Volkswagen Amarok 2011 Service & Maintenance
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Volkswagen Amarok 2011 Service & Maintenance

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Service
Maintenance
Amarok 2011 ➤
Edition 10.2012
Service Department. Technical Information

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Summary of Contents for Volkswagen Amarok 2011

  • Page 1 Service Maintenance Amarok 2011 ➤ Edition 10.2012 Service Department. Technical Information...
  • Page 2 In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2012 Volkswagen AG, Wolfsburg D3E8027339B...

  • Page 3: Table Of Contents

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Contents Engine list ............. .
  • Page 4 Amarok 2011 ➤ Maintenance - Edition 10.2012 5.29 Resetting programmed values in engine control unit ......121 5.30...

  • Page 5: Engine List

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Engine list (VIGG000558; Edition 10.2012) Diesel engines ⇒ page 1 Petrol engines ⇒ page 1 Diesel engines Note To ease the search for an engine, the engine codes are listed in alphabetical order.
  • Page 6 Amarok 2011 ➤ Maintenance - Edition 10.2012 Engines: ⇒ Petrol Capacity Introduction Week 42/2010 ► Engine code CFPA Camshaft drive Chain 1. Engine list...

  • Page 7: General Rules Of Cleanliness

    Amarok 2011 ➤ Maintenance - Edition 10.2012 General rules of cleanliness Note Only some examples are given in this document. Not all concrete situations are covered. ♦ Before disconnecting, thoroughly clean connections and sur‐ rounding areas. ♦ Place removed parts onto a clean surface and cover. Use only lint-free cloths.
  • Page 8 Amarok 2011 ➤ Maintenance - Edition 10.2012 Cleaning automatic dipstick ⇒ page 4 Cleaning filling device -VAS 6542- ⇒ page 5 Clean sealing surfaces on oil filter housing and oil filter cover ⇒ page 5 Cleaning sliding window seals ⇒ page 5 Cleaning electro-hydraulic 3-way tipper ⇒...
  • Page 9 Amarok 2011 ➤ Maintenance - Edition 10.2012 2.1.2 Cleaning filling device -VAS 6542- – Open both cut-off taps -3- and -6- and clean or rinse all parts of filling device for AdBlue -VAS 6542- under running water. 2.1.3 Clean sealing surfaces on oil filter hous‐...
  • Page 10 Amarok 2011 ➤ Maintenance - Edition 10.2012 Note Only install clean parts. ♦ Do not take replacement parts out of their packaging until im‐ ♦ mediately before they are installed. Do not use parts that have been kept unpackaged (for exam‐...
  • Page 11 Amarok 2011 ➤ Maintenance - Edition 10.2012 2.1.8 Cleaning threads of threaded connec‐ tions – Clean threads of threaded connections -1- (shown here for Crafter) with a commercially available wire brush (brass or plastic) and, if necessary, remove dirt such as “rust” or “un‐...
  • Page 12 Amarok 2011 ➤ Maintenance - Edition 10.2012 Note Before blowing out the air filter housing with compressed air, ♦ cover components that conduct air such as the air mass meter, air inlet pipes etc. with a clean cloth or with blue blotting paper in order to prevent malfunctions.
  • Page 13 Amarok 2011 ➤ Maintenance - Edition 10.2012 2.1.16 Cleaning holes for filling and draining in transfer box – Clean surroundings of oil filler plug -1- and oil drainage plug -2- using a commercially available wire brush, if necessary using compressed air as well.

  • Page 14: Rules Of Cleanliness During Work With Information Material "Maintenance Manual

    Amarok 2011 ➤ Maintenance - Edition 10.2012 2.1.20 Cleaning holes for filling and draining in front-axle differential – Remove dirt from the surroundings of the filler plug -1- and drainage plug -2- with a commercially available brush or with a non-fibrous, lint-free cloth (for example universal cloth -VAS 6385- ).
  • Page 15 Amarok 2011 ➤ Maintenance - Edition 10.2012 Cleaning sealing flange on pulley side ⇒ page 11 Cleaning work on fuel tank ⇒ page 11 Cleaning work on fuel pressure sender -G247- ⇒ page 11 Cleaning work on air mass meter -G70- ⇒...
  • Page 16 Amarok 2011 ➤ Maintenance - Edition 10.2012 Note Do not allow dirt to get into the high-pressure accumulator ♦ hole. Do not allow any cleaning agent to get into the connector, ♦ clean it carefully. – Dry the fuel pressure sender -G247- .
  • Page 17 Amarok 2011 ➤ Maintenance - Edition 10.2012 WARNING Acetone is highly inflammable. Please comply with the acci‐ dent prevention regulations and the safety instructions when handling highly inflammable fluids. Wear protective goggles and protective clothing to avoid injury and contact with the skin.
  • Page 18 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Dip injectors together with mounting plate for injection mod‐ ules -VAS 6418/1- into the cleaning agent. – Set a temperature of 50 degrees with the rotating knob -4-. – Set a cleaning time of 30 minutes with the rotating knob -5-.
  • Page 19 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Open throttle valve by hand and block it in the open position with a suitable object (e.g. plastic or wooden wedge) -arrow- WARNING Acetone is highly inflammable. Comply with the accident pre‐...

  • Page 20: Rules Of Cleanliness During Work With Information Material "Maintenance Manual

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Rules of cleanliness during work with in‐ formation material “Maintenance Man‐ ual” Special tools and workshop equipment required ♦ Drip tray for V.A.G 1202 -V.A.G 1306/- ♦ Universal cloth -VAS 6385- ♦ Non-fibrous lint-free cloths ♦...

  • Page 21: Rules Of Cleanliness During Work With Information Material "Maintenance Manual

    Amarok 2011 ➤ Maintenance - Edition 10.2012 2.3.3 Cleaning tyre pressure sensor/wheel Note Make sure that the tyre and the tyre pressure sensor do not ♦ touch each other during removal or assembly work. Make sure that the wheel rim and the tyre pressure sensor do ♦...

