Volkswagen Amarok 2011 Workshop Manual

MANUALVolkswagenVolkswagen Amarok

Workshop Manual Amarok 2011. 4-cylinder injection engine, 2.0 l direct injection engine, turbocharger. Engine ID CFPA. Edition 02.2011

Repair Group
00 – Technical data
10 – Removing and installing engine
13 – Crankshaft group
15 – Cylinder head, valve gear
17 – Lubrication
19 – Cooling
20 – Fuel supply system
21 – Turbocharging/supercharging
24 – Mixture preparation – injection
26 – Exhaust system
28 – Ignition system

CONTENTS

  • 00 – Technical data
  • 1 Technical data
  • 1.1 Engine number
  • 1.2 Engine data
  • 10 – Removing and installing engine
  • 1 Removing and installing engine
  • 1.1 Removing engine
  • 1.2 Securing engine on engine and gearbox support – VAS 6095 –
  • 1.3 Notes on installing
  • 1.4 Assembly and gearbox mountings
  • 13 – Crankshaft group
  • 1 Cylinder block (pulley end)
  • 1.1 Assembly overview – poly V-belt drive
  • 1.2 Removing and installing tensioner for poly V-belt
  • 1.3 Removing and installing poly V-belt
  • 1.4 Removing and installing ancillary bracket
  • 1.5 Removing and installing vibration damper
  • 2 Cylinder block (gearbox end)
  • 2.1 Assembly overview – sealing flange and drive plate
  • 2.2 Removing and installing drive plate
  • 2.3 Removing and installing needle bearing in/from drive plate
  • 2.4 Removing and installing sealing flange on gearbox side
  • 3 Pistons and conrods
  • 3.1 Assembly overview – pistons and conrods
  • 3.2 Separating new conrod
  • 3.3 Piston and cylinder dimensions
  • 4 Crankshaft
  • 4.1 Assembly overview – crankshaft
  • 4.2 Allocation of crankshaft bearing shells (classification)
  • 4.3 Crankshaft dimensions
  • 4.4 Measuring axial clearance of crankshaft
  • 4.5 Measuring radial clearance of crankshaft
  • 4.6 Pulling needle bearing out of and driving into crankshaft . . . .
  • 15 – Cylinder head, valve gear
  • 1 Cylinder head
  • 1.1 Assembly overview – cylinder head
  • 1.2 Removing and installing cylinder head
  • 1.3 Checking compression
  • 1.4 Removing and installing vacuum pump
  • 2 Chain drive
  • 2.1 Assembly overview – timing chain cover
  • 2.2 Removing and installing inlet camshaft control valve 1 N205
  • 2.3 Removing and installing upper timing chain cover
  • 2.4 Removing and installing timing chain cover (bottom)
  • 2.5 Renewing oil seal for vibration damper
  • 2.6 Camshaft timing chain – exploded view
  • 2.7 Removing and installing camshaft timing chain
  • 2.8 Assembly overview – balancer shaft timing chain
  • 2.9 Removing and installing balancer shaft module
  • 2.10 Renewing balancer shaft for inlet camshaft
  • 2.11 Renewing balancer shaft for exhaust camshaft
  • 2.12 Checking valve timing
  • 3 Valve gear
  • 3.1 Assembly overview – valve gear
  • 3.2 Removing and installing camshafts
  • 3.3 Renewing valve stem seals with cylinder head installed
  • 3.4 Renewing valve stem seals with cylinder head removed
  • 3.5 Checking valve guides
  • 3.6 Checking axial clearance of camshafts
  • 17 – Lubrication
  • 1 Parts of lubrication system
  • 1.1 General notes on the lubrication system
  • 1.2 Engine oil
  • 1.3 Assembly overview – sump, oil pump
  • 1.4 Removing and installing coarse oil separator
  • 1.5 Removing and installing oil pump
  • 1.6 Removing and installing lower part of sump
  • 1.7 Removing and installing upper part of sump
  • 2 Oil filter bracket, oil pressure, engine oil cooler and oil supply line
  • 2.1 Assembly overview – oil filter, engine oil cooler
  • 2.2 Removing and installing engine oil cooler
  • 2.3 Removing and installing oil pressure switch F22
  • 2.4 Removing and installing oil supply line to turbocharger
  • 2.5 Checking oil pressure
  • 19 – Cooling
  • 1 Cooling system
  • 1.1 General notes on cooling system
  • 1.2 Draining and filling coolant
  • 1.3 Checking cooling system for leaks
  • 2 Coolant hose schematic diagram
  • 2.1 Coolant hose schematic diagram for vehicles with heat exchanger
  • 2.2 Coolant hose schematic diagram for vehicles with 2nd heat exchanger
  • 3 Parts of cooling system, engine side
  • 3.1 Assembly overview – coolant pipes and continued coolant circulation pump V51
