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Volkswagen Amarok 2011 User Manual

Volkswagen Amarok 2011
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Workshop Manual
Amarok 2011 ➤
4-cylinder injection engine (2.0 l direct injection
engine, turbocharger)
Engine ID
CFP
A
Edition 02.2011
Service
Service Department. Technical Information

Table of Contents

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Volkswagen Amarok 2011 Specifications

General IconGeneral
BrandVolkswagen
ModelAmarok 2011
CategoryAutomobile
LanguageEnglish

Summary

00 - Technical Data

Engine Number

Information on how to find and identify the engine number.

Engine Data

Detailed technical specifications of the engine.

10 - Removing and Installing Engine

Removing Engine

Detailed steps for the engine removal process, including special tools.

Securing Engine on Engine and Gearbox Support

Procedure for securing the engine on a specific support equipment.

Notes on Installing Engine

Important notes and precautions for engine installation.

Assembly and Gearbox Mountings

Details on how to assemble and mount the engine and gearbox.

13 - Crankshaft Group

Assembly Overview - Poly V-belt Drive

Overview of the poly V-belt drive system components.

Removing and Installing Poly V-belt

Procedures for removing and installing the poly V-belt.

Removing and Installing Ancillary Bracket

Steps for removing and installing the ancillary bracket.

Cylinder Block (Gearbox End)

Components and procedures for the gearbox end of the cylinder block.

Assembly Overview - Sealing Flange and Drive Plate

Overview of the sealing flange and drive plate assembly.

Removing and Installing Drive Plate

Steps for removing and installing the drive plate.

Removing and Installing Needle Bearing

Procedures for removing and installing needle bearings.

Removing and Installing Sealing Flange on Gearbox Side

Steps for removing and installing the sealing flange on the gearbox side.

Pistons and Conrods

Components and procedures related to pistons and conrods.

Assembly Overview - Pistons and Conrods

Overview of pistons, conrods, and related parts.

Separating New Conrod

Procedure for separating new conrods.

Piston and Cylinder Dimensions

Specific dimensions for pistons and cylinder bores.

Crankshaft

Components and procedures related to the crankshaft.

Assembly Overview - Crankshaft

Overview of crankshaft assembly and its parts.

Allocation of Crankshaft Bearing Shells

How to classify and allocate crankshaft bearing shells.

Crankshaft Dimensions

Specific dimensions related to the crankshaft.

Measuring Axial Clearance of Crankshaft

Procedure for measuring the crankshaft's axial clearance.

Measuring Radial Clearance of Crankshaft

Method for measuring the crankshaft's radial clearance.

Pulling Needle Bearing into Crankshaft

Procedures for removing and installing needle bearings in the crankshaft.

15 - Cylinder Head, Valve Gear

Cylinder Head

Components and procedures related to the cylinder head.

Assembly Overview - Cylinder Head

Overview of cylinder head components and assembly.

Removing and Installing Cylinder Head

Procedures for removing and installing the cylinder head.

Checking Compression

Procedure for checking engine compression.

Removing and Installing Vacuum Pump

Steps for removing and installing the vacuum pump.

Chain Drive

Components and procedures related to the timing chain drive.

Assembly Overview - Timing Chain Cover

Overview of timing chain cover components.

Removing and Installing Inlet Camshaft Control Valve

Steps for removing and installing the inlet camshaft control valve.

Removing and Installing Upper Timing Chain Cover

Procedures for removing and installing the upper timing chain cover.

Removing and Installing Timing Chain Cover (Bottom)

Steps for removing and installing the bottom timing chain cover.

Renewing Oil Seal for Vibration Damper

Procedure for renewing the oil seal for the vibration damper.

Camshaft Timing Chain - Exploded View

Exploded view of camshaft timing chain components.

Removing and Installing Camshaft Timing Chain

Procedures for removing and installing the camshaft timing chain.

Assembly Overview - Balancer Shaft Timing Chain

Overview of balancer shaft timing chain components.

Removing and Installing Balancer Shaft Module

Procedures for removing and installing the balancer shaft module.

Renewing Balancer Shaft for Inlet Camshaft

Procedure for renewing the balancer shaft for the inlet camshaft.

Renewing Balancer Shaft for Exhaust Camshaft

Procedure for renewing the balancer shaft for the exhaust camshaft.

Valve Gear

Components and procedures related to the valve gear.

Assembly Overview - Valve Gear

Overview of valve gear components and assembly.

Removing and Installing Camshafts

Procedures for removing and installing camshafts.

Renewing Valve Stem Seals (Cylinder Head Installed)

Procedure for replacing valve stem seals with head installed.

