Volkswagen Amarok. Manual - part 2

Amarok 2011 ➤

4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011

- Tighten new bolts -1- for left engine mounting -A-.

olks

- Tighten new bolts -1- for right engine mounting -A-.

- Install catalytic converter ⇒ page 240 .

- Install air conditioner compressor ⇒ Heating, air conditioning;

Rep. gr. 87 .

- Install vane pump for power steering ⇒ Running gear, axles,

steering; Rep. gr.

48 ; Removing and installing vane pump .

– Install starter ⇒ Electrical system; Rep. gr. 27 ; Removing and

installing starter .

- Fit engine guard, if available ⇒ Body, front; Rep. gr. 50 ; En‐

gine guard .

- Install bonnet ⇒ General body repairs, exterior; Rep. gr. 55 ;

Bonnet .

- Fit new screw-type clips with „barb“, notes on screw-type clips

⇒ page 184 .

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 fuel system between fuel tank and high-pres‐

sure pump are removed or renewed, „Bleeding fuel system“

function must be carried out to bleed fuel system using vehicle

diagnosis tester in „Guided Functions“ ⇒ page 209 .

♦ 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.

- Check oil level ⇒ page 115 .

Note

♦ Only reuse drained coolant if neither cylinder head nor cylinder

block have been renewed.

♦ Soiled coolant must not be reused.

- Replenish coolant ⇒ page 133 .

- Carry out road test and read fault memory.

Specified torques ⇒ page 17 .

16 Rep. gr.10 - Removing and installing engine

Amarok 2011 ➤

4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011

1.4

Assembly and gearbox mountings

Left and right engine support to crankcase

Caution

• Nut -2- must not be loosened.

• If nut -2- is loosened, engine mounting must subsequently

be renewed.

♦ Engine mounting connection to engine support may only

be loosened if engine mounting is to be renewed.

- Secure engine support -1- to crankcase with bolts -3-.

- Always renew bolts -3- and tighten to 50 Nm + 180° (1/2 turn).

olks

Right engine mounting to frame

- Secure engine mounting -A- to frame with bolts -1-.

- Always renew bolts -1- and tighten to 50 Nm + 90° (1/4 turn).

Left engine mounting to frame

- Secure engine mounting -A- to frame with bolts -1-.

- Always renew bolts -1- and tighten to 50 Nm + 90° (1/4 turn).

Left engine mounting to engine support

- Bolt new engine mounting -3- to engine support -1- with nut

-2-.

- Always renew nut -2- and tighten to 90 Nm + 90° (1/4 turn).

1. Removing and installing engine

17

Amarok 2011 ➤

4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011

Right engine mounting to engine support

o

- Bolt new engine mounting -3- to engine support -2- with nut

-1-.

- Always renew nut -1- and tighten to 90 Nm + 90° (1/4 turn).

Gearbox mounting to gearbox

- Secure gearbox mounting -A- to gearbox with bolts -1-.

- Always renew bolts -1- and tighten to 50 Nm + 90° (1/4 turn).

- Removing and installing gearbox mounting ⇒ Rep. gr. 34

Gearbox mounting to gearbox cross member

- Secure gearbox mounting -A- to gearbox cross member with

bolts -1-.

- Always renew bolts -1- and tighten to 30 Nm + 90° (1/4 turn).

- Removing and installing gearbox mounting ⇒ Rep. gr. 34

18 Rep. gr.10 - Removing and installing engine

Amarok 2011 ➤

4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011

13 - Crankshaft group

1

Cylinder block (pulley end)

1.1

Assembly overview - poly V-belt drive

1 - Poly V-belt

❑ Check for wear.

❑ Do not kink.

❑ Poly V-belt routing

⇒ page 21 .

Caution

If a used belt runs in the

opposite direction when

it is refitted, this can

cause breakage.

Before removing, mark

direction of rotation of

poly V-belt with chalk or

felt-tipped pen for re-in‐

stallation.

o

❑ Removing and installing

⇒ page 22 .

❑ When installing, make

sure it is properly seated

on pulleys.