  • Page 22: Rules Of Cleanliness During Work With Information Material "Maintenance Manual For Heating, Ventilation And Air Conditioning System

    Amarok 2011 ➤ Maintenance - Edition 10.2012 – Thoroughly clean contact surface with isopropanol (technical alcohol). 2.4.2 Cleaning cables – Clean sockets, connectors and cables with a non-fibrous, lint- free cloth (for example universal cloth -VAS 6385- ) and con‐...
  • Page 23 Amarok 2011 ➤ Maintenance - Edition 10.2012 ♦ A/C service station -VAS 6007A- ♦ Suction feed spray gun -V.A.G 1538- ♦ A/C service station with rinsing device -VAS 6381- ♦ A/C service station with rinsing device -VAS 6337- ♦ Adapter case, car kit, VW/Audi -VAS 6338/1- ♦...
  • Page 24 Amarok 2011 ➤ Maintenance - Edition 10.2012 Cleaning housing covers of the Hydronic “DW5S” ⇒ page 20 Rinsing (cleaning) refrigerant circuit with R134a refrigerant ⇒ page 20 Cleaning plug mantle on supplementary heater ⇒ page 27 Cleaning the evaporator with the suction feed spray gun -V.A.G 1538- and spraying lance ⇒...
  • Page 25 R134a refrigerant. Note How to rinse a refrigerant circuit is explained in the ⇒ Volkswagen ServiceNet; Volkswagen TV; API Online; OR Volkswagen TV Net; API / PKW under Modules, Body, and then the information broad‐...
  • Page 26 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Remove collecting receptacle (vehicle-specific) ⇒ Heating, air-conditioning system and connect refrigerant pipes to each other (using the adapters and the filling hose -VAS 6338/31- ) from the adapter case, car kit, VW/Audi -VAS 6338/1- .
  • Page 27 Amarok 2011 ➤ Maintenance - Edition 10.2012 Note Before the expansion valve is drilled open open, some parts ♦ have to be removed from it. There are different types of expansion valve. In the case of ♦ type -A-, you have to remove parts -B-, -C- and -D-. Then, detach the regulating element -E- from part -D-.
  • Page 28 Amarok 2011 ➤ Maintenance - Edition 10.2012 Note The components must always be rinsed in the direction oppo‐ ♦ site to the refrigerant's direction of flow during operation of the air-conditioning system. During rinsing, impurities from the refrigerant circuit get into ♦...
  • Page 29 Amarok 2011 ➤ Maintenance - Edition 10.2012 Note Rinsing of a refrigerant circuit is to be carried out in accordance ♦ with the operating instructions for the A/C service station. ♦ The container for old oil holds only approx. 125 cm of refrig‐...
  • Page 30 Amarok 2011 ➤ Maintenance - Edition 10.2012 – After a rinsing cycle, check the sight glass(es) of the rinsing device for refrigerant circuits and, if they are dirty, clean them in accordance with the operating instructions for the rinsing device for refrigerant circuits or the A/C service station. Carry out a rinsing cycle again to be on the safe side.
  • Page 31 Amarok 2011 ➤ Maintenance - Edition 10.2012 2.5.3 Cleaning plug mantle on supplementary heater 1 - Plug mantle for B1LC; B3LP and B3LC heaters - (fibre metal) 2 - Plug mantle for D1LC; D3LP and D3LC heaters - (screen) – Pull plug mantle out of plug socket by the lug -arrow A- with the help of pliers.
  • Page 32 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Before installing the heat exchanger, clean the seal's contact surface -3- on the roof of the vehicle. Rules of cleanliness during work with in‐ formation material “Maintenance Man‐ ual - Body” Special tools and workshop equipment required ♦...
  • Page 33 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Scrape off the still-soft adhesive residue, using a suitable spatula. – Completely remove any remaining adhesive residue with a primer applicator or cloth soaked in cleaning solution. 2.6.2 Cleaning in the event of dirt caused by adhesive sealing material –...
  • Page 34 Amarok 2011 ➤ Maintenance - Edition 10.2012 2.6.5 Cleaning work on the side window – Clean a 20 mm wide strip all round the edge of the side window in the sliding door -1- with the cleaning solution -D 009 401 04- .
  • Page 35 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Apply PUR adhesive sealing material -AKD 476 KD5- in white to all the points of connection -arrow-. 2.6.9 Cleaning work before renewal of em‐ blems etc. – Before removing an emblem etc., heat it with the hot-air blower -V.A.G 1416- .
  • Page 36 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Spray a thin film of soapy water onto the surface of the outer panel, using a spray bottle. – Pull backing of the bonding surface off the protective film. – Apply and align protective film.
  • Page 37 Amarok 2011 ➤ Maintenance - Edition 10.2012 Note An auxiliary tool - a probe which is approx. 2,300 mm long and made of speedometer drive shaft cores - is recommended for cleaning. 2.6.12 Cleaning water drainage hoses The water drainage hoses at the front are routed through or along the A-pillars and end in the plenum chamber.
  • Page 38 Amarok 2011 ➤ Maintenance - Edition 10.2012 The water drainage hoses at the rear are routed through the D- pillars and end in the rear wheel housings. Cleaning is carried out from the wheel housing and, to do this, the wheel housing liner must be removed.

  • Page 39: Rules Of Cleanliness During Work With Information Material "Maintenance Manual - Body

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Note A probe which is approx. 2,300 mm long and made of speedom‐ eter drive shaft cores is recommended for cleaning. Rules of cleanliness during work with in‐ formation material “Maintenance Man‐ ual - Body”...
  • Page 40 Amarok 2011 ➤ Maintenance - Edition 10.2012 Cleaning ATF lines and ATF cooler ⇒ page 36 Removing locking agent from threaded holes ⇒ page 36 Cleaning work on the clutch ⇒ page 37 Cleaning work on bolts and nuts ⇒ page 37 2.7.1...
  • Page 41 Amarok 2011 ➤ Maintenance - Edition 10.2012 2.7.3 Cleaning work on the clutch Note Clean splines of drive shaft and, if the clutch plate has been used, clean the splines of the hub. Remove corrosion and apply a very thin layer of lubricating grease for male splines of clutch plates - G 000 100- to the splines.

  • Page 42: Service Work

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Service work This chapter provides information on the following subjects: ♦ Information reference flexible or fixed service ⇒ page 38 ♦ Service tables ⇒ page 40 ♦ Scopes of service ⇒ page 50...
  • Page 43 For vehicles with a fixed service, fixed services are calculated. This means that the indicated mileage or time intervals have al‐ ready been determined and specified by Volkswagen Commer‐ cial Vehicles. For normal operating conditions achieving these service intervals is technically assured.