Renewing Valve Stem Seals (Cylinder Head Removed)

Procedures for replacing valve stem seals with head removed.

Checking Valve Guides

Method for checking valve guides.

Checking Axial Clearance of Camshafts

Procedure for checking camshaft axial clearance.

17 - Lubrication

Parts of Lubrication System

Components of the engine's lubrication system.

General Notes on Lubrication System

Important general information about the lubrication system.

Engine Oil

Details about engine oil, including capacities and specifications.

Oil Filter Bracket, Oil Pressure, Oil Cooler and Oil Supply Line

Components related to oil filter, pressure, cooler, and supply line.

Assembly Overview - Oil Filter, Engine Oil Cooler

Overview of the oil filter and engine oil cooler assembly.

Removing and Installing Engine Oil Cooler

Steps for removing and installing the engine oil cooler.

Removing and Installing Oil Pressure Switch

Procedures for removing and installing the oil pressure switch.

Removing and Installing Oil Supply Line to Turbocharger

Steps for removing and installing the oil supply line to the turbocharger.

Checking Oil Pressure

Method for checking engine oil pressure.

Assembly Overview - Sump, Oil Pump

Overview of sump and oil pump components.

Removing and Installing Coarse Oil Separator

Steps for removing and installing the coarse oil separator.

Removing and Installing Oil Pump

Procedures for removing and installing the oil pump.

Removing and Installing Lower Sump Part

Procedures for removing and installing the lower part of the sump.

19 - Cooling System

General Notes on Cooling System

Important general notes for the cooling system.

Draining and Filling Coolant

Procedures for draining and refilling the coolant.

Checking Cooling System for Leaks

Method for checking the cooling system for leaks.

Coolant Hose Schematic Diagram

Diagrams illustrating coolant hose routing.

Parts of Cooling System, Engine Side

Components of the cooling system on the engine side.

Assembly Overview - Coolant Pipes and Circulation Pump

Overview of coolant pipes and the circulation pump V51.

Removing and Installing Coolant Circulation Pump

Procedures for removing and installing pump V51.

Coolant Pump and Thermostat - Exploded View

Exploded view of coolant pump and thermostat components.

Removing and Installing Coolant Temperature Sender

Steps for removing and installing the coolant temperature sender.

Removing and Installing Toothed Belt for Coolant Pump

Procedure for removing and installing the toothed belt for the coolant pump.

Parts of Cooling System, Body Side

Components of the cooling system on the vehicle body.

Assembly Overview - Air Ducting and Radiator Fan

Overview of air ducting and radiator fan assembly.

Removing and Installing Cowling with Radiator Fan

Steps for removing and installing the cowling and fan.

Removing and Installing Radiator

Procedures for removing and installing the radiator.

20 - Fuel Supply System

General Notes on Fuel System

General information and safety precautions for the fuel system.

Safety Precautions when Working on Fuel Supply System

Crucial safety measures for working on the fuel system.

Rules for Cleanliness

Guidelines for maintaining cleanliness in the fuel system.

Releasing Pressure in High-Pressure Area

Procedure to safely release pressure in the high-pressure fuel system.

Fuel Pump

Information and procedures related to the fuel pump.

Checking Fuel Pump

Methods for checking the fuel pump's function.

Checking Function and Voltage Supply

Checking the fuel pump's function and electrical supply.

Checking Fuel Pressure

Methods for checking fuel pressure.

Checking Holding Pressure

Procedure for checking fuel system holding pressure.

Checking Fuel Delivery Rate

Method for checking fuel delivery rate.

Fuel Tank

Components and procedures related to the fuel tank.

Assembly Overview - Fuel Tank

Overview of the fuel tank assembly and its parts.

Removing and Installing Fuel Tank

Steps for removing and installing the fuel tank.

Removing and Installing Fuel Delivery Unit

Procedures for removing and installing the fuel delivery unit.

Removing and Installing Fuel Gauge Sender

Steps for removing and installing the fuel gauge sender.

Removing and Installing Filler Neck

Procedures for removing and installing the filler neck.

Assembly Overview - Fuel Filter with Attachments

Overview of the fuel filter assembly and its parts.

Removing and Installing Fuel Filter

Steps for removing and installing the fuel filter.

Removing and Installing Fuel Pump Control Unit

Procedures for removing and installing the fuel pump control unit.

4 - Electronic Power Control (EPC)

Assembly Overview - Accelerator Module

Overview of the accelerator module assembly and its parts.

Removing and Installing Accelerator Module

Steps for removing and installing the accelerator module.

5 - Activated Charcoal Filter System

Breather Line

Information about the breather line.