2 - Guide roller

❑ 20 Nm

3 - Bolt

❑ Renew.

❑ 150 Nm + 90° further

❑ Use counterhold -

T10355- when loosen‐

ing and tightening

Caution

Risk of damage to en‐

gine.

To avoid disturbing valve

timing, do not turn crank‐

shaft when bolt has been

removed.

4 - O-ring

❑ Renew.

5 - Vibration damper

❑ With poly V-belt pulley.

❑ Removing and installing ⇒ page 27 .

1. Cylinder block (pulley end)

19

Amarok 2011 ➤

4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011

Caution

Risk of damage to en‐

gine.

To avoid disturbing valve

timing, do not turn crank‐

shaft out of „TDC“ posi‐

tion when vibration

olks

damper is removed.

6 - Bolt

❑ 40 Nm

7 - Tensioning element for poly V-belt

❑ Swing with spanner to slacken poly V-belt.

❑ Lock with locking tool -T40098- .

❑ Removing and installing ⇒ page 21 .

8 - Bracket for ancillaries

❑ With oil filter and engine oil cooler

❑ Removing and installing ancillary bracket ⇒ page 24 .

❑ Removing and installing engine oil cooler ⇒ page 129 .

9 - Alternator

❑ Removing and installing ⇒ Rep. gr. 27 .

10 - Bolt

❑ Specified torque ⇒ Rep. gr. 27

11 - Bolt

❑ Tightening sequence ⇒ page 21 .

12 - Bolt

❑ Specified torque ⇒ Rep. gr. 48

13 - Sleeve

14 - Vane pump

❑ Removing and installing ⇒ Rep. gr. 48 .

15 - Air conditioner compressor

❑ Do not unscrew or disconnect refrigerant hoses or pipes.

❑ Removing and installing ⇒ Rep. gr. 87 .

16 - Bolt

❑ Specified torque ⇒ Rep. gr. 87

17 - Dowel sleeve

❑ For air conditioner compressor.

18 - Bolt

❑ Specified torque ⇒ Rep. gr. 48

20 Rep. gr.13 - Crankshaft group

Amarok 2011 ➤

4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011

Bracket for ancillaries - tightening sequence

- Fit bracket for ancillaries (first tighten bolt -4-).

- Tighten bolts in the sequence -1 … 5- in 3 stages as follows:

1.

Tighten bolts hand tight.

2.

Tighten bolts to 20 Nm.

3.

Turn bolts 90° further.

Poly V-belt route with air conditioning system

1 - Vibration damper

2 - Guide roller

3 - Poly V-belt tensioning element

4 - Alternator

5 - Vane pump

6 - Air conditioner compressor

olks

Poly V-belt route without air conditioner

1 - Vibration damper

2 - Guide roller

3 - Poly V-belt tensioning element

4 - Alternator

5 - Vane pump

1.2

Removing and installing tensioner for

poly V-belt

Special tools and workshop equipment required

1. Cylinder block (pulley end)

21

Amarok 2011 ➤

4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011

♦ Locking tool -T40098-

Removing

Caution

If a used belt runs in the opposite direction when it is refitted,

this can cause breakage.

♦ Before removing, mark direction of rotation of poly V-belt

with chalk or felt-tipped pen for re-installation.

- To slacken poly V-belt turn tensioner in direction of -arrow-.

- Lock tensioner with locking tool -T40098- .

- Remove poly V-belt from tensioner.

- Remove bolt -1- and take off tensioner for poly V-belt from

bracket for ancillaries.

Installing

Installation is carried out in the reverse order. When installing,

note the following:

olks

• Specified torque ⇒ page 19 .

- Install poly V-belt ⇒ page 22 .

1.3

Removing and installing poly V-belt

Special tools and workshop equipment required

♦ Locking tool -T40098-

22 Rep. gr.13 - Crankshaft group

Amarok 2011 ➤

4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011

Removing

Caution

If a used belt runs in the opposite direction when it is refitted,

this can cause breakage.

♦ Before removing, mark direction of rotation of poly V-belt

with chalk or felt-tipped pen for re-installation.

olks

- To slacken poly V-belt turn tensioner in direction of -arrow-.

