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♦ The high pressure pump must be filled with fuel before the
hole
spec
engine is started the 1st time ⇒ page 316 . (It is important
es, in part or in w
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ty.)
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nf
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♦ Puller - T40064-
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or c
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- V.A.G 1331-
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♦ 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-.
– Place removed high-pressure line -1- on a clean
wage
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– Loosen clips from fuel hoses -1- and pull fuel hoses off high-
t to the co
pressure pump.
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mer
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pulley.
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c
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Caution
After new or removed parts such as the fuel filter or fuel lines
have been fitted, the high-pressure pump must be efilled . Vwith
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fuel before the engine is started for the first time.olkAvoid
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♦ If components of the fuel system between the fuel tank and
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itte
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tester ⇒ page 316 .
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minated prematurely.
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– Install toothed belt ⇒ page 107 .
– Install high-pressure lines ⇒ page 338 .
rrectness of i
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Note
nf
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m
atio
♦ Check taper seat of high-pressure line for deformation and
om
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cracks.
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Specified torques t. C rig
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♦ ⇒ “1.3 Assembly overview - fuel system”, page 311
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♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 105
♦ Socket - T40055-
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WARNING
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t.
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4. High-pressure pump
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
Procedure
WARNING
Note
Specified torques
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Component Nm
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High-pressure line on injector rise 30 nte
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High-pressure line on fuel rail s au 30 ra
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If there is fuel in the high-pressure pump tester - VAS 6683- , the
ility
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Installing
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Note
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io
♦ The line hole must not be deformed, constricted or damaged.
n
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and socket - T40055- , tighten high-pressure line to specified Cop py
torque of 30 Nm.
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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
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 n AG. Volkswagen AG do
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9 - Clamp d b ua
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11 - Bolt
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❑ 8 Nm
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❑ Renew if damaged.
hole
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⇒ page 357 .
14 - Bolt
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❑ 8 Nm
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15 - Bolt
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❑ 9 Nm
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16 - Clip
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t. C rig
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Special tools and workshop equipment required
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♦ Socket set, 22 piece - VAS 5528-
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Special tools and workshop equipment required
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♦ XZN 8 bit - T40159- or Torx T 30 bit - T10405- t. Cop py
rig
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agen
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– 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- .
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– Pull connector -2- off throttle valve module - J338- together
pt
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with throttle valve potentiometer - G69- and intake manifold
itte
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– Continue releasing oil dipstick by forcing off the spreader clip
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with removal lever - 80 - 200- .
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Renew all gaskets and seals.
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, is n
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agonal sequence from the inside to the outside with XZN 8 bit hole
- T40159- or Torx T30 bit - T10405- .
spec
es, in part or in w
t to the co
– Observe instructions for installing high-pressure lines
⇒ page 338 .
– Install high-pressure lines (without tension).
rrectness of i
– The fuel system must first be filled with fuel before the engine
l purpos
nf
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orm
♦ ⇒ “5.1 Assembly overview - intake manifold”, page 354
m
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or c
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tiometer - G69- and intake manifold flap
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motor - V157-
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Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1410-
Removing
Observe rules for cleanliness ⇒ page 8 .
Removing screw-type clips ⇒ page 11 .
– 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- .
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– Pull connector -2- off throttle valve module - J338- together
ole,
spec
urposes, in part or in wh
t to the co
– Undo bolts -arrows- and remove throttle valve module - J338-
together with throttle valve potentiometer - G69- and intake
manifold flap motor - V157- -4-.
rrectne
Installing
ss
Installation is carried out in the reverse order; note the following:
o
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Specified torques
mer
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⇒ “6.5 Removing and installing fuel pressure sender G247 ”, page
erm
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365
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- G70-
spec
es, in part or in w
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Special tools and workshop equipment required
♦ Hose clip pliers - VAS 6340-
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– Pull off connector -3- for air mass meter - G70- . Prote AG.