  • Page 44: Service Tables

    Service tables The following chapter contains the well-known service tables with the service specifications of the Volkswagen Commercial Vehi‐ cles brand. Since, in the past, individual service specifications were set up in various markets, mostly through severe operating conditions, these are listed in service tables with specific devia‐...
  • Page 45 Amarok 2011 ➤ Maintenance - Edition 10.2012 Service intervals Caution Only applies to diesel engines: • Some countries have an elevated sulphur content in diesel fuel. ♦ The high sulphur content leads to excessive wear of cyl‐ inders and it considerably reduces the cleanliness of pis‐...
  • Page 46 Amarok 2011 ➤ Maintenance - Edition 10.2012 Amarok 2013► Service intervals 2013► From - to PR No. Service: Indication on SID Intervals (with oil change) 2013► Oil change service (fixed): every 5,000 km or 1 year Oil change service (fixed):...
  • Page 47 3.2.2 Service tables with market-specific de‐ viations The following chapter contains the service tables for Volkswagen commercial vehicles for markets with individual maintenance re‐ quirements that differ from the German market due to the more difficult vehicle operating conditions in those markets.
  • Page 48 Amarok 2011 ➤ Maintenance - Edition 10.2012 Amarok 2010 ► Service interval 2010 ►2012 From to Engine/ Service: Indication on SID Engine code/ Intervals (with oil change) PR No./Remarks 2010 ▶ Diesel engines with high Oil change service depending on sul‐...
  • Page 49 Amarok 2011 ➤ Maintenance - Edition 10.2012 Amarok 2013► Service intervals 2013► From - to PR No. Service: Indicated on Intervals service interval display (includes oil change) 2013► Oil change service (fixed): every 5,000 km or 1 year Oil change service (fixed):...
  • Page 50 Amarok 2011 ➤ Maintenance - Edition 10.2012 Amarok ► 2012 Oil change intervals depending on sulphur content in fuel Fuel quality (EN590) ◀ 500 ppm 500-2,000 ppm 2,000-4,000 ppm ► 4,000 ppm Change interval 20 tkm/1 year 10 tkm/1 year 7.5 tkm/1 year...
  • Page 51 Amarok 2011 ➤ Maintenance - Edition 10.2012 Amarok ► 2012 Oil change intervals depending on sulphur content in fuel Fuel quality (EN590) ◀ 500 ppm 500-2,000 ppm 2,000-4,000 ppm ► 4,000 ppm Change interval 20 tkm/1 year 10 tkm/1 year 7.5 tkm/1 year...
  • Page 52 Amarok 2011 ➤ Maintenance - Edition 10.2012 Amarok ► 2012 Oil change intervals depending on sulphur content in fuel Fuel quality (EN590) ◀ 500 ppm 500-2,000 ppm 2,000-4,000 ppm ► 4,000 ppm Change interval 20 tkm/1 year 10 tkm/1 year 7.5 tkm/1 year...
  • Page 53 Amarok 2011 ➤ Maintenance - Edition 10.2012 Amarok ► 2012 Oil change intervals depending on sulphur content in fuel Fuel quality (EN590) ◀ 500 ppm 500-2,000 ppm 2,000-4,000 ppm ► 4,000 ppm Change interval 20 tkm/1 year 10 tkm/1 year 7.5 tkm/1 year...

  • Page 54: Scopes Of Service

    Scopes of service The following chapter contains the well-known service tables of the Volkswagen Commercial Vehicles brand. Since, in the past, individual service specifications were set up in various markets, mostly through severe operating conditions, these are listed in the scopes of service tables with market specific deviations.
  • Page 55 Amarok 2011 ➤ Maintenance - Edition 10.2012 Work to be completed Page ♦ All switches, electrical consumers, sockets, gauges and other control elements: Check function ♦ Door handles, door locks, central locking and windows: Check function and ease of movement ♦...
  • Page 56 Amarok 2011 ➤ Maintenance - Edition 10.2012 Work to be completed Page ♦ Vehicle underside (floor pan): Perform visual check for damage ⇒ page 146 ♦ Brake system: Perform visual check for leaks and damage ⇒ page 92 Engine compartment ♦...
  • Page 57 Amarok 2011 ➤ Maintenance - Edition 10.2012 3.3.2 Scopes of service Note The various types of service can be combined under certain ♦ circumstances (oil change or interval service in conjunction with an inspection service). Whereupon doubly listed activities are only charged once.
  • Page 58 Amarok 2011 ➤ Maintenance - Edition 10.2012 Int. Insp. Measure ♦ Tread depth, condition, wear pattern, age, inflation pressure (including spare tyre): Check, rectify as necessary ⇒ page 89 Vehicle from below ♦ Engine and components in engine compartment (from below), gearbox, final drive, rear axle and protective bellows: Perform visual check for leaks and damage ♦...
  • Page 59 Amarok 2011 ➤ Maintenance - Edition 10.2012 Int. Insp. Measure ♦ Cooling system: Check frost protection and coolant level, replenish if necessary • Specified antifreeze value: “-25 °C” In countries with an arctic climate “-35 °C” ⇒ page 115 Final checks ♦...
  • Page 60 Amarok 2011 ➤ Maintenance - Edition 10.2012 Additional work Interval Description of work ♦ Brake fluid: Change (comply with specification ) Every 2 years ⇒ page 95 • Check whether brake fluid service is due. ♦ Air filter: Clean housing and renew filter element Every 90,000 km ⇒...
  • Page 61 Amarok 2011 ➤ Maintenance - Edition 10.2012 Measure: Interval ♦ Dust and pollen filter (cabin filter): Clean housing Every 60,000 km and renew filter element ⇒ page 110 ♦ Spark plugs: Renew ⇒ page 149 ♦ Air filter: Clean housing and renew filter element (reset learnt values of engine control unit -J623- ) ♦...
  • Page 62 Amarok 2011 ➤ Maintenance - Edition 10.2012 Measure: Interval ♦ Camshaft drive toothed belt: Check Every 2 years • Valid in “dusty” regions, diesel engines ⇒ page 148 ♦ Dust and pollen filter (cabin filter): Clean housing and renew filter element ⇒...

  • Page 63: General

    Amarok 2011 ➤ Maintenance - Edition 10.2012 General ♦ Sticker ⇒ page 62 ♦ Entries in service schedule ⇒ page 63 ♦ Severe conditions ⇒ page 60 ♦ Vehicle identification number (chassis number) ⇒ page 59 ♦ Vehicle data sticker ⇒...

  • Page 64: Severe Operating Conditions

    Amarok 2011 ➤ Maintenance - Edition 10.2012 The sticker shows the following vehicle data. 1 - Vehicle identification number (chassis number) 2 - Vehicle type, engine output, gearbox 3 - Engine and gearbox code letters, paint number, interior equip‐ ment...
  • Page 65 Amarok 2011 ➤ Maintenance - Edition 10.2012 Country Dusty country Belize Benin Bhutan Bolivia Botswana Brazil China Guinea-Bissau Guyana India Israel Yemen Jordan Cambodia Cameroon Kazakhstan Canada Qatar Kenya Kuwait Laos Lesotho Lebanon Liberia Libya Madagascar Malawi Mali Singapore Somalia...