- Lock tensioner with locking tool -T40098- .

- Remove poly V-belt.

Installing

Installation is carried out in the reverse order. When installing,

note the following:

Note

Alternator and air conditioner compressor must be firmly mounted

before poly V-belt is installed.

- Fit poly V-belt as shown in figure.

Vehicles with air conditioner

Vehicles with no air conditioner

1. Cylinder block (pulley end)

23

Amarok 2011 ➤

4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011

- Turn tensioner in -direction of arrow- and withdraw locking tool

-T40098- .

- Release tensioner.

- Check that poly V-belt is properly seated.

- Start engine and check that poly V-belt runs properly.

1.4

Removing and installing ancillary brack‐

et

Special tools and workshop equipment required

♦ Drip tray for workshop hoist -VAS 6208-

olks

♦ Locking tool -T40098-

Removing

- Drain coolant ⇒ page 133 .

Caution

If a used belt runs in the opposite direction when it is refitted,

this can cause breakage.

♦ Before removing, mark direction of rotation of poly V-belt

with chalk or felt-tipped pen for re-installation.

- To slacken poly V-belt turn tensioner in direction of -arrow-.

24 Rep. gr.13 - Crankshaft group

Amarok 2011 ➤

4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011

- Lock tensioner with locking tool -T40098- .

- Remove poly V-belt.

- Remove bolt -1- and take off tensioner for poly V-belt from

bracket for ancillaries.

Note

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

caping engine oil.

- Detach connector -2- from oil pressure switch -F22- -1-.

- Unbolt water pipe ⇒ Item 19 (page 141) from bracket for an‐

cillaries.

- Release clip -3- from pressure hose -4-.

- Release hose clip -arrow- from throttle valve module -J338- .

- Unscrew bolt -1- from pressure pipe -2- and remove pressure

pipe -2-.

- Remove alternator ⇒ Rep. gr. 27 .

Vehicles with air conditioner

olks

1. Cylinder block (pulley end)

25

Amarok 2011 ➤

4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011

- Disconnect electrical connector -1- for magnetic clutch on air

conditioner compressor.

WARNING

Risk of injury caused by refrigerant.

♦ The air conditioner refrigerant circuit must not be opened.

- Remove bolts -arrows- for air conditioner compressor.

Caution

Danger of damage to refrigerant lines and hoses.

♦ Do NOT stretch, kink or bend refrigerant lines and hoses.

- Tie up air conditioner compressor together with refrigerant ho‐

ses to longitudinal member (refrigerant hoses remain connec‐

ted).

Continuation for all vehicles

Note

Hydraulic lines and vane pump remain connected.

- Unscrew bolts -1- from front through belt pulley, unscrew bolt

-2- from rear.

olks

Note

The vane pump is shown without a belt pulley and without hy‐

draulic lines in the figure.

- Place vane pump with attached hydraulic lines on longitudinal

member.

- Release oil filter -arrow- using oil filter tool -3417- and remove

oil filter.

- Remove bolts from bracket of continued coolant circulation

pump -V51- .

26 Rep. gr.13 - Crankshaft group

olks

Amarok 2011 ➤

4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011

- Remove bolt -arrow- for dipstick guide tube.

- Unscrew bolts -1 … 5- and detach bracket for ancillary units

from coolant pump housing.

Installing

Installation is carried out in the reverse order. When installing,

note the following:

• Specified torques ⇒ page 19 .

Note

♦ Renew bolts that are tightened with specified further tightening

angle.

♦ Renew O-rings and seals.

- Coat O-rings -4- with coolant additive, coolants ⇒ Electronic

parts catalogue .

- Insert connection -2- into coolant pump housing -3-.

- Push bracket for ancillaries -1- onto connection, fit bolts and

tighten, tightening sequence.

- Install vane pump ⇒ Rep. gr. 48 .

- If present, fit air conditioner compressor ⇒ Rep. gr. 87 .

- Install alternator ⇒ Rep. gr.

27 .

– Install poly V-belt ⇒ page 22 .

