Volkswagen Amarok 2011 Installation and user guide

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

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Maintenance
Heading
1. Engine list
2. General rules of cleanliness
3. Service work
4. General
5. Descriptions of work
6. Exhaust emissions test
7. Glossary
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2012 Volkswagen AG, Wolfsburg D3E8027339B

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Contents
1 Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General rules of cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Rules of cleanliness during work with information material “Maintenance Manual” . . . . . . 3
2.2 Rules of cleanliness during work with information material “Maintenance Manual” . . . . . . 10
2.3 Rules of cleanliness during work with information material “Maintenance Manual” . . . . . . 16
2.4 Rules of cleanliness during work with information material “Maintenance Manual” . . . . . . 17
2.5 Rules of cleanliness during work with information material “Maintenance manual for heating,
ventilation and air conditioning system” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.6 Rules of cleanliness during work with information material “Maintenance Manual - Body”
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.7 Rules of cleanliness during work with information material “Maintenance Manual - Body”
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3 Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.1 Information reference flexible or fixed service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2 Service tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.3 Scopes of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.1 Vehicle identification number (chassis number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.2 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.3 Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.4 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.5 Countries with high levels of dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.6 Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.7 Entries in service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5 Descriptions of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.1 Lifting the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.2 Swivel joints: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.3 Reading ash mass (saturation level) of diesel particulate filter . . . . . . . . . . . . . . . . . . . . . . 80
5.4 Battery: Check battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . . . . 81
5.5 Battery: Perform visual check and check magic eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.6 Removing relay for battery disconnection (if fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.7 Front passenger front airbag: Check key switch and “On/Off function” . . . . . . . . . . . . . . . . 88
5.8 Checking tyres: Condition, wear pattern, tyre pressure, tread depth . . . . . . . . . . . . . . . . . . 89
5.9 Brake system: Perform visual check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . 92
5.10 Thickness of brake pads and condition of front brake discs and rear drum brake linings:
check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.11 Brake system and shock absorbers: Perform visual check for leaks and damage . . . . . . 95
5.12 Brake fluid: Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.13 Brake fluid level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.14 Climatronic: Set temperature to 22 °C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.15 Window regulators: Check positioning (open and close functions) . . . . . . . . . . . . . . . . . . 102
5.16 Vehicle diagnosis tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.17 Performing vehicle system test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.18 Four-wheel drive: Insert fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.19 Protective bellows: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.20 Dust and pollen filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . 110
5.21 Poly V-belt: Check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.22 Poly V-belt: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.23 Fuel filter: Renew (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.24 Fuel system: Bleed (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.25 Fuel filter: Drain water (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.26 Cooling system: Check frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.27 Air filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.28 Air filter with saturation indicator in dash panel insert: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Amarok 2011 ➤
Maintenance - Edition 10.2012
Contents i

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5.29 Resetting programmed values in engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.30 Engine oil level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.31 Engine oil: Drain or extract; renew oil filter and replenish engine oil . . . . . . . . . . . . . . . . . . 122
5.32 Engine and components in engine compartment (from above and below): Perform visual
check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.33 Bonnet catch: Clean, ensure attachment is secure and lubricate . . . . . . . . . . . . . . . . . . . . 127
5.34 Check breakdown set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.35 Performing road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.36 Wheel securing bolts: Tighten to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.37 Reading radio code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.38 Radio / radio navigation system: Enter anti-theft coding PIN . . . . . . . . . . . . . . . . . . . . . . . . 133
5.39 Radio navigation system: Insert navigation CD/DVD and perform update . . . . . . . . . . . . . . 134
5.40 Timing chain: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.41 Windscreen wash/wipe system and headlight washer system: Check function and settings
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.42 Windscreen wiper blades: Check park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.43 Headlight adjustment: Check, if necessary adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.44 Service interval display: Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.45 Service interval display: Adapt (export) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.46 Track rod ends: Check clearance, security and boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.47 Power assisted steering: Check fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.48 Doors: Grease door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.49 Paint: Perform visual check for damage and corrosion, interior and exterior when doors and
bonnet/rear lid/flaps are open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.50 Protective foil: Remove (if fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.51 Underbody protection: Perform visual check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.52 Clock: Set to correct time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.53 Camshaft drive toothed belt and toothed belt tensioning roller: Renew . . . . . . . . . . . . . . 148
5.54 Camshaft drive toothed belt: Check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.55 Toothed belt for water pump: renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.56 Toothed belt for balancer shaft: renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.57 Spark plugs: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5.58 Removing and installing skid plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.59 Steering: Check bellows for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
6 Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.1 General information for exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.2 Exhaust emissions test for petrol engines with engine code CFPA . . . . . . . . . . . . . . . . . . 153
6.3 Exhaust emissions test for diesel engines with engine codes CDBA, CDCA . . . . . . . . . . 160
6.4 Exhaust emissions test with OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
7 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Amarok 2011 ➤
Maintenance - Edition 10.2012
ii Contents

