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Service

Maintenance
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Edition 01.2011

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Service Department. Technical Information


Service
Maintenance

Heading
1. Engine list
2. Service work
3. General
4. Descriptions of work
5. Exhaust emissions test
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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.

All rights reserved.


No reproduction without prior agreement from publisher.

Copyright © 2011 Volkswagen AG, Wolfsburg D3E8027339B


Amarok 2011 ➤
AG. Volkswagen AMaintenance - Edition 01.2011
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1 Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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2 Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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2.1 Information on LongLife service and time or distance dependent service . . . . . . . . . . . . . . 2

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2.2 Service tables, inland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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2.3 Service tables, export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Service tables, Argentina and Brazil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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2.5 VW engine oil standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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2.6 Delivery inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.7 Scopes of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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2.8 Time or distance dependent additional work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.9 Market specific deviations - scope of work for Argentina and Brazil . . . . . . . . . . . . . . . . . . 17
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3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 Vehicle identification number (chassis number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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3.2 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19


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3.3 Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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3.4 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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3.5 Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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3.6 Entries in service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22


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3.7 RME fuel (biodiesel) that does not conform with the standard . . . . . . . . . . . . . . . . . . . . . . 22

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4 Descriptions of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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4.1 Lifting vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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4.2 Swivel joints: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.3 Reading ash mass (saturation level) of diesel particulate filter . . . . . . . . . . . . . . . . . . . . . . 45
4.4 Battery: Check battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . . . . 47
4.5 Battery: Perform visual check and check magic eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.6 Removing relay for battery disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.7 Front passenger front airbag: Check key switch and „On/Off function“ . . . . . . . . . . . . . . . . 55
4.8 Checking tyres: Condition, wear pattern, tyre pressure, tread depth . . . . . . . . . . . . . . . . . . 56
4.9 Brake system: Perform visual check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . 60
4.10 Front brake pads/linings: Check thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.11 Rear drum brake linings: Check thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.12 Brake system and shock absorbers: Perform visual check for leaks and damage . . . . . . 65
4.13 Brake fluid: Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.14 Brake fluid level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.15 Climatronic: Set temperature to 22 °C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.16 Window regulators: Check positioning (open and close functions) . . . . . . . . . . . . . . . . . . 71
4.17 Connecting vehicle diagnosis tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.18 Performing vehicle system test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.19 Four-wheel drive: Insert fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.20 Protective bellows: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.21 Dust and pollen filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . 80
4.22 Poly V-belt: Check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.23 High pressure pump: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.24 Poly V-belt: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.25 Fuel filter: Renew (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.26 Fuel system: Bleed (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.27 Fuel filter: Drain water (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.28 Cooling system: Check frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.29 Air filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.30 Air filter with saturation indicator in dash panel insert: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.31 Resetting programmed values in engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.32 Engine oil level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.33 Engine oil: Drain or extract; renew oil filter and replenish engine oil . . . . . . . . . . . . . . . . . . 91

Contents i
Amarok 2011 ➤
Maintenance - Edition 01.2011

4.34 Engine and components in engine compartment (from above and below): Perform visual
check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.35 Bonnet catch: Clean, ensure attachment is secure and lubricate . . . . . . . . . . . . . . . . . . . . 96
4.36 Check breakdown set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.37 Performing road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.38 Wheel securing bolts: Tighten to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.39 Reading radio code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.40 Radio / radio navigation system: Enter anti-theft coding PIN . . . . . . . . . . . . . . . . . . . . . . . . 101
4.41 Radio navigation system: Insert navigation CD/DVD and perform update . . . . . . . . . . . . . . 102
4.42 Timing chain: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.43 Windscreen wash/wipe system and headlight washer system: Check function and settings
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.44 Windscreen wiper blades: Check park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.45 Headlight adjustment: Check, if necessary adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.46 Service interval display: Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.47 Service interval display: Recode (adapt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.48 Service interval: Adjusting (inland) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.49 Service interval: Adjusting (export) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.50 Service interval: Adjusting (Argentina and Brazil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.51 Track rod ends: Check clearance, security and boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.52 Power assisted steering: Check fluid level . . . . . . . . . . . . . . . A. G. ..V.ol.k.sw. a.g.e.n .A. . . . . . . . . . . . 126
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4.53 Doors: Grease door arrester . . . . . . . . . . . . . . . . . . V.o.lk.sw. a. . . . . . . . . . . . . . . .d.oe. s.n.ot. . . . . . 128
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4.54 Paint: Perform visual check for damage and corrosion, ise
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bonnet/rear lid/flaps are open . . . . . . . . . . . .th.o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .te.e o128
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4.55 Protective foil: Remove (if fitted) . . . . . . .ss.a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 c

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4.56 Underbody protection: Perform visual check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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4.57 Clock: Set to correct time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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4.58 Camshaft drive toothed belt and toothed belt tensioning roller: Renew . . . . . . . . . . . . . . 130

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4.59 Camshaft drive toothed belt: Check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

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4.60 Coolant pump toothed belt sprocket and toothed belt: Renew . . . . . . . . . . . . . . . . . . . . . . 131

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4.61 Spark plugs: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

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4.62 Removing and installing skid plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

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4.63 Steering: Check bellows for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5 Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