- Replenish coolant ⇒ page 133 .

1.5

Removing and installing vibration damp‐

er

Special tools and workshop equipment required

♦ Locking pin -T10060 A-

1. Cylinder block (pulley end)

27

Amarok 2011 ➤

4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011

♦ Counterhold tool -T10355-

Removing

- Remove poly V-belt ⇒ page 22 .

- Remove engine guard, if fitted ⇒ Body, front; Rep. gr. 50 ;

Engine guard .

- Turn vibration damper to „TDC“ position -arrow- using coun‐

olk

terhold -T10355- .

• Notch on vibration damper must align with arrow marking on

cover for timing chains (bottom).

- Remove bolt for vibration damper using counterhold -

T10355- .

Caution

Risk of damage to engine.

♦ To avoid disturbing valve timing, do not turn crankshaft out

of „TDC“ position when vibration damper is removed.

Installing

• Specified torque ⇒ page 19 .

Installation is carried out in the reverse order; note the following:

Note

♦ Renew bolt for vibration damper.

♦ Renew O-ring -1-.

- Lubricate sealing lip of oil seal with gear oil.

- Fit vibration damper (pay attention to shape of tooth -arrow-).

28 Rep. gr.13 - Crankshaft group

Amarok 2011 ➤

4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011

2

Cylinder block (gearbox end)

2.1

Assembly overview - sealing flange and drive plate

1 - Cylinder block

2 - Sealing flange with oil seal

❑ Removing and installing

⇒ page 33 .

❑ Renew complete only.

❑ Do not oil or grease oil

seal sealing lip.

❑ Use support sleeve sup‐

plied when installing.

❑ Before installing, re‐

move oil residue from

crankshaft journal using

a clean cloth.

3 - Bolt

❑ Tightening sequence

⇒ page 30 .

4 - Drive plate

❑ To loosen securing

bolts, lock using 3067.

❑ Removing and installing

⇒ page 30 .

5 - Bolt

❑ 60 Nm + 90°

❑ Renew.

o

6 - Needle bearing

❑ Removing and installing

needle bearing

⇒ page 32

7 - Intermediate plate

❑ Must seat on dowel

sleeves.

❑ Do not damage or bend

when assembling.

❑ Is fitted onto sealing flange ⇒ page 30

8 - Dowel sleeve

2. Cylinder block (gearbox end)

29

Amarok 2011 ➤

4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011

Sealing flange at gearbox end - tightening sequence

- Tighten bolts -1 to 8- in the sequence shown:

-

1. Screw in bolts hand-tight.

–

2. Tighten bolts to 9 Nm.

Installing intermediate plate

- Hook intermediate plate onto sealing flange and slide onto

dowel sleeves -arrows-.

2.2

Removing and installing drive plate

Special tools and workshop equipment required

olks

♦ Counterhold tool -VW 558-

♦ Depth gauge

♦ Hexagon bolt M8×40 and hexagon nut M8

- Remove gearbox ⇒ Power transmission; Rep. gr. 37 ; Re‐

moving and installing gearbox .

30 Rep. gr.13 - Crankshaft group

Amarok 2011 ➤

4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011

Preparing counterhold tool -VW 558- :

- Tighten hexagon bolt M8x40 -A- with hexagon nut on clutch

counter-hold tool -VW 558- .

Loosening and tightening drive plate:

- Insert counterhold -VW 558- in cylinder block and drive plate

as shown.

Installation position of counterhold: -A- to loosen, -B- to tighten.

Installing drive plate:

- Fit drive plate without washer -A- first.

– Fit used securing bolts -3- and tighten to 30 Nm.

- Check dimension between drive plate and cylinder block at

three points and calculate average.

Note

Measure through hole in drive plate to milled surface of cylinder

block. When measuring intermediate plate, plate thickness has to

be taken into account.

• Specification measured without intermediate plate: 19.5…

21.1 mm

• Specification measured with intermediate plate: 18.8…

20.4 mm

If the specification is not reached, replace all securing bolts and

tighten.

2. Cylinder block (gearbox end)

31