  • 3.2 Removing and installing continued coolant circulation pump V51
  • 3.3 Coolant pump and thermostat – exploded view
  • 3.4 Removing and installing coolant temperature sender G62
  • 3.5 Removing and installing toothed belt for coolant pump
  • 3.6 Renewing oil seal for coolant pump drive
  • 3.7 Removing and installing coolant pump
  • 3.8 Removing and installing thermostat
  • 4 Parts of cooling system, body side
  • 4.1 Assembly overview – parts of cooling system, body side
  • 4.2 Assembly overview – air ducting with radiator fan V7
  • 4.3 Removing and installing cowling with radiator fan V7
  • 4.4 Removing and installing radiator
  • 20 – Fuel supply system
  • 1 General notes on fuel system
  • 1.1 General notes on fuel system
  • 1.2 Safety precautions when working on fuel supply system
  • 1.3 Rules for cleanliness
  • 1.4 Releasing pressure in high-pressure area
  • 2 Fuel pump
  • 2.1 Checking fuel pump
  • 3 Fuel tank
  • 3.1 Assembly overview – fuel tank
  • 3.2 Removing and installing fuel tank
  • 3.3 Removing and installing fuel delivery unit
  • 3.4 Removing and installing fuel gauge sender G
  • 3.5 Removing and installing filler neck
  • 3.6 Assembly overview – fuel filter with attachments
  • 3.7 Removing and installing fuel filter
  • 3.8 Removing and installing fuel pump control unit J538
  • 4 Electronic power control (EPC)
  • 4.1 Assembly overview – accelerator module
  • 4.2 Removing and installing accelerator module
  • 5 Activated charcoal filter system
  • 5.1 Checking fuel tank breather
  • 21 – Turbocharging/supercharging
  • 1 Charge air system
  • 1.1 Safety precautions
  • 1.2 Rules for cleanliness
  • 1.3 Instructions for hose connections with screw-type clips
  • 1.4 Assembly overview – charge air cooling
  • 1.5 Removing and installing pressure pipe
  • 1.6 Removing and installing charge pressure sender G31
  • 1.7 Removing and installing charge air cooler
  • 1.8 Checking charge air system for leaks
  • 2 Turbocharger
  • 2.1 Assembly overview – turbocharger
  • 2.2 Removing and installing turbocharger
  • 2.3 Checking vacuum unit for turbocharger
  • 24 – Mixture preparation – injection
  • 1 Safety precautions and rules for cleanliness
  • 1.1 General notes on self-diagnosis
  • 2 Injection system
  • 2.1 Overview of fitting locations
  • 2.2 Assembly overview – air filter
  • 2.3 Removing and installing air filter housing
  • 2.4 Removing and installing air filter element
  • 2.5 Removing and installing air mass meter G70
  • 2.6 Assembly overview – intake manifold
  • 2.7 Assembly overview – fuel rail
  • 2.8 Removing and installing intake manifold
  • 2.9 Removing and installing injectors
  • 2.10 Renewing Teflon seal on injector
  • 2.11 Cleaning injectors
  • 2.12 Removing and installing fuel pressure sender -G247
  • 2.13 Removing and installing throttle valve module J338
  • 2.14 Cleaning throttle valve module J338
  • 2.15 Assembly overview – high-pressure pump
  • 2.16 Removing and installing high-pressure pump
  • 2.17 Removing and installing engine control unit
  • 3 Checking components
  • 3.1 Check fuel holding pressure upstream of high-pressure pump
  • 3.2 Checking intake manifold change-over
  • 3.3 Checking fuel pressure sender G247
  • 3.4 Checking double non-return valve
  • 26 – Exhaust system
  • 1 Assembly overview – parts of the exhaust system
  • 1.1 Removing and installing catalytic converter
  • 1.2 Removing and installing exhaust manifold
  • 1.3 Removing and installing centre silencer
  • 1.4 Removing and installing rear silencer
  • 1.5 Checking exhaust system for leaks
  • 1.6 Aligning exhaust system free of stress
  • 1.7 Installation position and specified torque of the clamp
  • 28 – Ignition system
  • 1 Repairing ignition system
  • 1.1 General notes on ignition system
  • 1.2 Safety precautions
  • 1.3 Assembly overview – ignition system
  • 1.4 Removing and installing ignition coils with output stage
  • 1.5 Removing and installing spark plugs
  • 1.6 Removing and installing knock sensor 1 G61
  • 1.7 Removing and installing engine speed sender G28
  • 1.8 Test data, spark plugs

Language: English
Format: PDF
Pages: 259

Volkswagen Amarok 2011 Workshop Manual