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5.1 General information for exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.2 Exhaust emissions test for petrol engines with engine code CFPA . . . . . . . . . . . . . . . . . . 135
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5.3 Exhaust emissions test for diesel engines with engine codes CDBA, CDCA . . . . . . . . . . 142
5.4 Exhaust emissions test with OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
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6 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
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ii Contents
Amarok 2011 ➤
Maintenance - Edition 01.2011

1 Engine list
Diesel engines ⇒ page 1
Petrol engines ⇒ page 1
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Engines: ⇒ Diesel engines Diesel engines
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Capacity I 2,0 2,0
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Introduction WEEK 05/2010 ▶ WEEK 05/2010 ▶
Engine code CDBA CDCA

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No. of cylinders/valves per cylinder 4/4 4/4
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Output kW at rpm 90/3750 120/4000


Torque Nm at rpm 340/1750-2500 400/1500-2000

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Bore ∅ mm 81,0 81,0


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Injection/ignition TDI common rail TDI common rail


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Diesel particulate filter yes/no1) yes/no1)
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Petrol engines
Engines: ⇒ Petrol engines
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
Camshaft drive Chain

1. Engine list 1
Amarok 2011 ➤
Maintenance - Edition 01.2011

2 Service work
♦ Information on LongLife service and time or distance depend‐
ent service ⇒ page 2
♦ Scopes of service ⇒ page 12
♦ Service tables ⇒ page 5
♦ Delivery inspection ⇒ page 10
♦ Time or distance dependent additional work ⇒ page 15

2.1 Information on LongLife service and


time or distance dependent service
♦ LongLife service ⇒ page 2
♦ Service identification ⇒ page 2
♦ Service interval display ⇒ page 4
♦ Time or distance dependent service ⇒ page 3

2.1.1 Service identification


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– Check vehicle data sticker to determine agen
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The PR number is decisive for rise service intervals
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The vehicle data sticker -arrow- is attached to the left A-pillar low‐
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This vehicle data sticker is also found in the service schedule for ab
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Vehicle ID with PR number
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„QG1“ indicates „LongLife service“.


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„QG2“ or „QG0“ indicates „time or distance dependent“ service.


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2.1.2 LongLife service


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Vehicles with PR number „QG1“


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With the LongLife system, a new technology was introduced by


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Volkswagen commercial vehicles whereby an interval service is


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only performed when the vehicle needs it.


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What is so special about it is that individual conditions of use and


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Note
AG.

If no LongLife engine oil is filled or replenished, the time or dis‐


tance dependent service applies. A shorter service interval ap‐
plies in this instance. Information about the different intervals can
be gleaned from ⇒ page 5 Service tables, inland.

2 2. Service work
Amarok 2011 ➤
Maintenance - Edition 01.2011

Note

For the LongLife service a special LongLife engine oil is required


⇒ page 10 .

Vehicles with PR number „QG1“ are set up for active LongLife


service before they leave the factory. This means that these ve‐
hicles have a flexible service interval display and are fitted with
the following components:
♦ Flexible service interval display in dash panel insert
♦ Engine oil level sensor
For vehicles with LongLife service the service interval is deter‐
mined by the control unit and is indicated on service interval
display (SID) ⇒ page 4 .
Therefore the service intervals for LongLife service are flexible.
These flexible service intervals are valid for all types of service
including an engine oil change.

2.1.3 Time or distance dependent service


On vehicles with time or distance dependent service with PR
number „QG0/QG2“ non-flexible service intervals apply.
For normal operating conditions achieving these service intervals
is technically assured.
This means that the indicated mileage or time intervals have al‐
ready been determined and specified by Volkswagen Commer‐
cial Vehicles.
Therefore the service intervals for time or distance dependent
service are non-flexible.
For vehicles
♦ that were delivered without extended service intervals
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(production control number QG0Volksw= without ESI, production not
control number QG2 = ESIed b cannot be activated)
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♦ When the extendedauservicing
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♦ or in which LongLife engine oil has not been used,
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the time or distance dependent service applies.


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These flexible service intervals are valid for all types of service
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Vehicles with PR number „QG0“


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These vehicles are „not“ factory-fitted with components for Long‐


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Life service. For maintenance the time or distance dependent


intervals (non-flexible intervals) apply.
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Vehicles with PR number „QG2“


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For these vehicles the LongLife service is not factory-activated.


Therefore, these vehicles have a non-flexible service interval dis‐
play (SID) ⇒ page 4 and for maintenance the time or distance
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dependent intervals (non-flexible intervals) are valid. These ve‐


hicles are fitted with the following components:
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♦ Non-flexible service interval display in dash panel insert


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♦ Engine oil level sensor


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Prote AG. 2. Service work
Amarok 2011 ➤
Maintenance - Edition 01.2011
AG. Volkswagen AG d
2.1.4 Service interval display Volkswagen oes
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Introduction of extended servicing intervals
or
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Ask your importer if the extendedsservicing
sa interval (ESI) is avail‐ c
able for your country.