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1 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.
Engines: ⇒ Diesel Diesel Diesel Diesel Diesel Diesel
Capacity I 2.0 2.0 2.0 2.0 2.0 2.0
Introduction Week 05/2010 ► Week 05/2010 ► Week
05/2012 ►
Week
22/2012 ►
Week 30/2012 ► Week
05/2012 ►
Engine code CDBA CDCA CNEA CNFA CNFB CSHA
No. of cylinders/
valves per cylin‐
der
4/4 4/4 4/4 4/4 4/4 4/4
Output kW at
rpm
90/3750 120/4000 132/4000 90/3750 103/3500 132/4000
Torque Nm at
rpm
340/1750-2500 400/1500-2000 400/1500 -
2250
340/1600 -
2000
340/1600-2250 420/1750
Bore ∅ mm 81.0 81.0 81.0 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5 95.5 95.5 95.5
Compression
ratio
16.5 16.5 16.0 16.0 16.0 16.0
Injection/igni‐
tion
TDI common rail TDI common rail TDI com‐
mon rail
TDI com‐
mon rail
TDI common rail TDI com‐
mon rail
Diesel particu‐
late filter yes/no1) yes/no1) yes/no1) yes/no1) yes/no1) yes/no1)
Camshaft drive Toothed belt Toothed belt Toothed
belt
Toothed
belt
Toothed belt Toothed
belt
Petrol engines
Engines: ⇒ Petrol
Capacity I 2.0
Introduction Week 42/2010 ►
Engine code CFPA
No. of cylinders/valves per cylinder 4/4
Output kW at 1 rpm 118/3800-5500
Torque Nm at rpm 300/1600-3750
Bore ∅ mm 82.5
Stroke mm 92.8
Compression ratio 9.6
Injection/ignition Motronic MED 17.5 TSI turbocharg‐
er
Amarok 2011 ➤
Maintenance - Edition 10.2012
1. Engine list 1

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.
Engines: ⇒ Petrol
Capacity I 2.0
Introduction Week 42/2010 ►
Engine code CFPA
Camshaft drive Chain
Amarok 2011 ➤
Maintenance - Edition 10.2012
2 1. Engine list

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2 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.
♦ If the repair is not performed immediately, carefully cover or
seal opened components.
♦ Fit only clean parts. Remove spare parts from their packaging
only immediately before their use. Do not use parts that have
been kept unpackaged (for example in toolboxes or similar).
♦ If a system is open, avoid working with compressed air if pos‐
sible. If possible, do not move the vehicle.
⇒ “2.1 Rules of cleanliness during work with information material
Maintenance Manual ”, page 3
⇒ “2.2 Rules of cleanliness during work with information material
Maintenance Manual ”, page 10
⇒ “2.3 Rules of cleanliness during work with information material
Maintenance Manual ”, page 16
⇒ “2.4 Rules of cleanliness during work with information material
Maintenance Manual ”, page 17
⇒ “2.5 Rules of cleanliness during work with information material
Maintenance manual for heating, ventilation and air conditioning
system ”, page 18
⇒ “2.6 Rules of cleanliness during work with information material
Maintenance Manual - Body ”, page 28
⇒ “2.7 Rules of cleanliness during work with information material
Maintenance Manual - Body ”, page 35
2.1 Rules of cleanliness during work with in‐
formation material “Maintenance Man‐
ual”
Special tools and workshop equipment required
♦ Universal cloth -VAS 6385-
♦ Non-fibrous lint-free cloths
♦ Soft commercially available sponge
♦ Commercially available wire brush (brass or plastic)
♦ Commercially available vacuum cleaner
Amarok 2011 ➤
Maintenance - Edition 10.2012
2. General rules of cleanliness 3