– Loosen screw-type clip -4- and remove intake hose from air
mass meter - G70- .
– 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
important to observe the following notes and instructions. agen
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quantity is calculated.
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– Check for salt residues, dirt and leaves in air mass meter -
G70- and air intake hose (pure air side).
rrectne
– Check intake channel for contamination as far as air filter el‐
ement. If contamination is found, remove salt residues, dirt
and leaves from top and bottom part of air filter housing by
ss
rinsing out or using a vacuum cleaner if necessary.
o
cial p
f inform
Specified torques
mer
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♦ Torque wrench - V.A.G 1410- p by
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Removing
Note
Note
– Release connector -2- and pull off from exhaust gas pressure
sensor 1 - G450- -1-.
– Undo and remove bolt -3- in bracket
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gas pressure sensor 1 - VG450-wag-1-. does
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– 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- .
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late filter)”, page 377
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6.3 Removing and installing fuel pressure
regulating valve - N276-
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ercia
pressure circuit).
m
at
om
If pressure is too high in the fuel high pressure circuit, the regu‐
ion
c
lating valve will open. A small amount of fuel from the high
in t
or
pressure accumulator will thereby make its way back to the fuel his
ate
cum
or
If pressure is too low in the fuel high pressure circuit, the regulat‐
f
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ing valve will close. The valve seals the high pressure side against
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the low pressure side in this way.
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Procedure
co lksw
by
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Prote AG.
Note
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.
Note
Note
Installing
WARNING
agen
AG. Volkswagen AG d
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For vehicles with solenoids,
orise the learnt values from the fuel sys‐ ante
d
tem must be reset following
au
th the renewal of the fuel pressure eo
ra
regulating valve - N276-
ss ⇒ Vehicle diagnostic tester. c
ce
le
un
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an
d
itte
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ility
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Note
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ole,
once. t to the co
♦ Check that sealing surfaces (deformable sealing lip) and
threads on fuel pressure regulating valve - N276- are undam‐
rrectne
aged.
♦ Check the sealing surface of the high-pressure accumulator
ss
hole as well.
o
cial p
f inform
n
c
i
or
n thi
te
sd
iva
o
pr
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t.
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Cop py
t. rig
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co lksw
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Prote AG.
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– Renew seal -1-.
nl
pt
du
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itte
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– Tighten union nut -2- by hand.
erm
ab
ility
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wit
, is n
Note
h re
hole
spec
Connector connection piece must point vertically upwards.
es, in part or in w
t to the co
– Align fuel pressure regulating valve - N276- so that connector
connection piece points vertically upwards.
rrectness of i
– Counterhold at housing hexagon -3- and tighten union nut
l purpos
-2-.
– Bleeding fuel system ⇒ page 316 .
nform
ercia
at
om
ion
c
in t
or
his
ate
do
riv
cum
for
en
g
t.
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once. Check high pressure part of fuel system again for leaks. Cop py
t. rig
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– Read event memory again. p by
co Vo
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Specified torques Prote AG.
WARNING
Procedure
WARNING
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♦ Adhereaustrictly
th to the rules for cleanliness; no dirt muste obe r a al‐
lowedssto get into the disconnected return line and the open c
return line connection.
ce
le
un
pt
an
d
itte
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erm
ab
degreaser before removing them.
ility
ot p
wit
is n
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ole,
spec
– Release spring-type clip -arrow- and pull fuel return hose off
urposes, in part or in wh
fuel rail.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
c
– Seal the open fuel return hose -1- with a clean sealing plug.
um
r
fo
en
ng
t.
yi
– Connect an auxiliary hose -2- to return connection of fuel rail
Co
op py
-3-.
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rig by
py
– Hold auxiliary hose in measuring beaker -4- to measure return
co Vo
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flow rate. Prote AG.
