Volkswagen Amarok 2011 Workshop Manual

Volkswagen 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

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

Volkswagen Amarok 2011 Workshop Manual

CONTENTS