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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 5
Cleaning bonnet lock ⇒ page 6
Cleaning guide rails of sliding sunroof ⇒ page 6
Cleaning threads of threaded connections ⇒ page 7
Cleaning holes in rear axle for checking and draining
⇒ page 7
Cleaning fuel filter housing and fuel filter connections
⇒ page 7
Cleaning fuel filter housing ⇒ page 7
Cleaning dipstick ⇒ page 8
Cleaning padded surface and the foamed surface of the airbag
unit ⇒ page 8
Cleaning filler neck of reducing-agent tank ⇒ page 8
Cleaning rear door hinges ⇒ page 8
Cleaning holes for checking and draining in manual gearbox
⇒ page 9
Cleaning spray jets for headlight cleaning system ⇒ page 9
Cleaning dust and pollen filter housing ⇒ page 9
Cleaning holes for filling and draining in transfer box
⇒ page 9
Cleaning holes for filling and draining in front-axle differential
⇒ page 10
Cleaning water drain hole in floor area of sliding door
⇒ page 10
2.1.1 Cleaning automatic dipstick
– Pull out automatic dipstick and wipe with a clean, non-fibrous
lint-free cloth or the universal cloth -VAS 6385- , then push
dipstick back in as far as it will go.
Amarok 2011 ➤
Maintenance - Edition 10.2012
4 2. General rules of cleanliness

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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‐
ing and oil filter cover
– Clean sealing surfaces on threaded cap and on oil filter hous‐
ing with a non-fibrous, lint-free cloth (for example universal
cloth -VAS 6385- ).
Note
♦ Ensure that no engine oil comes into contact with coolant ho‐
ses or other engine parts or painted parts. If necessary, clean
hoses immediately.
♦ Observe disposal regulations!
2.1.4 Cleaning sliding window seals
– Remove all dirt and dust from the seals of the sliding window
and from the contact surfaces of the sliding window seals, us‐
ing a soft sponge or a non-fibrous and lint-free cloth (for
example universal cloth -VAS 6385- ) and normal rinsing wa‐
ter.
Note
After cleaning, treat the sliding window seals using a commer‐
cially available anti-soiling rubber care product.
2.1.5 Cleaning electro-hydraulic 3-way tipper
– Before undoing connections, thoroughly clean them and their
surroundings with a non-fibrous, lint-free cloth (for example
universal cloth -VAS 6385- ).
– Place removed parts on a clean surface and cover them with
a non-fibrous, lint-free cloth (for example universal cloth -VAS
6385- ).
– Carefully cover opened components with a non-fibrous, lint-
free cloth (for example universal cloth -VAS 6385- ).
Amarok 2011 ➤
Maintenance - Edition 10.2012
2. General rules of cleanliness 5

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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‐
ple in toolboxes etc.).
2.1.6 Cleaning bonnet lock
– Clean bonnet catch -arrow- with cleaning solution -D 009 401
04- and, for example, a universal cloth -VAS 6385- . Also use
“compressed air” to clean if necessary.
2.1.7 Cleaning guide rails of sliding sunroof
– Clean guide rails of sliding sunroof -arrows- with a non-fibrous,
lint-free cloth (for example universal cloth -VAS 6385- ) or a
soft sponge.
Note
After cleaning the guide rails, lubricate them again with grease -
G 000 450 02- .
Amarok 2011 ➤
Maintenance - Edition 10.2012
6 2. General rules of cleanliness