Note
ce
e
nl
pt
du
an
itte
Read through the rules for cleanliness and the instructions for
y li
erm
ab
working on the fuel system ⇒ page 7 .
ility
ot p
wit
, is n
h re
ing on the fuel system.
hole
spec
es, in part or in w
t to the co
– Clean threaded area around the regulating valve with com‐
mercially available degreaser, for example, before removing
it. Under no circumstances may dirt enter the hole of the high-
rrectness of i
pressure accumulator (fuel rail).
l purpos
Note
nf
ercia
orm
Clean carefully; cleaning solvent must not enter the electrical
m
atio
m
connector.
o
n in
or c
thi
te
sd
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.
Note
Installing
Installation is carried outswinagthe
en Areverse
G. Volkswaorder;
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does
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Note utho eo
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ss
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pt
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♦ Check the sealing surface of the high-pressure accumulator
ility
ot p
hole as well.
wit
, is n
h re
♦ Thread of fuel pressure sender - G247- is coated with an anti-
hole
spec
friction lacquer. The thread must therefore be free of oil and
es, in part or in w
grease. t to the co
– Tightening sender.
l purpos
at
ion
c
in t
r
his
ate
do
riv
cum
or
once. Check high pressure part of fuel system again for leaks.
f
en
ng
t.
yi Co
– Read event memory again. t. Cop py
rig
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Specified torques p by
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♦ ⇒ “1.3 Assembly overview - fuel system”, page 311 Prote AG.
7 Air filter
⇒ “7.1 Assembly overview - air filter”, page 368
⇒ “7.2 Removing and installing air filter”, page 370
ce
le
un
pt
an
d
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of air filter.
erm
ab
ility
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wit
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ole,
4 - Bolt
spec
urposes, in part or in wh
t to the co
to lower part of air filter.
❑ 8.5 Nm
rrectne
5 - Water drainage pipe
⇒ page 370
s
❑ Clipped onto lower part
s o
of air filter.
cial p
f inform
❑ Make sure it is mounted
mer
in correct position on
atio
m
longitudinal member
o
n
c
i
or
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❑ Clean if soiled
thi
te
sd
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6 - Filter element
i
o
pr
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fo
t.
yi
and replace filter ele‐
Co
Cop py
ment ⇒ Maintenance ;
t. rig
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Booklet 11 p by
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❑ Renewing air filter: with
agen
Prote AG.
saturation indication in
dash panel insert
⇒ Maintenance ; Book‐
let 11
7 - Air filter upper part
8 - Bolt
❑ 2 Nm
9 - O-ring
❑ Renew if damaged.
10 - Intake manifold pressure sender - G71-
11 - 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 .
15 - Bolt
❑ 1.6 Nm agen
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16 - Screw-type clip d by ara
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Caution ss c
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nl
The screw-type clips on
pt
du
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itte
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ab
always be tightened to
ility
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wit
too low or too high, the
, is n
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charge air hose may slip
hole
spec
off the charge air pipe
es, in part or in w
t to the co
❑ 5.5 Nm
rrectness of i
17 - Intake hose
l purpos
❑ It is essential that the marks on intake hose be in line with the webs on the turbocharger.
❑ Clean oil from ends of hoses before installing.
nf
ercia
o
❑ Do not use lubricants containing oil.
rm
m
atio
❑ To turbocharger.
om
n in
c
❑ With heater element for crankcase breather - N79- and connection for crankcase breather/cylinder head
or
thi
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sd
iva
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rp
cu
18 - Screw-type clip
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m
f
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ng
t.
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op py
Caution t. C rig
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The screw-type clips on cop Vo
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the charge air lines must
cted agen
Prote AG.
always be tightened to
5.5 Nm. If the torque is
too low or too high, the
charge air hose may slip
off the charge air pipe
during vehicle operation.
❑ 5.5 Nm
19 - Vacuum hose
20 - Bracket
❑ For wiring harness.
21 - Heat shield
22 - Bolt
❑ 2 Nm
23 - Mounting for air duct
❑ Secured to lock carrier.