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Flexible service interval display (only vehicles with LongLife serv‐
itte

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Calculation of service intervals:

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♦ To calculate the service intervals for vehicles with LongLife
hole

spec
service, input values such as distance driven, fuel consump‐
es, in part or in w

tion, oil temperature and load of diesel particulate filter are

t to the co
evaluated.
♦ The result of the evaluation is a measure of the deterioration

rrectness of i
of the oil due to thermal load.
l purpos

♦ Oil deterioration is the decisive factor in determining the dis‐


tance that can still be driven before the next service.

nform
mercia

Note

a
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tion in
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For vehicles with LongLife service (PR number QG1) but which

thi
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are serviced according to time or distance dependent intervals,

do
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the service interval display need not be recoded to „non-flexible“


rp

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⇒ page 111 .

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Cop py
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Non-flexible service interval display (only vehicles with time or
gh ht
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distance dependent service, PR number „QG0/QG2“)
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Prote AG.
Calculation of service intervals:
♦ The service interval for vehicles with time-dependent or mile‐
age-dependent service is calculated in so-called non-flexible
service intervals.
♦ This means that the mileage or time values have been previ‐
ously determined and specified by Volkswagen.
♦ For normal operating conditions achieving these service in‐
tervals is technically assured.
Servicing when service is due
♦ When a service is due, „Service“ or „Service now“ appears on
the „trip recorder“ on the dash panel insert display or on the
display for various kinds of information in the dash panel insert.
The service messages disappear after a few seconds or if the
engine is running.
Service initial warning
If a service is due, an „advance service warning“ appears on the
dash panel insert display when the ignition is switched on.
♦ The dash panel insert display shows the »symbol of a work‐
shop spanner« and a km number.
The service messages disappear after a few seconds or if the
engine is running.
♦ The remaining distance displayed is always rounded to the
nearest 100 km or the remaining time rounded to full days.
Requesting service information.
The current service information can be requested at any time with
the ignition switched on, the engine turned off and the vehicle at
a standstill.

4 2. Service work
Amarok 2011 ➤
Maintenance - Edition 01.2011

– Press button -A- in dash panel insert four times until „spanner
symbol“ appears in dash panel insert -B-.
♦ On the dash panel insert display, an overdue service is indi‐
cated by a minus sign in front of the mileage or day information.

Note
. Volkswage
Service message goes out after
lksw
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AG
when
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-A- is pressed. o not
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2.2 Service tables, inland

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itte

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♦ Service intervals ⇒ page 5

ility
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2.2.1 Service intervals

h re
hole

spec
To ensure that every service is carried out at the right time and
es, in part or in w

that no service is forgotten, a service sticker on the door pillar or

t to the co
the service interval indicator on the display of the dash panel in‐
sert serves as a reminder.

rrectness of i
Information about service sticker is displayed at ⇒ page 20 .
l purpos

Caution

nf
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o
♦ Diesel engines: In some regions, elevated sulphur content
rm
m

may be evident. The high sulphur content leads to exces‐ atio


om

sive wear of cylinders and it considerably reduces the


n in
or c

cleanliness of pistons. Short service intervals apply in this


thi
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sd

instance.
iva

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Depending on the conditions of use and the vehicle's equipment,
Prote AG.

extra service work must be performed in addition to the inspection


service or oil change service ⇒ page 15 .

2. Service work 5
Amarok 2011 ➤
Maintenance - Edition 01.2011

Amarok
n AG. VolService intervals,
kswagen AG
inland 2010 ►
lkswage does
not
o
From to d by V Engine/ gu
ara Service: Indication on SID
oris
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Engine code/ nte Intervals
eo (with oil change)
th PR No./Remarks ⇒ page 4
au ra
c
ss
2010 ▶ QG0/QG2 or QG1 vehi‐ Oil change service every YES

ce
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nl

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cles coded to fixed inter‐ 10,000 km 1) diesel en‐

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vals

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Oil change service every YES
ot p

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15,000 km, petrol engines
, is n

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Oil change service every YES
hole

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20,000 km or 1 year 1) die‐
es, in part or in w

t to the co
sel engines
Interval service max. YES
40,000km or 2 years1)

rrectness of i
QG1 vehicles Interval service max. YES
l purpos

30,000km or 2 years2),
petrol engines

nform
ercia

Interval service max. YES


40,000 km or 2 years 1)
m

at
om

diesel engines

ion
c

in t
r

All vehicles First inspection service af‐ NO


o

his
te

ter 3 years, then every 2


a

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years
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1) Vehicles with elevated sulphur content in diesel fuel.
Co
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2)
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Whichever occurs first yri
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2.3 Service tables, export


♦ Service intervals depending on sulphur content in fuel
⇒ page 7

2.3.1 Service intervals


To ensure that every service is carried out at the right time and
that no service is forgotten, a service sticker on the door pillar or
the service interval indicator on the display of the dash panel in‐
sert serves as a reminder.

Caution

♦ Diesel engines: In some countries, the sulphur content in


the diesel fuel deviates from the EN590 standard. The
elevated sulphur content leads to increased wear in the
cylinders and impairs piston cleanliness considerably.
Short service intervals apply in this instance.
♦ To find out which countries have increased sulphur con‐
tent in the diesel fuel, see ⇒ page 7 .

Note

Depending on the conditions of use and the vehicle's equipment,


extra service work must be performed in addition to the inspection
service or oil change service.

