Volkswagen Amarok 2011 Workshop Manual
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