❑ Check for secure engagement.
24 - Bolt
❑ 8.5 Nm
ce
e
nl
pt
du
an
– Water drainage pipe -1- is clipped into lower part of air filter
itte
y li
-arrow-.
erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
at
om
io
♦ Torque wrench - V.A.G 1410-
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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.
ce
le
– Pull off connector -3- for air mass meter - G70- .
un
pt
an
d
itte
– Loosen screw-type clip -4- and remove intake hose from air
y li
erm
ab
mass meter - G70- .
ility
ot p
wit
– Open screwed-attached clip -2- and pull intake pipe -4- off the
is n
h re
air filter container.
ole,
spec
urposes, in part or in wh
– Unclip wiring harness from brackets on air filter housing.
t to the co
– Unscrew securing bolt -2- ⇒ Item 4 (page 368) for air filter
rrectne
housing -1- in area of coolant expansion tank.
– Pull air filter out of mountings.
ss o
cial p
f
Installing
inform
mer
atio
om
Specified torques
n
c
i
or
n thi
e
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
– Pull engine control unit out of its bracket.
itte
y li
erm
ab
Installing
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
Note
t to the co
Use new shear-head bolts.
rrectness of i
l purpos
nf
ercia
orm
Note
m
atio
om
n in
c
thi
e
event memory. Read event memory before and after making re‐
t
sd
iva
cu
o
m
f
en
ng
t.
yi Co
op py
Caution t. C rig
gh ht
pyri by
Vo
co lksw
by
• When the engine control unit is renewed, the “injector de‐ cted agen
Prote AG.
livery calibration values” must be written into the new
engine control unit ⇒ page 327 .
Removing
– Before removing engine control unit, read identification and
coding of present control unit ⇒ Vehicle diagnostic tester.
– Remove engine control unit ⇒ page 372 .
ce
le
un
pt
Use new shear-head bolts.
an
d
itte
y li
erm
ab
ility
– Install engine control unit ⇒ page 372 .
ot p
wit
is n
h re
ole,
diagnostic tester.
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
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 - 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.
pt
du
an
itte
ab
hanger
ility
ot p
spec
4 - Rear silencer
l purpos
❑ Removing:
nform
ercia
at
om
point.
ion
c
in t
or
do
riv
en
ng
t.
yi Co
5 - Double clamp Cop py
t. rig
gh
❑ Note installation position.
ht
pyri by
Vo
o
by c lksw
❑ Installation of double clamp ⇒ page 375 Prote
cted AG.
agen
❑ 31 Nm
6 - Mounting
❑ Fasten mounting on gearbox cross member ⇒ page 375
7 - Bolt
❑ 20 Nm
ce
e
nl
pt
– Align front silencer -2- and rear silencer -1- horizontally, and
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Installation location of rubber mounting
hole
spec
es, in part or in w
– Align rubber mounting -1- in such a way that the distance -a-
t to the co
is 8 mm.
rrectness of i
Note
l purpos
orm
m
atio
om
n in
or c
thi
te
sd
iva
cu
o
m
f
en
ng
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectness
• Exhaust system must be aligned when cold.
o
cial p
f in
Procedure
form
mer
atio
– Loosen bolts of double clamp -3-.
om
n
c
i
or
n
– Tighten bolts hand tight.
thi
te
sd
va
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
pt
an
d
hand
itte
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rm
ab
❑ When installing, first fit
pe
ility
screw-type clip on tur‐
ot
wit
, is n
h re
pipe.
hole
spec
❑ 8 Nm
es, in part or in w
t to the co
2 - Gasket
❑ Renew after removing
rrectness of i
❑ Note installation posi‐
tion.
l purpos
tion in
probe body.
do
r
rp
cum
❑ 50 Nm
fo
en
ng
t.
yi Co
4 - Control line with union nut t. Cop py
rig
gh
❑ 20 Nm
ht
pyri by
Vo
co lksw
by
5 - Exhaust gas temperature
cted agen
Prote AG.