6 2. Service work
Amarok 2011 ➤
Maintenance - Edition 01.2011

Amarok
Service interval, export 2010 ►
From to Engine/ Service: Indication on SID
Engine code/ agen AG. VolkIntervals
swagen AG
does (with oil change)
PR No./Remarks olksw not
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ara
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2010 ▶ QG0/QG2 or thQG1or
is vehi‐
Oil change service 1)
nte
e YES
cles codeds ato fixed inter‐
u ⇒ page 7
or
ac
vals s
Interval service max. YES

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40,000km or 2 years2)

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QG1 vehicles Interval service max. YES

ility
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30,000km or 2 years2),

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petrol engines

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Interval service max. YES

spec
urposes, in part or in wh

40,000 km or 2 years 2)

t to the co
diesel engines
All vehicles First inspection service af‐ NO
ter 3 years, then every 2

rrectne
years

s
1)For oil change service intervals, please refer to table specified

s o
cial p

f
for relevant country.

inform
mer

2) Whichever occurs first

atio
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i
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2.3.2 Oil change intervals depending on sulphur content in fuel
iva

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Oil change intervals depending on sulphur content in fuel


t.
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op py
Fuel quality (EN590) ◀ 500 ppm 500-2,000 ppm 2,000-4,000 ppm ▶ 4,000 ppm
t. C rig
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Change interval ESI 20,000 km 10,000 km 7,500 km 5,000 km
cop Vo
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Turkey X 1) 2)
AG.

Norway X
Iceland X
Switzerland X
Croatia X 2) X 1)
Albania X
Macedonia X 2) X 1)

Montenegro X 2) X 1)
Serbia X
Bosnia-Herzegovina X
RUS X 3) X East 1) X (West )
Belarus X 1)
Ukraine X 1) 2)
Moldova X
Armenia X
Azerbaijan X
Georgia X 1) 2)
Kazakhstan X
Kirghizia X
Mongolia X
Turkmenistan X
Uzbekistan X

2. Service work 7
Amarok 2011 ➤
Maintenance - Edition 01.2011

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 ESI 20,000 km 10,000 km 7,500 km 5,000 km
Mexico X
Chile X
Venezuela X
Columbia X
Ecuador X
Surinam X
Peru AG. Volkswagen AG d
X
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Bolivia yV
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Paraguay orise X nte
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Uruguay ss a X ra
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France overseas territo‐ X

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ries and departments

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Caribbean X

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Israel X

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Bahrain X
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Qatar X
es, in part or in w

t to the co
Kuwait X
Oman X

rrectness of i
Saudi Arabia X
United Arab Emirates X
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Africa X

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Kenya X

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Algeria
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n in
Libya X
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Tunisia X 4) X 1)
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Egypt X
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Ivory Coast X
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Ghana X
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Mauritius X
Mali X
Nigeria X
Senegal X
Zimbabwe X
Tanzania X
Tajikistan X
Uzbekistan X
Dominican Republic X
Guatemala X
Honduras X
Trinidad and Tobago X
Gabon X
Madagascar X
Iraq X

8 2. Service work
Amarok 2011 ➤
Maintenance - Edition 01.2011

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 ESI 20,000 km 10,000 km 7,500 km 5,000 km
Iran X
Jordan X
Lebanon X
Syria X
El Salvador X
Jamaica X
Cuba X
Panama X

1) Local diesel
2) Euro diesel AG. Volkswagen AG d
agen oes
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3) Eco diesel d by ara
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2.4 Service tables, Argentina and Brazil


un

pt
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d
itte

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♦ Service interval ⇒ page 9
rm

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ility

2.4.1 Service intervals


ot

wit
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h re
hole

To ensure that every service is carried out at the right time and
spec

that no service is forgotten, a service sticker on the door pillar or


es, in part or in w

t to the co

the service interval indicator on the display of the dash panel in‐
sert serves as a reminder.
Information about service sticker is displayed at ⇒ page 20 .
rrectness of i

Amarok
l purpos

Service intervals, Brazil/Argentina 2010 ►


nform
ercia

From to Engine/ Service: Indication on SID


Engine code/ Intervals (with oil change)
m

PR No./Remarks
com

tion in
r

2010 ► QG0/QG2 or QG1 vehi‐ Initial oil change service at YES


te o

thi

cles coded to fixed inter‐ 5,000 km, then every


s
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do
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vals 10,000 km 1)
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Oil change service every YES


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10,000 km or 6 months 2)
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Adapt service interval to respective distance-based interval.
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2) Whichever occurs first

2. Service work 9
Amarok 2011 ➤
Maintenance - Edition 01.2011

2.5 VW engine oil standards

Note

♦ For vehicles with LongLife service (PR number QG1) that are
serviced according to time or distance dependent intervals,
the service interval display does not have to be recoded to
„non-flexible“.
♦ Only engine oils approved by Volkswagen Commercial Vehi‐
cles may be used. Up-to-date information ⇒ Volkswagen
Commercial Vehicles ServiceNet, Technical information, In‐
spections and servicing, Approved oils