  • Page 66: Sticker

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Country Dusty country West Sahara Sticker ♦ Attaching service sticker “Your next service dates” ⇒ page 62 ♦ Attaching “vehicle data sticker” into customer service schedule and in vehicle ⇒ page 62 4.6.1 Attaching service sticker “Your next...

  • Page 67: Entries In Service Schedule

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Installation position of vehicle data sticker ⇒ page 59 1 - Week of production 2 - PR number Entries in service schedule ♦ If a component such as the toothed belt is replaced and is subject to a replacement interval stipulated by the manufac‐...

  • Page 68: Descriptions Of Work

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Descriptions of work ♦ Swivel joints: Visual check ⇒ page 79 ♦ Four-wheel drive: Insert fuse ⇒ page 107 ♦ Lifting the vehicle ⇒ page 65 ♦ Reading ash mass (saturation level) of diesel particulate filter ⇒...

  • Page 69: Lifting The Vehicle

    Amarok 2011 ➤ Maintenance - Edition 10.2012 ♦ Engine and components in engine compartment (from above and below): Perform visual check for leaks and damage ⇒ page 126 ♦ Engine oil: Drain or extract; renew oil filter and replenish en‐...
  • Page 70 Amarok 2011 ➤ Maintenance - Edition 10.2012 5.1.1 Safety notes WARNING ♦ Before driving onto a lifting platform, ensure that there is sufficient clearance between low-lying vehicle compo‐ nents and lifting platform. ♦ Before driving a vehicle onto a lifting platform it must be ensured that the vehicle weight does not exceed the per‐...
  • Page 71 Amarok 2011 ➤ Maintenance - Edition 10.2012 Note Raising vehicle with wheel lifts should mainly be done for all ♦ assembly work on vehicle. Only use support points listed in document when assembly ♦ work is performed on running gear or on axles.
  • Page 72 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Vehicle can now be raised and lowered to required working height. 5. Descriptions of work...
  • Page 73 Amarok 2011 ➤ Maintenance - Edition 10.2012 Raising vehicle under rear axle tube Special tools and workshop equipment required ♦ Prismatic support with minimum opening angle 120°. Note that the versions differ from one lifting platform manufacturer to another. Perform the following jobs: –...
  • Page 74 Amarok 2011 ➤ Maintenance - Edition 10.2012 – If necessary, secure vehicle additionally with tensioning straps -T10038- -4- directly on frame of front and rear support arms of lifting platform. – Vehicle can now be raised and lowered to required working height.
  • Page 75 Amarok 2011 ➤ Maintenance - Edition 10.2012 Raising vehicle before rear axle tube Perform the following jobs: – Front support arms of lifting platform with rubber plate sup‐ ports are positioned in area of front bolted gearbox cross member. – Rear support arms of lifting platform with rubber plate supports -1- are positioned in front of front leaf spring supports -2- under vehicle frame.
  • Page 76 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Vehicle can now be raised and lowered to required working height. 5. Descriptions of work...
  • Page 77 Amarok 2011 ➤ Maintenance - Edition 10.2012 5.1.3 Alternative ways of lifting the vehicle This chapter indicates different ways of lifting the vehicle. Please comply with the safety notes in chapter ⇒ page 66 and the in‐ structions for alternative ways of lifting the vehicle.
  • Page 78 Amarok 2011 ➤ Maintenance - Edition 10.2012 Alternative lift for front of vehicle Perform the following jobs: – Front support arms -1- of lifting platform with rubber plate sup‐ ports are positioned in area of front bolted gearbox cross member.
  • Page 79 Amarok 2011 ➤ Maintenance - Edition 10.2012 Alternative lift for rear of vehicle Perform the following jobs: – Front support arms of lifting platform with rubber plate sup‐ ports are positioned in area of front bolted gearbox cross member. – The rear support arms of the lifting platform with anti-slip discs -V.A.G 1994- -1- are positioned in front of the front leaf spring...
  • Page 80 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Vehicle can now be raised and lowered to required working height. 5. Descriptions of work...
  • Page 81 Amarok 2011 ➤ Maintenance - Edition 10.2012 5.1.4 Additional support of vehicle Note Depending on assembly condition of vehicle, it can be secured ♦ using height-adjustable stands -2- in addition to lashing it to support arms of lifting platform with tensioning straps - T10038- .
  • Page 82 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Alternatively, height-adjustable stands -2- can be positioned under rear leaf spring bracket -1- on rear axle tube. 5. Descriptions of work...

  • Page 83: Swivel Joints: Visual Check

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Swivel joints: Visual check Perform the following jobs: 5. Descriptions of work...

  • Page 84: Reading Ash Mass (Saturation Level) Of Diesel Particulate Filter

    Amarok 2011 ➤ Maintenance - Edition 10.2012 – Check boots -arrow- of lower swivel joints for leaks and dam‐ age. – Check boots -arrow- of upper swivel joints for leaks and dam‐ age. Reading ash mass (saturation level) of diesel particulate filter...

  • Page 85: Battery: Check Battery Terminal Clamps For Secure Seating

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Axle mass DPF Please observe the limits for maximum carbon black loading (val‐ ues are indicated in the following table): Engine Emis‐ Limit for changing DPF First test for DPF exchange sions (ash volume in ml or ash mass in (km or mi) stand‐...
  • Page 86 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Battery installation position ⇒ Electrical system; Rep. gr. 27 Perform the following jobs: – Switch off ignition, all electrical consumers and withdraw igni‐ tion key. Note It can be necessary to remove battery positive terminal cover, depending on equipment variant.
  • Page 87 Amarok 2011 ➤ Maintenance - Edition 10.2012 5.4.2 Battery terminal connections Caution To prevent damage to the battery terminal clamps and the bat‐ tery terminals, observe the following: ♦ The battery terminal clamps must only be connected by hand (without using force).

  • Page 88: Battery: Perform Visual Check And Check Magic Eye

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Battery: Perform visual check and check magic eye Perform the following jobs: – Visual inspection of battery as well as a battery check using “magic eye” ♦ Battery: Perform visual check ⇒ Electrical system; Rep. gr.
  • Page 89 Amarok 2011 ➤ Maintenance - Edition 10.2012 On RHD vehicles an additional adapter cable is installed to extend the electrical wiring harness of the battery cut-off relay to connect the brake fluid reservoir in right engine compartment. The battery cut-off relay protects the battery from discharging by electrical consumers not required during transportation from man‐...
  • Page 90 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Separate connector -2- of electrical wiring harness for battery cut-off relay from brake fluid reservoir. – Secure vehicle side cable -1- back on brake fluid reservoir connection. – Unscrew securing bolt (10 mm) -1- of battery cut-off relay from jump start point for battery positive terminal and remove.
  • Page 91 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Remove cable tie by unscrewing it from stud. Procedure for all vehicles Perform the following jobs: – Remove battery cut-off relay with electrical wiring harness and, if necessary, adapter cable for RHD.