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
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
17 - Bracket
un
pt
an
d
itte
ab
❑ Metal type
ility
ot p
wit
h re
ole,
18 - Bolt
spec
urposes, in part or in wh
❑ 20 Nm
t to the co
19 - Mounting
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
Note
pt
du
an
itte
y li
erm
ab
♦ After working on the exhaust system, ensure that the system is not under stress and that there is sufficient
ility
ot p
clearance to the bodywork. Loosen double clamp and clip if necessary. Align silencer and exhaust pipe so
wit
, is n
that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.
h re
hole
spec
♦ Renew self-locking nuts.
es, in part or in w
t to the co
1 - Screw-type clip
rrectness of i
❑ Always renew after re‐
moving
l purpos
nf
ercia
o
❑ When installing, first
rm
m
atio
m
n in
or c
on turbocharger
thi
te
sd
a
❑ 8 Nm
iv
o
r
rp
cu
o
m
2 - Gasket
f
en
ng
t.
yi Co
❑ Renew after removing t. Cop py
rig
gh
❑ Note installation posi‐
ht
pyri by
Vo
tion.
co lksw
by
cted agen
Prote AG.
3 - Front exhaust pipe with cat‐
alytic converter
❑ Take into account the
fact that there are differ‐
ent types ⇒ ETKA (elec‐
tronic parts catalogue)
❑ Handle carefully to
avoid damage.
❑ When installing, first
fasten the top screw-
type clip for the exhaust
pipe on turbocharger
• Transport shock-free.
• Do not kink flexible hose.
• Do not stretch flexible hose.
❑ Removing and installing
⇒ page 387 .
4 - Bolt
❑ 20 Nm
5 - Bracket
❑ Secured to gearbox on right
❑ Attaching bracket to gearbox ⇒ page 380
6 - Bolt
❑ 20 Nm
7 - Bracket
❑ Fastened to engine support on right
❑ Metal type
❑ Attaching bracket to engine support ⇒ page 380
8 - Bolt
❑ 20 Nm
9 - Bolt
❑ 20 Nm
AG. Volkswagen AG d
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un
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an
d
itte
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erm
ab
ility
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wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
Special tools and workshop
un
pt
an
d
equipment required
itte
y li
rm
ab
♦ Torque wrench (5…50 Nm) pe
ility
ot
- V.A.G 1331-
wit
, is n
h re
♦ Torque wrench (40…200
hole
spec
Nm) - V.A.G 1332-
es, in part or in w
t to the co
♦ Hose clip pliers - VAS
6362-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
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-.
– Open clips -arrows- and remove toothed belt guard -1-.
AG. Volkswagen AG d
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aut ra
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un
pt
an
d
itte
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ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Loosen cable ties -3-, free lines -1 and 2- from fittings, and lay
them to one side.
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
3094- .
– Open spring-type clip -1- for coolant hose -2- and pull coolant
rrectness of i
hose off.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
383
co Vo
by lksw
cted 2. Cleansing exhaust emissions
agen
Prote AG.
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
AG. Volkswagen AG d
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d b ara
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nl
pt
du
an
itte
ab
ility
– Undo and remove bolts -3- for exhaust pipe bracket -4-.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
AG. Volkswagen AG d
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olksw not
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ara
ed
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aut ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
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d ran
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
urposes, in part or in wh
♦ When installing particulate filter, push -1- the coolant pipe -2-
t to the co
a little to one side.