Activated Charcoal Filter

Information about the activated charcoal filter.

Checking Fuel Tank Breather

Procedure for checking the fuel tank breather.

21 - Turbocharging/Supercharging

Charge Air System

General information and safety for the charge air system.

Safety Precautions

Safety instructions for the charge air system.

Rules for Cleanliness

Cleanliness rules for the charge air system.

Hose Connections with Screw-Type Clips

Guidance on hose connections using screw-type clips.

Assembly Overview - Charge Air Cooling

Overview of the charge air cooling system components.

Removing and Installing Pressure Pipe

Steps for removing and installing the pressure pipe.

Removing and Installing Charge Pressure Sender

Procedures for removing and installing the charge pressure sender.

Removing and Installing Charge Air Cooler

Steps for removing and installing the charge air cooler.

Checking Charge Air System for Leaks

Method for checking the charge air system for leaks.

Turbocharger

Information and procedures related to the turbocharger.

Assembly Overview - Turbocharger

Overview of turbocharger assembly and its parts.

Removing and Installing Turbocharger

Steps for removing and installing the turbocharger.

Checking Vacuum Unit for Turbocharger

Procedure for checking the turbocharger's vacuum unit.

24 - Mixture Preparation - Injection

Safety Precautions and Rules for Cleanliness

Safety and cleanliness rules for mixture preparation.

General Notes on Self-Diagnosis

General information on the self-diagnosis system.

Injection System

Components and procedures for the injection system.

Overview of Fitting Locations

Location of various injection system components.

Assembly Overview - Air Filter

Overview of the air filter assembly and its parts.

Removing and Installing Air Filter Housing

Steps for removing and installing the air filter housing.

Removing and Installing Air Filter Element

Procedures for removing and installing the air filter element.

Removing and Installing Air Mass Meter

Steps for removing and installing the air mass meter.

Assembly Overview - Intake Manifold

Overview of the intake manifold assembly and its parts.

Assembly Overview - Fuel Rail

Overview of the fuel rail assembly and its parts.

Removing and Installing Intake Manifold

Procedures for removing and installing the intake manifold.

Removing and Installing Injectors

Steps for removing and installing the injectors.

Renewing Teflon Seal on Injector

Procedure for replacing the Teflon seal on the injector.

Cleaning Injectors

Method for cleaning fuel injectors.

Removing and Installing Fuel Pressure Sender

Steps for removing and installing the fuel pressure sender.

Removing and Installing Throttle Valve Module

Procedures for removing and installing the throttle valve module.

Cleaning Throttle Valve Module

Method for cleaning the throttle valve module.

Assembly Overview - High-Pressure Pump

Overview of the high-pressure pump assembly and its parts.

Removing and Installing High-Pressure Pump

Steps for removing and installing the high-pressure pump.

Removing and Installing Engine Control Unit

Procedures for removing and installing the engine control unit.

3 - Checking Components

Check Fuel Holding Pressure Upstream of High-Pressure Pump

Procedure to check fuel holding pressure upstream of the high-pressure pump.

Checking Intake Manifold Change-over

Method for checking intake manifold change-over.

Checking Fuel Pressure Sender

Procedure for checking the fuel pressure sender.

Checking Double Non-Return Valve

Method for checking the double non-return valve.

26 - Exhaust System

Assembly Overview - Parts of the Exhaust System

Overview of exhaust system components and assembly.

Removing and Installing Catalytic Converter

Steps for removing and installing the catalytic converter.

Removing and Installing Exhaust Manifold

Procedures for removing and installing the exhaust manifold.

Removing and Installing Centre Silencer

Steps for removing and installing the centre silencer.

Removing and Installing Rear Silencer

Procedures for removing and installing the rear silencer.

Checking Exhaust System for Leaks

Method for checking the exhaust system for leaks.

Aligning Exhaust System Free of Stress

How to align the exhaust system without stress.

28 - Ignition System

Repairing Ignition System

General procedures for repairing the ignition system.

General Notes on Ignition System

Important general notes for the ignition system.

Safety Precautions

Safety instructions for the ignition and injection systems.

Assembly Overview - Ignition System

Overview of the ignition system components and assembly.

Removing and Installing Ignition Coils with Output Stage

Steps for removing and installing ignition coils.

Removing and Installing Spark Plugs

Procedures for removing and installing spark plugs.

Removing and Installing Knock Sensor 1

Steps for removing and installing the knock sensor.

Removing and Installing Engine Speed Sender

Procedures for removing and installing the engine speed sender.

Test Data, Spark Plugs

Technical data and test information for spark plugs.

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