  • Page 92: Front Passenger Front Airbag: Check Key Switch And "On/Off Function

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Front passenger front airbag: Check key switch and “On/Off function” Note If the airbag is deactivated, the front airbag, side airbag and cur‐ tain airbag are deactivated on the front passenger side. All other airbags in the vehicle remain functional.

  • Page 93: Checking Tyres: Condition, Wear Pattern, Tyre Pressure, Tread Depth

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Checking tyres: Condition, wear pattern, tyre pressure, tread depth Note The following descriptions of work also apply to the spare ♦ wheel, if a spare wheel with standard tyres is fitted. For safety reasons, only tyres of same type and tread pattern ♦...
  • Page 94 Amarok 2011 ➤ Maintenance - Edition 10.2012 Note If damage is determined, always check to see if a new tyre should be fitted. Tests at interval service Perform the following jobs: – Check following areas of tyre for damage: ♦ »Tyre treads«...
  • Page 95 Amarok 2011 ➤ Maintenance - Edition 10.2012 Note The minimum tread depth is reached when the tyres have ♦ worn down level with the 1.6 mm high tread wear indicators -arrows- positioned at intervals around the tyre. If the tread depth is approaching the minimum allowed depth, ♦...

  • Page 96: Brake System: Perform Visual Check For Leaks And Damage

    Amarok 2011 ➤ Maintenance - Edition 10.2012 ♦ V: up to 240 km/h Tyre pressure table: Applies to all factory-fitted tyre sizes. Permitted axle load Type of tyre Half payload Full payload Full load: FA / RA (kg) front rear...

  • Page 97: Thickness Of Brake Pads And Condition Of Front Brake Discs And Rear Drum Brake Linings: Check

    Amarok 2011 ➤ Maintenance - Edition 10.2012 WARNING Faults found must always be rectified (repair measure). 5.10 Thickness of brake pads and condition of front brake discs and rear drum brake linings: check Front disc brake pads: Check thickness ⇒ page 93 Rear drum brake pads: Check thickness ⇒...
  • Page 98 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Assess or measure inner and outer pad thickness. a - Pad thickness “without” backplate Wear limit: 2 mm WARNING The brake pads have reached their wear limit at a brake pad thickness of 2 mm (without backplate) and must be renewed (repair measure).

  • Page 99: Brake System And Shock Absorbers: Perform Visual Check For Leaks And Damage

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Wear limit: 1.5 mm (lining thickness only). WARNING The brake pads have reached their wear limit at a brake pad thickness of 2 mm (without backplate) and must be renewed (repair measure). Inform customer! Note Check linings for brake fluid or grease contamination.
  • Page 100 Amarok 2011 ➤ Maintenance - Edition 10.2012 WARNING ♦ Brake fluid must under no circumstances come into con‐ tact with fluids containing mineral oils (oil, petrol, cleaning solutions). Mineral oils will damage seals and sleeves of brake system. ♦ Brake fluid is poisonous. In addition, due to its corrosive nature, it must not come into contact with paint.
  • Page 101 Amarok 2011 ➤ Maintenance - Edition 10.2012 Perform the following procedure: – Unscrew sealing cover -1- from brake fluid reservoir -2-. Note The strainer in brake fluid reservoir must not be removed. – Extract as much brake fluid as possible using suction hose from brake filling and bleeding equipment -VAS 5234- .
  • Page 102 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Pull cover cap off bleeder valve of clutch slave cylinder -arrow-. – Push collector bottle bleeder hose onto bleeder valve of clutch slave cylinder. – Open bleeder valve and allow approx. 0.1 litre or 100 cm flow out.
  • Page 103 ⇒ Electronic parts catalogue “ETKA” . Permissible brake fluid specifications ♦ Volkswagen recommends using new brake fluid acc. to VW Standard 501 14 for optimum function of brake system. ♦ Alternatively, a brake fluid acc. to requirements of US standard FMVSS 116 DOT4 or DIN ISO 4925 Class 4 can be used.

  • Page 104: Brake Fluid Level: Check

    Amarok 2011 ➤ Maintenance - Edition 10.2012 ♦ Specification is stated on brake fluid packaging. 5.13 Brake fluid level: Check ♦ Checking brake fluid level at delivery inspection ⇒ page 100 ♦ Checking brake fluid level at interval service and inspection service ►...

  • Page 105: Climatronic: Set Temperature To 22 °C

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Recommended brake fluid level “BEFORE” brake pads are at wear limit: • “At MIN marking or just above”, -2- Then “REPLENISHING IS NOT REQUIRED!” Recommended brake fluid level, brake pads new or well within wear limit: •...

  • Page 106: Window Regulators: Check Positioning (Open And Close Functions)

    Amarok 2011 ➤ Maintenance - Edition 10.2012 5.15 Window regulators: Check positioning (open and close functions) WARNING After batteries have been disconnected and reconnected the roll-back function of the window regulators is disabled. Severe pinching injuries could result! Note The automatic opening and closing functions of the electric ♦...
  • Page 107 Amarok 2011 ➤ Maintenance - Edition 10.2012 ♦ Diagnosis cable -VAS 5051/5A- ♦ Vehicle diagnostic and service information system -VAS 5052 ♦ Diagnosis cable, 2 m -VAS 5052/3 A- ♦ Diagnosis cable, 5 m -VAS 5052/3 A-1- Note Observe current operating instructions for vehicle diagnostic, ♦...

  • Page 108: Performing Vehicle System Test

    Amarok 2011 ➤ Maintenance - Edition 10.2012 – Connect diagnosis cable connector to diagnosis connection with ignition switched off. – Switch on tester. – Switch on ignition. – Touch the field on the screen for Guided fault finding Guided functions –...
  • Page 109 Amarok 2011 ➤ Maintenance - Edition 10.2012 Note If faults are stored, the respective event memory must not be cleared. Reason: If the subsequent fault finding (repair measure) is performed using vehicle diagnosis, testing and information system -VAS 5051B- or vehicle diagnosis and service information system -VAS 5052...
  • Page 110 Amarok 2011 ➤ Maintenance - Edition 10.2012 Indicated on display: – Select function -arrow- on display of Vehicle system test vehicle diagnostic, testing and information system -VAS 5051B- or vehicle diagnostic and service information system -VAS 5052 A- . – Start system test by selecting function...