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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‐
derbody sealing compound”.
2.1.9 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.
– Cover magnet of oil drainage plug with a non-fibrous, lint-free
cloth (for example universal cloth -VAS 6385- ).
Note
Observe disposal regulations!
2.1.10 Cleaning fuel filter housing and fuel filter
connections
– Remove dirt from fuel filter housing and fuel filter connections
with a non-fibrous, lint-free cloth (for example universal cloth
-VAS 6385- ), if necessary using a wire brush as well (brass
or plastic).
– Cover surroundings of fuel filter connections with a non-fi‐
brous, lint-free cloth (for example universal cloth -VAS 6385- ).
Note
♦ Ensure that no diesel fuel contacts coolant hoses. If necessa‐
ry, clean hoses immediately.
♦ Observe disposal regulations!
2.1.11 Cleaning fuel filter housing
– Remove air filter element.
– Then, clean filter housing with a non-fibrous, lint-free cloth or
the universal cloth -VAS 6385- , a vacuum cleaner or with
compressed air.
Amarok 2011 ➤
Maintenance - Edition 10.2012
2. General rules of cleanliness 7

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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.
♦ When replacing air filter, make sure that no dirt gets into intake
hose, air mass meter -G70- and air filter cover.
2.1.12 Cleaning dipstick
– Pull out dipstick and wipe with a clean, non-fibrous lint-free
cloth or the universal cloth -VAS 6385- , then push dipstick
back in as far as it will go.
2.1.13 Cleaning padded surface and the
foamed surface of the airbag unit
WARNING
It is not permissible to cover or attach stickers to the padded
surface of the steering wheel and the foamed surface of the
airbag or to modify them in some other way.
– Remove dirt from padded surface of steering wheel and the
foamed surface of the airbag with a dry cloth or a cloth mois‐
tened with water.
2.1.14 Cleaning filler neck of reducing-agent
tank
– Clean filler neck of reducing-agent tank with a lint-free cotton
cloth moistened with water or with a non-fibrous, lint-free cloth
(for example universal cloth -VAS 6385- ).
2.1.15 Cleaning rear door hinges
– Remove dirt from door hinges -arrows- with a non-fibrous, lint-
free cloth (for example universal cloth -VAS 6385- ).
Amarok 2011 ➤
Maintenance - Edition 10.2012
8 2. General rules of cleanliness

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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.
– Cover magnet of oil drainage plug with a non-fibrous, lint-free
cloth (for example universal cloth -VAS 6385- ).
Note
Observe disposal regulations!
2.1.17 Cleaning spray jets for headlight clean‐
ing system
– Flush removed spray jets in direction opposite to spraying di‐
rection and, if necessary, use compressed air to clean them
in spraying direction and opposite direction.
Caution
♦ Never use items to clean the spray jets!
♦ Never use a needle or a similar object to adjust the spray
jets, otherwise the water passages in the spray jet will be
damaged!
2.1.18 Cleaning dust and pollen filter housing
– Clean the surroundings of the dust and pollen filter with a vac‐
uum cleaner, for example, or a non-fibrous, lint-free cloth or
the universal cloth -VAS 6385- .
– Remove dust and pollen filter.
– Before installing the dust and pollen filter, clean the shaft of
the heating and air-conditioning unit with a vacuum cleaner or
a non-fibrous, lint-free cloth or the universal cloth -VAS 6385- .
2.1.19 Cleaning holes for filling and draining in
transfer box
– 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- ).
Amarok 2011 ➤
Maintenance - Edition 10.2012
2. General rules of cleanliness 9