Amarok
VW ENGINE OIL STANDARDS
With LongLife service (QG1) Without LongLife service (QG0, QG2)
PETROL ENGINE
4-cylinder 504 00 n4-cylinder
AG. Volkswagen AG d 504 00
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alternative 503 00 y Volks
alternative
not
gu 501 01 / 502
db ara
ir se nte 00
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DIESEL ENGINES aut ra
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4-cylinder 507 00 1) 4-cylinder 507 00 1)

ce
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nl

pt
du

(with Bosch EDC 17 505 01 2) (with Bosch EDC 17 505 012)

an
itte

TDI common rail with die‐ TDI common rail with die‐

y li
erm

ab
sel particulate filter) sel particulate filter)

ility
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4-cylinder 507 00 1) 4-cylinder 507 00 1)

wit
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(with Bosch EDC 17 505 012) (with Bosch EDC 17 505 012)
hole

TDI common rail without TDI common rail without

spec
diesel particulate filter) diesel particulate filter)
es, in part or in w

t to the co
rrectness of i
1) Only for markets where diesel complies with EN 590.
l purpos

2) Only for markets with elevated sulphur content in diesel fuel.


Further engine oils of other suppliers approved by Volkswagen
nf
ercia

commercial vehicles can be found in ⇒ Volkswagen Commercial


orm

Vehicles ServiceNet, Technical information, Inspections and


m

atio
m

Servicing, Approved oils


o

n in
or c

2.6 Delivery inspection


thi
te

sd
iva

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rp

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♦ The sequence of the individual service tasks has been tested


o

m
f

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ng

and optimised. The sequence must be followed in order to


t.
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avoid unnecessary interruptions in work. Cop py
t. rig
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Work to be completed Page
cop Vo
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Electrics
Prote AG.

♦ Battery isolator relay (if fitted): Remove (remove and return to manufacturer) ⇒ page 51
• Vehicles with transport equipment

♦ Battery: Check battery terminal clamps by hand for tightness ⇒ page 47

♦ Battery: Perform visual check and check magic eye (if fitted) ⇒ page 51

♦ Four-wheel drive fuse: Insert (PR number „1x1“) ⇒ page 77

♦ Vehicle system test: Perform ⇒ page 74

10 2. Service work
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes Maintenance - Edition 01.2011
olksw not
y V gu
db ara
ise nte
Work to be completed
tho
r eo Page
au ra
c
♦ Radios code: Request
s
(customer should be informed of radio code IF DESIRED) ⇒ page 99

ce
le
un

pt
an
d

Vehicle interior
itte

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rm

ab
♦ All switches, electrical consumers, sockets, gauges and other control elements: Check
pe

ility
function
ot

wit
, is n

h re
hole

♦ Door handles, door locks, central locking and windows: Check function and ease of

spec
movement
es, in part or in w

t to the co
♦ Front passenger airbags: Check key switch and „ON/OFF function“, set switch to „ON“ ⇒ page 55

rrectness of i
♦ Window regulators: Check positioning (open and close functions) ⇒ page 71
l purpos

♦ Clock: Set to correct time ⇒ page 129

nform
ercia

♦ Climatronic: Set temperature to 22 ℃ ⇒ page 70


m

a
com

t
♦ Transportation mode: Switch off

ion in
r
te o

thi
♦ Radio/radio navigation system: Activate anti-theft coding, store local radio stations to ⇒ page 101

s
iva

do
station buttons
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rp

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en
ng

t.
♦ Radio navigation system: Insert navigation CD/DVD and perform update
Cop
yi Co
py ⇒ page 102
t. rig
gh ht
♦ Seat protective covers and protective foils: Remove
yri
p by
co Vo
by lksw
cted agen
Prote
♦ Vehicle interior: Check for cleanliness (front and rear seats, interior trim, carpets/mats,
AG.

windows)

Vehicle exterior
♦ All equipment that has been introduced to the vehicle (mats, wipers, spoilers, roof aerial,
full sized wheel trims/wheel trims, wheel bolt covers, tyre valve extensions): Install (if
featured)

♦ Edge protection on doors (plastic foil): Remove

♦ Vehicle exterior: Check for cleanliness (paintwork, decorative parts, windows, wiper
blades, surfaces)

♦ Protective foil: Remove (if fitted) ⇒ page 128

Tyres
♦ Spare wheel tyre: Check condition and inflation pressure (if fitted) ⇒ page 56

♦ Front left tyre: Check condition and inflation pressure ⇒ page 56

♦ Rear left tyre: Check condition and inflation pressure ⇒ page 56

♦ Rear right tyre: Check condition and inflation pressure ⇒ page 56

♦ Front right tyre: Check condition and inflation pressure ⇒ page 56

♦ Wheel securing bolts: Tighten to specified torque ⇒ page 98

Vehicle, bottom
♦ Vehicle from below (without removing underbody protection): Perform visual check for ⇒ page 129
leaks and damage ⇒ page 80
♦ Engine, CV joint boots/bellows, brake system, steering, axles, gearbox/final drive, ho‐
ses, fluid reservoirs/containers

♦ Vehicle underside (floor pan): Perform visual check for damage ⇒ page 129

2. Service work 11
Amarok 2011 ➤
Maintenance - Edition 01.2011

Work to be completed Page


♦ Brake system: Perform visual check for leaks and damage ⇒ page 60

Engine compartment
♦ Engine and components in engine compartment (from above): Perform visual check for ⇒ page 95
leaks and damage