  • Page 111: Four-Wheel Drive: Insert Fuse

    Amarok 2011 ➤ Maintenance - Edition 10.2012 There are two ways to clear the event memory: ♦ Clearing event memory by selecting individual control units: Perform the following jobs: – Select control unit in question individually in overview, select and then press...
  • Page 112 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Release fuse holder C -SC- -1- -arrows- and fold down fuse holder C -SC- . – Remove “SC fuse / 25 A” -arrow-, which is attached to dash panel insert -K- .
  • Page 113 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Connect vehicle diagnostic, testing and information system - VAS 5051B- or vehicle diagnostic and service information system -VAS 5052 A- ⇒ page 102 Note Observe current operating instructions for vehicle diagnostic, ♦...

  • Page 114: Protective Bellows: Visual Check

    Amarok 2011 ➤ Maintenance - Edition 10.2012 5.19 Protective bellows: Visual check Perform the following jobs: – Check outer and inner CV joint boots -arrows- for leaks and damage. Note Carry out a “firm seating” visual inspection of the rear prop‐...

  • Page 115: Poly V-Belt: Check Condition

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Observe installation position of filter element -arrows-. – Insert new filter -1-. – Close cover -2- and bolt on with bolts -1-. 5.21 Poly V-belt: Check condition Perform the following jobs: – Use a socket spanner to turn the engine at the vibration damp‐...

  • Page 116: Poly V-Belt: Renew

    Amarok 2011 ➤ Maintenance - Edition 10.2012 – Check poly V-belt -1- for: ♦ Substructure cracks (cracks, core ruptures, cross sectional breaks) ♦ Layer separation (top layer, cord strands) ♦ Base break-up ♦ Fraying of cord strands ♦ Flank wear (material wear, frayed flanks, brittle flanks -glassy flanks-, surface cracks) ♦...

  • Page 117: Fuel Filter: Renew (Diesel Engine)

    Amarok 2011 ➤ Maintenance - Edition 10.2012 5.23 Fuel filter: Renew (diesel engine) Caution The fuel system must also be vented after replacement of the common rail high-pressure pump and all components that are upstream of the common rail high-pressure pump in the low- pressure fuel system.

  • Page 118: Fuel System: Bleed (Diesel Engine)

    Amarok 2011 ➤ Maintenance - Edition 10.2012 – Push fuel lines -1- onto fuel filter connection. When doing this ensure that fuel lines are seated securely on fuel filter. – Fuel system: Bleed (diesel engine) ⇒ page 114 – Start engine and conduct a visual check of fuel system on fuel filter.

  • Page 119: Cooling System: Check Frost Protection And Coolant Level

    Amarok 2011 ➤ Maintenance - Edition 10.2012 – Screw drain plug back in, if necessary first fitting it with a new seal if the old one was damaged. Note Observe disposal regulations! 5.26 Cooling system: Check frost protection and coolant level Caution Only distilled water may be used for mixing coolant additives.
  • Page 120 Amarok 2011 ➤ Maintenance - Edition 10.2012 ♦ Refractometer -T10007- Note Read precise value for the following tests at bright/dark boundary. Using a pipette, place a drop of water on the glass to improve the readability of the bright/dark boundary. The bright/dark boundary can be clearly recognised on the “WATERLINE”.
  • Page 121 Amarok 2011 ➤ Maintenance - Edition 10.2012 Frost protection to °C Quantity to drain (in litres) – Check coolant additive concentration after road test again. 5.26.2 Mixing coolants Refer to the table to glean which coolants can be mixed and which coolant can be added to the standard filling.

  • Page 122: Air Filter: Clean Housing And Renew Filter Element

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Recommended coolant level at delivery inspection: ♦ Coolant level above “Min. marking” -arrow-. Recommended coolant level at inspection service • Slightly above area -arrow-. – If coolant is too low, add required amount according to mixture ratio.
  • Page 123 Amarok 2011 ➤ Maintenance - Edition 10.2012 ♦ Spring-type clip pliers -VAS 5024/A- ♦ Torque wrench -V.A.G 1783- ♦ Torque screwdriver -VAS 6494- Perform the following jobs: Removing – Before changing air filter, clean outside of components with compressed air.
  • Page 124 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Loosen bolts -arrows- of air filter cover. – Raise air filter upper part and remove upwards. – Remove air filter element -1-. – Clean air filter housing if necessary. Installing Perform the following jobs: –...

  • Page 125: Air Filter With Saturation Indicator In Dash Panel Insert

    Amarok 2011 ➤ Maintenance - Edition 10.2012 5.28 Air filter with saturation indicator in dash panel insert: Note When rectifying a saturated filter as a separate job, clean air filter housing and renew filter element. Perform the following jobs: Saturation indicator is located in dash panel insert -K- and dis‐...

  • Page 126: Engine Oil Level: Check

    Amarok 2011 ➤ Maintenance - Edition 10.2012 5.30 Engine oil level: Check Note In engines with engine codes CFPA, CDBA and CDCA, it is only possible to assess and check oil level when engine is at operating temperature. Perform the following jobs: –...
  • Page 127 Amarok 2011 ➤ Maintenance - Edition 10.2012 5.31.1 Draining or extracting engine oil Note For engines with standing oil filter the oil filter must be renewed before changing the engine oil. When removing the filter element a valve is opened, the oil in the filter housing automatically flows into crankcase.
  • Page 128 Amarok 2011 ➤ Maintenance - Edition 10.2012 ♦ Renewing oil filter, engine with engine code CFPA ⇒ page 125 5.31.3 Renewing oil filter, engine with engine codes CDBA, CDCA Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-...
  • Page 129 Amarok 2011 ➤ Maintenance - Edition 10.2012 5.31.4 Renewing oil filter, engine with engine code CFPA Note Observe disposal regulations! Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Oil filter tool -VAS 3417- ♦ Oil filter with tensioning strap Hazet - 2171-1 ♦...

  • Page 130: Engine And Components In Engine Compartment (From Above And Below): Perform Visual Check For Leaks And Damage

    Amarok 2011 ➤ Maintenance - Edition 10.2012 5.31.5 Replenishing engine oil VW engine oil standards Engine oil capacities see ⇒ Engine lubrication; Rep. gr. 17 General notes Perform the following jobs: – After replenishing with oil, wait at least 3 minutes and then check oil level.