♦ Install particulate filter -1- carefully.
rrectne
♦ Screw in bolts -3- for particulate filter bracket -4- a few turns.
s
♦ Position particulate filter with new gasket
s o
⇒ Item 2 (page 377) and new screw-type clip
cial p
f in
⇒ Item 1 (page 377) .
form
mer
♦ Fit exhaust pipe bracket -4- and tighten bolts -3- hand-tight.
atio
om
n
c
i
or
n thi
te
sd
a
♦ Tighten screw -1- for screw-type clip ⇒ Item 1 (page 377) -2-.
iv
o
pr
cum
r
fo
t.
yi Co
op
♦ Tighten bolts ⇒ Item 18 (page 378) -3-. C py
t. rig
gh ht
yri by
♦ Tighten screw -1- for clamp -2-. cop Vo
by lksw
cted agen
Prote AG.
– Fasten lines -1 and 2- with new cable ties -3-.
Note
Specified torques
♦ ⇒ “2.1 Assembly overview - emission control
agen
AG.(diesel particu‐
Volkswagen AG
does
late filter)”, page 377 olksw not
y V gu
b ara
ed nte
♦ ⇒ “7.1 Assembly overviewtho-risair filter”, page 368 e or
au ac
ss
2.4 Removing and installing catalytic con‐
ce
le
un
pt
an
d
verter
itte
y li
rm
ab
pe
ility
Special tools and workshop equipment required
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Remove pipe -arrow- from cylinder head cover.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Release and pull off wiring harness connector -2-. Detach wir‐
ility
ot p
wit
, is n
– Open clips -1- and -4- and remove intake hose -3- together
h re
hole
spec
es, in part or in w
t to the co
– Pull vacuum hose -2- off vacuum unit of exhaust gas recircu‐
lation cooler and vacuum hose -1- off regulating flap potenti‐
rrectness of i
ometer - G584- .
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi
– Loosen screw -2- for clamp -1- between exhaust pipe -4- and
Co
op py
turbocharger.
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Loosen clamp -3- on exhaust pipe -1- and pull exhaust pipe
-1- off a little.
– Undo and remove bolts -3- holding exhaust pipe -2- on gear‐
box bracket -1-.
ce
e
nl
pt
du
an
Installation is carried out in the reverse order; note the following:
itte
y li
erm
ab
– Use new clips and gaskets.
ility
ot p
wit
, is n
– Install front exhaust pipe and first fasten the top screw-type
h re
clamp for the exhaust pipe on turbocharger
hole
spec
– Secure front exhaust pipe with all brackets, and fit screw-type
es, in part or in w
t to the co
clip ⇒ Item 1 (page 374) at bottom.
– Install air filter ⇒ page 368 rrectness of i
Specified torques
l purpos
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
1 - Exhaust gas recirculation
erm
ab
valve - N18- with exhaust gas
ility
ot p
recirculation potentiometer -
wit
, is n
G212-
h re
hole
spec
2 - Vacuum unit for exhaust
es, in part or in w
flap
t to the co
3 - Exhaust gas recirculation
cooler
rrectness of i
❑ Removing and installing
⇒ page 392 .
l purpos
4 - Connection
nform
ercia
at
om
io
5 - Bolt
n
c
in t
or
his
ate
Note
do
priv
cum
for
en
g
t.
yi Co
op
sure the correct torque for the bolts C py
ht. rig
of the exhaust gas recirculation rig ht
py by
cooler on the turbocharger side, co Vo
by lksw
hexagon bolts with part number »N
cted agen
Prote AG.
107 188 01« can be used.
❑ First, fit bolts on turbo‐
charger side and screw
them in hand-tight.
❑ 8 Nm
6 - Gasket
❑ Renew after removing
7 - Bolt
❑ 20 Nm
8 - Lower pipe
9 - Gasket
❑ Renew after removing
ce
le
un
pt
an
d
itte
12 - Upper pipe
y li
erm
ab
ility
13 - Gasket
ot p
wit
is n
❑ Renew after removing
h re
ole,
spec
14 - Bolt
urposes, in part or in wh
❑ Renew after removing
t to the co
❑ 8 Nm
rrectne
3.2 Assembly overview - exhaust gas recirculation, 132 kW engine
ss o
cial p
f inform
1 - Exhaust gas recirculation
mer
cooler
atio
om
n
❑ Removing and installing
c
i
or
n
⇒ page 398 .
thi
te
sd
iva
o
r
2 - Bracket
p
cum
r
fo
en
ng
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
en
ng
t.
yi Co
op
♦ Hose clamps up to 25 mm - 3094- C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
Note
– Detach vacuum hose -2- from upper toothed belt guard -1-.