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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- ).
2.1.21 Cleaning water drain hole in floor area
of sliding door
– Remove dirt from water drain holes -2- with a commercially
available brush or a non-fibrous, lint-free cloth (for example
universal cloth -VAS 6385- ).
– Poke through water drain holes -2- e.g. with an appropriate
cable tie -1- and, if necessary, remove dirt with a vacuum
cleaner.
2.2 Rules of cleanliness during work with in‐
formation material “Maintenance Man‐
ual”
Special tools and workshop equipment required
♦ Ultrasonic cleaning device -VAS 6418-
♦ Cleaning fluid -VAS 6418/2-
♦ Mounting plate for injection modules -VAS 6418/1-
♦ Universal cloth -VAS 6385-
♦ Nylon brush -T10133/4-
♦ Commercially available paintbrush
Amarok 2011 ➤
Maintenance - Edition 10.2012
10 2. General rules of cleanliness

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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 12
Cleaning work on fuel pressure regulating valve -N276-
⇒ page 12
Cleaning work on intake manifold flap housing ⇒ page 12
Cleaning work on holes of injectors ⇒ page 13
Cleaning work on injectors ⇒ page 13
Cleaning work on high-pressure lines ⇒ page 14
Cleaning work on the Teflon seal of the injectors ⇒ page 14
Cleaning work on throttle valve module -J338- ⇒ page 14
Cleaning work on a used injector (piezo injector) ⇒ page 15
Cleaning work when glow plugs are removed or installed
⇒ page 15
2.2.1 Cleaning sealing flange on pulley side
– Remove sealant residue from sealing flange with a rotating
plastic brush (wear protective goggles).
– Cover sealing surfaces with a commercially available brake
cleaner and a non-fibrous, lint-free cloth (for example univer‐
sal cloth -VAS 6385- ).
Note
Sealing surfaces must be free of oil and grease.
2.2.2 Cleaning work on fuel tank
Note
♦ Whenever work is done on the fuel system, ensure cleanliness
and do the work carefully.
♦ The fuel system reacts sensitively to the ingress of dirt.
– Clean inside of fuel tank with a lint-free cloth.
2.2.3 Cleaning work on fuel pressure sender -
G247-
– Before removing the fuel pressure sender -G247- , clean the
threaded area around it (e.g. with a commercially available
degreaser).
Amarok 2011 ➤
Maintenance - Edition 10.2012
2. General rules of cleanliness 11

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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- .
– Unscrew and remove fuel pressure sender -G247- -1-.
Note
Seal the high-pressure accumulator hole immediately with a suit‐
able bung in order to prevent the ingress of dirt.
2.2.4 Cleaning work on air mass meter -G70-
– Check intake port for dirt as far as the air filter element.
If any dirt is found.
– If there is any salt residue, dirt or leaves in the air filter housing,
wash the housing out with a non-fibrous, lint-free cloth (for ex‐
ample universal cloth -VAS 6385- ) or vacuum cleaner.
2.2.5 Cleaning work on fuel pressure regulat‐
ing valve -N276-
– Before removing the regulating valve, clean it with a commer‐
cially available degreaser, for example, or compressed air.
Note
♦ Do not allow dirt to get into the hole of the high-pressure ac‐
cumulator (fuel rail) in any circumstances.
♦ Do not allow any cleaning agent to get into the connector at
the fuel pressure regulating valve -N276- .
2.2.6 Cleaning work on intake manifold flap
housing
Note
Coking can occur in the housing of the throttle valve due to the
interplay of unfavourable factors. If coking is discovered, e.g. dur‐
ing removal of the exhaust gas recirculation valve -N18- or the
motor for the intake manifold flap -V157,- , the housing has to be
cleaned.
Amarok 2011 ➤
Maintenance - Edition 10.2012
12 2. General rules of cleanliness

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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.
– Remove intake manifold flap housing.
– Remove exhaust gas recirculation valve -N18- as well as the
motor for intake manifold flap -V157- .
– Thoroughly clean intake manifold flap housing, especially in
the area of the exhaust gas recirculation valve, using acetone
to DIN 53247 and a paintbrush.
– Wipe inside of intake manifold flap housing with a lint-free
cloth.
– Allow acetone to dry off completely.
– Complete the cleaned intake manifold flap housing.
– Replace seal and fit again.
2.2.7 Cleaning work on holes of injectors
– Thoroughly clean the holes of injector for cylinder 1 -N30- to
injector for cylinder 4 -N33- in the cylinder head with the nylon
brush -T10133/4- .
2.2.8 Cleaning work on injectors
Note
Comply with safety regulations and operating instructions for the
ultrasonic device.
– Ultrasonic device must have been filled with cleaning fluid -
VAS 6418/2- .
Note
Ultrasonic device must have been filled with cleaning agent up to
the upper edge of the holes (see magnifying glass).
– Insert injectors -1- into mounting plate for injection modules -
VAS 6418/1- as far as they will go -2-.
Amarok 2011 ➤
Maintenance - Edition 10.2012
2. General rules of cleanliness 13