  • Page 131: Bonnet Catch: Clean, Ensure Attachment Is Secure And Lubricate

    Amarok 2011 ➤ Maintenance - Edition 10.2012 5.33 Bonnet catch: Clean, ensure attach‐ ment is secure and lubricate Special tools and workshop equipment required ♦ Universal cloth -VAS 6385- Perform the following jobs: – Clean bonnet catch -arrow- with cleaning solution -D 009 401 04- and, for example, a universal cloth -VAS 6385- .

  • Page 132: Check Breakdown Set

    Amarok 2011 ➤ Maintenance - Edition 10.2012 – Screw cleaned bolt back in hand-tight and then tighten firmly to prescribed torque. Specified torque: 25 Nm – Then unscrew second bolt -1- and clean contact surfaces -arrows- with cleaning solution -D 009 401 04- and, for exam‐...

  • Page 133: Performing Road Test

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Note If the breakdown set is not found at the fitting location described, this can be found in ⇒ vehicle wallet . 5.34.2 Check minimum use-by date The breakdown set consists of the compressor and a tyre filler bottle with sealant .

  • Page 134: Wheel Securing Bolts: Tighten To Specified Torque

    Amarok 2011 ➤ Maintenance - Edition 10.2012 – Steering: Function, steering free clearance, steering wheel centred when vehicle is travelling straight ahead – Radio/radio navigation system: Function, reception, GALA, in‐ terference noise – Multi-function indicator (MFI): Functions – Air conditioning system: Function –...

  • Page 135: Reading Radio Code

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Loosening anti-theft wheel bolts. Note To loosen the theft-resistant wheel bolts a special adapter is re‐ quired, located in vehicle tool kit or use adapter set for tamper- proof wheel bolts -T10101- or adapter set for tamper-proof wheel bolts -T10190- –...
  • Page 136 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Switch on ignition. – Press the button on display of vehicle di‐ Guided functions agnostic, testing and information system -VAS 5051B- or ve‐ hicle diagnostic and service information system -VAS 5052 A- .

  • Page 137: Radio / Radio Navigation System: Enter Anti-Theft Coding Pin

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Note Radio codes cannot be read in “FISH” with the previous ac‐ ♦ cess authorization for radio codes. Reading only functions with the access authorization for “GeKo” (secrecy and component protection). The access authorization for “GeKo” (secrecy and component ♦...

  • Page 138: Radio Navigation System: Insert Navigation Cd/Dvd And Perform Update

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Note If an incorrect code number is entered when releasing the elec‐ tronic lock, the whole procedure can be repeated once. If an incorrect code number is entered again, the unit is locked for about one hour.
  • Page 139 Amarok 2011 ➤ Maintenance - Edition 10.2012 ♦ Refractometer -T10007- Read precise value for the following tests at bright/dark boundary. Using a pipette, place a drop of water on the glass to improve the readability of the bright/dark boundary. The bright/dark boundary can be clearly recognised on the “WATERLINE”.
  • Page 140 Windscreen Clear with antifreeze G 052 164. The scale -2- is designed for commercially available windscreen cleanser as well as a mixture of commercially available wind‐ screen cleanser and genuine Volkswagen Windscreen Clear with antifreeze G 052 164. Mixture ratio...

  • Page 141: Windscreen Wiper Blades: Check Park Position

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Windscreen spray jet settings: The washer jets are preset. However, small height differences can be compensated for. Perform the following jobs: – If spray field is not at correct height, adjust spray direction up‐...

  • Page 142: Headlight Adjustment: Check, If Necessary Adjust

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Wiper blade tips should be located at marked position -arrow- on windscreen. – Adjust park position by moving wiper arm if necessary. – Switch windscreen wiper on and off and let it move into park position.
  • Page 143 Amarok 2011 ➤ Maintenance - Edition 10.2012 Perform the following jobs: – Read fuel level in fuel tank on fuel gauge. Determine additional weight from following table and place weight in luggage com‐ partment. Fuel gauge table Fuel level of...
  • Page 144 Amarok 2011 ➤ Maintenance - Edition 10.2012 The bright core of the light beam must be to the right of the vertical line. Note To simplify determination of the breaking point -2-, cover and ♦ uncover left (from driver perspective) half of the headlight a few times.

  • Page 145: Service Interval Display: Reset

    Amarok 2011 ➤ Maintenance - Edition 10.2012 ♦ Height adjustment bolt -1- ♦ Height/lateral adjustment bolt -2- – For height adjustment, turn adjustment screws -1- and -2- with same number of turns. – For lateral adjustment, only turn adjuster screw -2-.
  • Page 146 Amarok 2011 ➤ Maintenance - Edition 10.2012 5.44.1 Resetting service interval display using VAS vehicle diagnosis tester software Carry out the following work: – Connect vehicle diagnosis tester ⇒ page 102 – Switch on ignition. – Select the »Guided functions« field on the screen and carry out vehicle identification.

  • Page 147: Service Interval Display: Adapt (Export)

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Note ♦ It is not necessary to log in in order to enter or call up vehicle data. If the options indicated in the working procedure are not shown ♦ on the display ⇒ Operating instructions for vehicle diagnosis tester 5.45...

  • Page 148: Track Rod Ends: Check Clearance, Security And Boots

    Amarok 2011 ➤ Maintenance - Edition 10.2012 End adaptation. – Confirm end of interval adaptation with the »Done« button. – Exit “Guided functions”. – Switch off ignition and separate diagnosis connections. 5.46 Track rod ends: Check clearance, se‐ curity and boots Perform the following jobs: –...

  • Page 149: Doors: Grease Door Arrester

    Amarok 2011 ➤ Maintenance - Edition 10.2012 5.47.2 Oil at operating temperature Test prerequisites • Engine switched off Perform the following jobs: – Unscrew sealing cover -arrow- with built-in dipstick from tank. – Wipe off dipstick using a clean cloth.

  • Page 150: Protective Foil: Remove (If Fitted)

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Note Inform the customer when faults are found during visual check ♦ and repair measures are necessary. Faults found must always be rectified (repair measure). There‐ ♦ fore, further damage and corrosion and rusting through can be avoided.
  • Page 151 Amarok 2011 ➤ Maintenance - Edition 10.2012 – To access hour display -B- in dash panel insert -K- , press button -A-. – Briefly pressing -A- changes time by one hour for 0.0 / SET every press. – Pressing -A- for longer changes hour value quick‐...

  • Page 152: Camshaft Drive Toothed Belt And Toothed Belt Tensioning Roller: Renew

    Amarok 2011 ➤ Maintenance - Edition 10.2012 – Pressing -A- button again finishes time setting. 5.53 Camshaft drive toothed belt and toothed belt tensioning roller: Renew – The procedure is described in workshop manual ⇒ Rep. gr. 15 . 5.54 Camshaft drive toothed belt: Check con‐...