– Open clips -arrows- and remove toothed belt guard -1-.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
– Remove pipe -arrow- afrom
u th
cylinder head cover. or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
– Pull vacuumaut hose off vacuum unit of exhaust gas recirculation ra
s c
cooler -1-
s and vacuum hose from regulating flap potentiometer
ce
le
- G584- -2-.
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
f inform
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– 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
ce
le
un
pt
an
– Unscrew and remove bolts -3- in bracket for front exhaust pipe
d
itte
y li
-4-.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Undo and remove bolts -3- for front exhaust pipe -2- at bracket
-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.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
– Undo and remove bolts -2- and -3- for pipe -1- and remove
itte
y li
pipe.
rm
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
396
AG.
Rep. gr.26 - Exhaust system
Amarok 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 04.2013
pt
an
d
itte
y li
erm
ab
ility
ot p
Note
wit
is n
h re
ole,
For better accessibility and to ensure the correct torque for the
spec
charger side, hexagon bolts with part number N 107 188 01 can
t to the co
be used.
rrectne
f inform
Note
mer
atio
om
i
or
n thi
te
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Drip tray for workshop hoist - VAS 6208-
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
♦ Hose clip pliers - VAS 6362-
agen
Prote AG.
Note
Removing
– Clamp off coolant hose -2- leading to input to exhaust gas re‐
circulation cooler -1- with hose clams up to 25 mm - 3094- .
– Loosen clamp -3- and pull coolant hose -2- off exhaust gas
recirculation cooler -1-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Clamp off coolant hose -1- coming from output of exhaust gas
wit
, is n
spec
– Loosen clamp -2- and pull coolant hose -1- off output of ex‐
es, in part or in w
nform
mercia
at
om
ion
c
in t
his
e
-5-.
at
do
priv
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
Installation is carried out in the reverse order; note the following:
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
First, screw in all pipe bolts loosely and then tighten them to
hole
spec
specified torque.
es, in part or in w
t to the co
Specified torques
♦ ⇒ “3.2 Assembly overview - exhaust gas recirculation, 132 kW
rrectness of i
engine”, page 391
l purpos
nf
ercia
orm
m
atio
m
Removing
o
n in
or c
thi
– Loosen clip -2- and pull pressure hose off throttle valve control
te
sd
iva
module - J338- .
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
– Detach connector -3- from throttle valve control module -
C py
t. rig
gh
J338- .
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– 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-.
AG. Volkswagen AG d
agen oes
ksw
– Undo and remove bolts -arrows- and remove exhaust by V gas re‐
ol not
gu
ara
circulation valve - N18- -1- from intake manifold.rised
nte
ho eo
ut
Installing ss a ra
c ce
e
pt
du
an
itte
y li
Specified torques
erm
ab
ility
ot p
t to the co
er - N345-
nform
ercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
Removing
un
pt
an
d
itte
– Pull connector -3- and vacuum lines and pull off changeover
y li
erm
ab
wit
– Unclip locking lug for changeover valve for exhaust gas recir‐
is n
h re
spec
t to the co
Installing
Installation is carried out in the reverse order; note the following:
rrectne
Caution
ss o
Do not kink, twist or crush the vacuum lines when routing. This
cial p
f in
atio
connection piece.