♦ Window wash/wipe system and headlight washer system: Check function and settings; ⇒ page 102
replenish to maximum level

♦ Engine oil level: Check (observe VW engine oil standards if replenishing) ⇒ page 91

♦ Coolant level: Check level is at maximum AG. Volkswagen AG d ⇒ page 84


agen oes
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♦ Brake fluid: Change db
y ⇒
gu
apage
ra 65
rise nte
• For stock vehicles and vehicles in storage tho
whose standing period of 6 months or more,
eo
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the brake fluid must be renewed. ss c

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nl

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an
♦ Brake fluid level: Check level is at maximum ⇒ page 69
itte

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erm

ab
ility
♦ Power assisted steering: Check fluid level ⇒ page 126
ot p

wit
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h re
Documentation/final checks
hole

spec
♦ Number and function of keys: Check, wipe off grease if necessary
es, in part or in w

t to the co
♦ Vehicle data sticker: Stick into service schedule and in vehicle ⇒ page 21

rrectness of i
♦ Service schedule: Enter delivery inspection, enter a cross for the 1st service and com‐
plete vehicle data in service schedule, see „Vehicle delivery documentation“
l purpos

♦ Interval service for vehicles with LongLife service (PR No. QG1) 1)

nform
ercia

♦ Oil change service for vehicles with time or distance dependent service (PR No. QG0/
QG2) 1)
m

at
om

ion
c

in t
♦ Vehicle literature: Check literature is complete and prepare for handover to customer
or

his
ate

do
riv

♦ Service interval display: Reset (observe „2024733“) ⇒ page 109


p

cum
for

en
ng

t.
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♦ Road test: Perform ⇒ page 97
Co
Cop py
t. rig
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1) Service identification ⇒ page 2
c by lksw
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Prote AG.

2.7 Scopes of service

Note

The various types of service can be combined under certain cir‐


cumstances (oil change or interval service in conjunction with an
inspection service). Whereupon doubly listed activities are only
charged once.

Note

Observe notes for oil change service, interval service and inspec‐
tion service on ⇒ page 3 .

♦ Depending on the vehicle equipment and the conditions under


which the vehicle is used, additional maintenance measures

12 2. Service work
Amarok 2011 ➤
Maintenance - Edition 01.2011

may need to be performed when services are due


⇒ page 15 .
♦ It is possible to have additional work done outside the service
intervals, with account being taken of the entries in the service
schedule (or service sticker: „Your next service dates“).

Caution

♦ Diesel engines: In some regions/countries, an elevated


sulphur content may be evident in the diesel fuel. This
leads to increased wear of the cylinders and impairs piston
cleanliness considerably. Short service intervals therefore
apply in this instance ⇒ page 7 .

Note

If faults are found within the scope of servicing which make repair
measures necessary, the customer must be informed and the
additional work invoiced separately where necessary.

♦ Abbreviations for scopes of service:


♦ 1) Oil: Oil change service, 2) Int.: Interval service,
♦ 3) Insp.: Inspection service
Oil Int. Insp. Measure
1) 2) 3)

Electrics
X ♦ Front lights - Side lights, dipped beam, main beam, fog lights, turn signals, hazard warning
lights: Check function
n AG. Volkswagen AG do
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X ♦ Rear lights - brake lights (including 3rdbybrakeVo l
light), tail lights, reversingot glights, rear fog
ua
light, number plate light, turn signals,ir se hazard warning lights: Check functionante
d r
tho eo
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X ♦ Interior, luggage and glove compartment
ss lights, cigarette lighter, sockets, horn andc warn‐
ing lamps: Check function ce
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X ♦ Battery: Perform visual check and check magic eye
erm

ab
ility
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⇒ page 51
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Vehicle exterior
hole

spec

X ♦ Doors: Grease door arrester


es, in part or in w

t to the co

⇒ page 128
X ♦ Windscreen wash/wipe system, spray jet settings: Check function and for damage, adjust
as necessary
rrectness of i
l purpos

X ♦ Wiper blades: Check for damage and park position, adjust as necessary
⇒ page 105
nform
ercia

X ♦ Paint: Perform visual check for damage and corrosion, interior and exterior when doors
m

and bonnet/rear lid/flaps are open


at
om

ion
c

⇒ page 128
in t
or

his
ate

X • Bonnet catch: Clean, ensure attachment is secure and lubricate


do
priv

cum
or

⇒ page 96
f

en
ng

t.
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Tyres t. Cop py
rig
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pyri by
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co lksw
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Prote AG.

2. Service work 13
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Amarok 2011 ➤ ut
ho eo
ra
a
Maintenance - Edition 01.2011
ss c

ce
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un

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an
d
Oil Int. Insp. Measure

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1) 2) 3)

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ility
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X ♦ Tread depth, condition, wear pattern, age, inflation pressure (including spare tyre):

wit
is n
Check, rectify as necessary

h re
ole,

spec
⇒ page 56 urposes, in part or in wh

t to the co
Vehicle from below
X ♦ Engine and components in engine compartment (from below): Visual check for leaks and
damage

rrectne
♦ Gearbox, final drive and drive shaft bellows

ss
⇒ page 95

o
cial p

f in
X ♦ Underbody: Visual check for damage to underbody protection and underbody trim/panels

form
mer

atio
⇒ page 129
om

n
c

X ♦ Exhaust system: Visual check for leaks, security and damage

i
or

n thi
te

sd
va

X ♦ Check track rod ends:


i

o
pr

cum
r
fo

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ng

⇒ page 126 yi
t.
Co
♦ play, attachment and damage to boots/bellows t. Cop py
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X ♦ CV joints, axial bearings, coupling rod bearings and anti-roll bar rubber bushes: Visual
op Vo
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check for damage
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Prote AG.