  • Page 153: Spark Plugs: Renew

    Amarok 2011 ➤ Maintenance - Edition 10.2012 5.57 Spark plugs: Renew Note Observe disposal regulations! Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331/- ♦ Spark plug socket and extension -VAS 3122B- ♦ Puller -T40039- 5. Descriptions of work...

  • Page 154: Removing And Installing Skid Plate

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Removing Perform the following jobs: – Pull out all ignition coils with final output stage from cylinder head approx. 30 mm using puller -T40039- . – Release connector -arrows- and simultaneously pull all con‐...

  • Page 155: Steering: Check Bellows For Leaks And Damage

    Amarok 2011 ➤ Maintenance - Edition 10.2012 – Unscrew bolts -2-, -3- and -4- one after another. – Remove skid plate -1- in -direction of arrow-. Note The assembly steps are basically a reverse of the dismantling procedure. – Screw in bolts hand-tight and then tighten to prescribed torque setting.

  • Page 156: Exhaust Emissions Test

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Exhaust emissions test Note The following exhaust emissions test description is applicable only in countries where no specific exhaust emission regulations have to be adhered to. Exhaust emissions test intervals in Germany: Vehicles with regulated catalytic converter or vehicles with diesel engine: ♦...

  • Page 157: Exhaust Emissions Test For Petrol Engines With Engine Code Cfpa

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Exhaust emissions test for petrol en‐ gines with engine code CFPA Note ♦ The following description refers to vehicles fitted with “On‐ board diagnosis” (OBD) and regulated catalytic converter. The OBD monitors all components and part systems influenc‐...
  • Page 158 Amarok 2011 ➤ Maintenance - Edition 10.2012 Initial screen – Select -arrow- button. Exhaust emissions test An overview is displayed to select the respective EET type. – Select -arrow-. EET petrol The display for warm-up phase appears. – Continue exhaust emission test according to instructions on display.
  • Page 159 ♦ Vehicle identification number -E- – Enter items -1…7- of vehicle data from vehicle registration certificate. ♦ -1- Vehicle manufacturer: “e.g. VOLKSWAGEN - VW” ♦ -2- Vehicle type: “e.g. 2H” ♦ -3- Key number to 2 (old) or 2.1 (new): “e.g. 0603”...
  • Page 160 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Enter displayed values on EET data sheet under “Test values for exhaust emissions test” on display in following sequence: Test speed (idling speed) Warm-up phase for catalytic converter Engine temperature Increased idling speed...
  • Page 161 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Connect diagnosis line connector to EOBD connection. – Switch on ignition. – Perform visual check of “MI lamp”. – If lamp lights up, press button -arrow C-. Lamp On – Follow instructions on display, see -arrow C- and -arrow A-.
  • Page 162 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Follow instructions on display. Measurement starts when the engine speed has reached the re‐ quired level. – Keep engine speed within required rpm range. The remaining time to perform the warm-up phase is displayed - arrow A -.
  • Page 163 Amarok 2011 ➤ Maintenance - Edition 10.2012 Measuring idling speed and CO content It is automatically switched to display for measuring the idling speed and CO content. Measurement starts when the engine speed has reached the re‐ quired level. The remaining time to perform measurement is displayed -arrow A-.

  • Page 164: Exhaust Emissions Test For Diesel Engines With Engine Codes Cdba, Cdca

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Exhaust emissions test for diesel en‐ gines with engine codes CDBA, CDCA Special tools and workshop equipment required ♦ Diesel tester -V.A.G 1743- ♦ Engine speed adapter -VAS 6296- ♦ Data sheets for exhaust emissions test...
  • Page 165 Amarok 2011 ➤ Maintenance - Edition 10.2012 ♦ Leakage ♦ Damage Note Faults found are to be rectified. With ignition switched off, connect testers as follows: – Pull on handbrake. – Manual gearbox: Gear lever in neutral – Connect diesel tester -V.A.G 1743- according to ⇒ operating instructions with ignition switched off.
  • Page 166 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Depress accelerator pedal fully and hold for specified time. – Check maximum engine speed (not adjustable). WARNING If the governed speed (maximum speed) is exceeded, lift off accelerator pedal immediately and perform repair measures.

  • Page 167: Exhaust Emissions Test With Obd

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Exhaust emissions test with OBD Note The following exhaust emission test description is only appli‐ ♦ cable in countries where specific exhaust emission regulations have to be adhered to. In motor vehicles with spark ignition engine or compression ♦...
  • Page 168 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Perform visual check: ♦ Crankcase breather system connected, ♦ Exhaust system must be leaktight, ♦ Catalytic converter and particulate filter present and undam‐ aged. Checking and adjusting prerequisites: ♦ Electrical consumers switched off, ♦...
  • Page 169 Amarok 2011 ➤ Maintenance - Edition 10.2012 – Select “Engine” -arrow- in vehicle diagnostic system guided menu. – Select “Generate readiness code” -arrow-. – Follow instructions of vehicle diagnostic, testing and informa‐ tion system -VAS 5051B- or vehicle diagnostic and service information system -VAS 5052- .

  • Page 170: Glossary

    Amarok 2011 ➤ Maintenance - Edition 10.2012 Glossary These explanations only apply to “Maintenance Manual”. They are not necessarily generally valid! Letter “A” ⇒ page 166 Letter “B” ⇒ page 166 Letter “C” ⇒ page 166 Letter “D” ⇒ page 167 Letter “E”...
  • Page 171 Amarok 2011 ➤ Maintenance - Edition 10.2012 Term Explanation Carbon monoxide is produced when fuels containing carbon are not combusted com‐ (Carbon monoxide) pletely. Measurement unit for ignition quality of diesel fuel (Cetane number) Letter “D” Term Explanation The diesel particulate filter is installed behind the catalytic converter and filters soot (Diesel particulate particles from emissions.
  • Page 172 Amarok 2011 ➤ Maintenance - Edition 10.2012 Letter “P” Term Explanation PR number Abbreviation for production control number. It identifies among other things optional equipment, country-specific deviations Letter “Q” Term Explanation Vehicles are “not” fitted at the factory with components for LongLife service. For main‐...
  • Page 173 Amarok 2011 ➤ Maintenance - Edition 10.2012 Letter “W” Term Explanation Extended servicing interval Letter “X” Term Explanation “Extra Load”, reinforced tyre, additional designation for tyres with increased load ca‐ pacity 7. Glossary...

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