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
t.
yi Co
op
cooler for leaks
C py
t. rig
gh ht
pyri by
Vo
• Exhaust gas recirculation cooler is removed ⇒ page 398 .
co lksw
by
cted agen
Prote AG.
n AG. Volkswagen AG do
swage es n
The exhaust gas recirculation cooler by Vis now ready to be immersed t gua
olk o
in the water. ir se
d ran
tee
tho or
au ac
ss
Note
ce
le
un
pt
an
d
itte
y li
ab
plied.
ility
ot p
wit
is n
test.
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
1 Glow plug system
erm
ab
ility
ot p
wit
⇒ “1.1 Checking glow plug system”, page 404
, is n
h re
hole
spec
es, in part or in w
t to the co
406
⇒ “1.4 Removing and installing Hall sender G40 ”, page 407
rrectness of i
1.1 Checking glow plug system
l purpos
Procedure
nf
ercia
o
Automatic glow period control unit - J179- -A- is located in front
rm
m
atio
om
n in
c
thi
e
sd
iva
capable of self-diagnosis.
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
the glow plug system. t. Cop py
rig
gh ht
The procedure for checking the glow plug system is described in yri
p by
o Vo
⇒ Vehicle diagnostic tester.
c by lksw
cted agen
Prote AG.
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.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
Removing
spec
es, in part or in w
Caution
rrectness of i
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
wiring harness is not damaged.
an
d
itte
y li
rm
ab
pe
ility
ot
h re
hole
spec
es, in part or in w
Note t to the co
♦ Cleaning procedure:
rrectness of i
♦ Then use an oil-soaked cloth to clean the glow pin plug open‐
m
ing.
com
tion in
r
te o
thi
s
iva
do
10 mm socket - 3220-
um
fo
en
ng
t.
yi
Installing
Co
Cop py
t. rig
gh
Installation is carried out in the reverse order; note the following:
ht
pyri by
Vo
co lksw
by
cted
– To tighten the glow plugs use special tool U/J extension and
agen
Prote AG.
socket, 10 mm - 3220- with a suitable torque wrench.
– Tighten glow plugs.
– Fit glow plug connectors to the respective glow plugs and en‐
sure they are firmly seated.
– Delete event memory of engine control unit.
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 78
ce
e
♦ Hexagon key extension, 4 mm - T10370-
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Removing
m
at
– Remove underbody guard, if fitted ⇒ General body repairs,
om
io
exterior; Rep. gr. 66 ; Underbody guard .
n
c
in t
or
his
e
– Pull the connector -2- off the engine speed sender - G28- be‐
at
do
riv
cum
for
en
ng
t.
yi Co
op
Note
C py
ht. rig
rig ht
py by
co Vo
To release electrical connector without assembly tool - T10118- ,
by lksw
cted agen
Prote
press connector on engine speed sender - G28- in with a screw‐
AG.
driver and at the same time raise release tab with a thin wire hook.
– Detach vacuum hose -2- from upper toothed belt guard -1-.
– Open clips -arrows- and remove toothed belt guard -1-.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
crankshaft stop into the teeth of the toothed belt pulley from
atio
m
n
c
n thi
te
sd
iva
o
pr
cum
r
fo
Note
en
ng
t.
yi Co
Cop py
Markings on crankshaft toothed belt pulley -2- and crankshaft stop
t. rig
gh ht
yri
- T10050- -1- must align. At the same time, the pin of the crank‐ p by
co Vo
lksw
shaft stop - T10050- must engage in the drilling in the sealing
by
cted agen
Prote
flange.
AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
– Remove bolts of toothed belt pulley of high-pressure pump
an
d
itte
y li
-2-.
rm
ab
pe
ility
– Loosen belt tensioner nut -1-.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
com
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
pt
an
d
itte
ab
pe
ility
– Pull wiring harness together with Hall sender - G40- out com‐
ot
wit
h re
hole
Installing
spec
es, in part or in w
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Install upper toothed belt guard -3- and secure with clips
-arrows-.
– Clip vacuum hose -2- into toothed belt guard -1-.
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.