⇒ page 44
X ♦ Brake system: Perform visual check for leaks and damage
⇒ page 60
X X ♦ Thickness of front and rear brake pads/linings: Check
⇒ page 61
Engine compartment
X ♦ Engine and components in engine compartment (from above): Perform visual check for
leaks and damage
⇒ page 95
X X ♦ Engine oil: Change and replace oil filter, ensure level is at maximum after filling system
and replenish if necessary
⇒ page 91
• Note VW engine oil standards
⇒ page 10
X ♦ Brake fluid: Change (after 3 years from initial registration and then every 2 years)
⇒ page 65
X ♦ Brake fluid level (depending on lining wear): Check (observe specification ⇒ page 69 )
⇒ page 69
X ♦ Brake system and shock absorbers: Perform visual check for leaks and damage
⇒ page 65
X ♦ Power assisted steering: Check fluid level
⇒ page 126
X ♦ Air filter with saturation indicator in dash panel insert: Check
⇒ page 90
X ♦ Cooling system: Check frost protection and coolant level, replenish if necessary
⇒ page 84
• Specified antifreeze value: „-25 °C“ In countries with an arctic climate „-35 °C“

Final checks

14 2. Service work
Amarok 2011 ➤
Maintenance - Edition 01.2011

Oil Int. Insp. Measure


1) 2) 3)

X ♦ Headlights: Check adjustment


⇒ page 106
X ♦ Vehicle system test: Perform
⇒ page 74
X X ♦ Service interval display: Reset (observe „2024733“)
⇒ page 109
X X X ♦ „Your next service“ sticker: Enter next due date 1) and attach service sticker to driver side
door pillar (B-pillar)
⇒ page 20
X ♦ Breakdown set (if fitted): Check (renew tyre inflation bottle with sealant if use-by date has
expired) n AG. Volkswagen AG
wage does
⇒ page 96 Volks not
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X X ♦ Road test: Perform thoris nte
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⇒ page 97 ss c

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2.8 Time or distance dependent additional

ility
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wit
work
, is n

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hole

spec
♦ Depending on conditions under which the vehicle is used and
es, in part or in w

vehicle equipment, extra service work must be performed in

t to the co
addition to the inspection service or oil change service/interval
service. These additional maintenance measures are invoiced
separately and are marked as extra work.

rrectness of i
Measure: Interval
l purpos

♦ Thickness of front ⇒ page 61 and rear Recommendation: 1)


⇒ page 64 brake pads/linings: Check

nf
ercia

orm
m

♦ Fuel filter: Renew – if vehicle runs on diesel fuel Every 10,000 km

atio
om

n in
c

• that does not conform with the standard „DIN EN


or

thi
e

590“
t

sd
iva

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rp

cu

• and has an elevated sulphur content (>2000 ppm)


o

m
f

en
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t.
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⇒ page 82
Co
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♦ Fuel filter: Drain water - if vehicle runs on diesel fuel Every 20,000 km
rig ht
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• that does not conform with the standard „DIN EN Prote
cted AG.
agen
590“
⇒ page 84
♦ Camshaft drive toothed belt: Check Every 40,000 km
• Valid in „dusty“ regions, diesel engines
⇒ page 130
♦ Fuel filter: Renew – if vehicle runs on diesel fuel
• that does not conform with the standard „DIN EN
590“
⇒ page 82

2. Service work 15
AG. Volkswagen AG d
Amarok 2011 ➤ ksw
agen oes
not
ol
Maintenance - Edition 01.2011 d byV gu
ara
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h
ut
Measure: ss a Interval ra
c

ce
le
♦ Dust and pollen filter (cabin filter): Clean housing Every 60,000 km

un

pt
and renew filter element

an
d
itte

y li
rm

ab
⇒ page 80

pe

ility
ot
♦ Spark plugs: Renew

wit
, is n

h re
hole
⇒ page 131

spec
es, in part or in w
♦ Air filter: Clean housing and renew filter element

t to the co
(reset learnt values of engine control unit -J623- )
♦ Valid in „dusty“ regions, petrol engines

rrectness of i
⇒ page 88
l purpos

♦ Fuel filter: Renew – if vehicle runs on diesel fuel Every 80,000 km


⇒ page 82

nform
ercia

♦ Air filter: Clean housing and renew filter element Every 120,000 km
m

a
(reset learnt values of engine control unit -J623- )
com

tion in
r

⇒ page 88
te o

thi
s
iva

♦ Camshaft drive toothed belt and toothed belt ten‐

do
r
rp

c
sioning roller: Renew

um
fo

en
ng

t.
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• Valid in „dusty“ regions, diesel engines
Co
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ht. rig
⇒ page 130 rig ht
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♦ Poly V-belt: Check condition Prote
cted AG.
agen