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.
– 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-.
– Switch on the ultrasonic device with button -3-.
Note
The set time starts as soon as the cleaning temperature reaches
50 degrees.
2.2.9 Cleaning work on high-pressure lines
– Before removing high-pressure lines, clean their surroundings
thoroughly and all over with brake cleaner and a lint-free cloth.
2.2.10 Cleaning work on the Teflon seal of the
injectors
– Before installing the injectors, clean holes of injectors in cyl‐
inder head thoroughly with the Nylon brush provided -
T10133/4- .
– Remove old seal and clean the groove of the seal -arrow-.
– Remove any deposits (coking) with a brass wire brush.
2.2.11 Cleaning work on throttle valve module
-J338-
Note
Make sure that the throttle valve housing is not scratched during
cleaning.
– Remove throttle valve module -J338- .
Amarok 2011 ➤
Maintenance - Edition 10.2012
14 2. General rules of cleanliness

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– 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‐
vention regulations and the safety instructions when handling
highly inflammable fluids. Do not use compressed air to clean
the throttle valve. Wear protective goggles and protective
clothing to avoid injury and contact with the skin.
– Thoroughly clean intake manifold flap housing, especially in
the area -arrows- of the closed throttle valve, using acetone to
DIN 53247 and a paintbrush.
– Wipe the inside of the throttle valve housing with a lint-free
cloth.
– Allow acetone to dry off completely and then installed the
cleaned throttle valve module.
2.2.12 Cleaning work on a used injector (piezo
injector)
Clean the sealing surface of the injectors (piezo injectors) in the
cylinder head and the injector shaft.
– Use a clean cloth soaked in diesel fuel or rust remover to re‐
move soot particles on the sealing surface.
Caution
Do not use engine oil for cleaning.
Avoid causing damage to the sealing surface.
2.2.13 Cleaning work when glow plugs are re‐
moved or installed
– Remove rough dirt in the glow plug channel in the cylinder
head with the help of a vacuum cleaner.
– Spray brake cleaner into the glow plug channel in the cylinder
head or spray a suitable cleaning agent into the glow plug
channel.
– After allowing cleaner to work in, blow out with compressed
air.
– Then, clean glow plug channel with a a non-fibrous, lint-free
cloth moistened with oil (for example universal cloth -VAS
6385- ).
Amarok 2011 ➤
Maintenance - Edition 10.2012
2. General rules of cleanliness 15

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2.3 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
♦ Commercially available screw tap
Removing tyre sealant from wheel rim ⇒ page 16
Care and treatment of alloy wheels ⇒ page 16
Cleaning tyre pressure sensor/wheel rim ⇒ page 17
Cleaning work on brake system ⇒ page 17
2.3.1 Removing tyre sealant from wheel rim
WARNING
Do not allow tyre sealant to come into contact with eyes or skin!
It is damaging to health and can cause eye irritation and aller‐
gies.
During assembly work, wear protective gloves and goggles.
– Using a suitable drill or cutter, carefully make a hole in the
shoulder area of the tyre.
– Hold wheel over drip tray and allow sealant to flow out.
– Remove tyre from wheel rim.
– Clean wheel rim with a damp cloth, for example.
2.3.2 Care and treatment of alloy wheels
Note
After cleaning or removing adhesive residue from the wheels, the
wheels must be rinsed with water again.
Amarok 2011 ➤
Maintenance - Edition 10.2012
16 2. General rules of cleanliness