⇒ page 81
♦ Fuel filter: Renew – if vehicle runs on diesel fuel
• Conforming to „DIN EN 590“
⇒ page 82
♦ Diesel particulate filter (if fitted): Interrogate ash At 160,000 km then every 40,000 km
mass (saturation level)
⇒ page 45
♦ Poly V-belt: Renew Every 180,000 km
• Applies for petrol engines
⇒ page 82
♦ Coolant pump toothed belt and toothed belt sprock‐
et: Renew
• Applies for petrol engines
⇒ page 131
♦ Camshaft drive toothed belt and toothed belt ten‐ Every 210,000 km
sioning roller: Renew
• Valid for diesel engines
⇒ page 130
♦ High pressure pump: Check Every 240,000 km
• Applies for petrol engines
⇒ page 82
♦ Timing chain: Renew Every 300,000 km
• Applies for petrol engines
⇒ page 102

16 2. Service work
Amarok 2011 ➤
Maintenance - Edition 01.2011

Measure: Interval
♦ Camshaft drive toothed belt: Check Every 2 years
• Valid in „dusty“ regions, diesel engines
⇒ page 130
♦ Dust and pollen filter (cabin filter): Clean housing
and renew filter element swage
n AG. Volkswagen AG do
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olk ot g
yV
⇒ page 80 d b ua
ran
ir se tee
o
♦ Air filter: Clean housing and renew filter element
auth Every 3 years or
ac
(reset learnt values of engine control unit -J623-
ss )

ce
le
un

pt
♦ Valid in „dusty“ regions, petrol engines

an
d
itte

y li
⇒ page 88
erm

ab
ility
ot p
♦ Emissions test: Perform (every 12 months in Ger‐ 3 years after initial registration and then every 2 years

wit
is n

many for commercial passenger transport, e.g.

h re
ole,

taxis)

spec
urposes, in part or in wh

⇒ page 134

t to the co
♦ Fuel filter: Renew – if vehicle runs on diesel fuel Every 4 years
• that does not conform with the standard „DIN EN

rrectne
590“
⇒ page 82

ss o
♦ Spark plugs: Renew
cial p

f inform
mer

⇒ page 131

atio
m

♦ Air filter: Clean housing and renew filter element Every 6 years
o

n
c

i
or

n
– Resetting programmed values in engine control

thi
te

sd
a

unit -J623-
iv

o
pr

cum
r
fo

⇒ page 88

en
ng

t.
yi Co
op
♦ Fuel filter: Renew – if vehicle runs on diesel fuel
C py
t. rig
gh ht
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• Conforming to „DIN EN 590“ cop Vo
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Prote
⇒ page 82
AG.

1) Wear on brake linings is heavily dependent on operating con‐


ditions and driving style. If urban and short-distance driving are
common as well as if there is a sporty driving style, Volkswagen
recommends having the thickness of the brake linings checked in
the workshop more often than specified in the service schedule.

2.9 Market specific deviations - scope of


work for Argentina and Brazil

Note

In this chapter you will find only market-specific deviations for Ar‐
gentina and Brazil. In other words, all of the service intervals not
listed here should be gleaned from the normal service interval
tables.

2. Service work 17
Amarok 2011 ➤
Maintenance - Edition 01.2011

Deviations in scope of work relating to oil change, interval and


inspection service
Additional work Page
♦ Toothed belt and tensioning roller for camshaft drive: Check
⇒ page 130
• Not with oil change service

♦ Windscreen wiper blades: Check for damage


⇒ page 105
♦ Expiry date of contents in first aid box: Check

Every 2 years
Additional work Page
AG. Volkswagen G d
♦ Brake fluid: Change (observe ksw
agen specificationA⇒ page
oes 69 )
not
Vol
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⇒ page 65 ise
d b ara
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• Check if brakeuthor
fluid service is due. eo
a ra
ss c
ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
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Cop py
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gh ht
pyri by
Vo
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by
cted agen
Prote AG.

18 2. Service work
Amarok 2011 ➤
Maintenance - Edition 01.2011

3 General
♦ Sticker ⇒ page 20
♦ Entries in service schedule ⇒ page 22
♦ Severe conditions ⇒ page 20
♦ Vehicle identification number (chassis number) ⇒ page 19
♦ Vehicle data sticker ⇒ page 19
♦ Engine code and engine number ⇒ page 20
♦ RME fuel (biodiesel) ⇒ page 22

3.1 Vehicle identification number (chassis


number)
A vehicle identification number is located behind the windscreen
on the driver side.
Second vehicle identification number is located on right side of
longitudinal member and can be seen in right wheel housing
-arrow-.

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Significance of vehicle identification
ss a number c
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un

WV1 ZZZ 2H Z B D 000 234


pt
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Manufacturer Filler charac‐ Type Filler charac‐ Model year Production lo‐ Serial number
rm

ab
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code ters ters 2011 cation


ility
ot

wit
, is n

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hole

spec

3.2 Vehicle data sticker


es, in part or in w

t to the co

The vehicle data sticker -arrow- is attached to the left A-pillar low‐
er trim panel in the footwell.
rrectness of i

This vehicle data sticker is also found in the service schedule for
l purpos

the customer.
On the left side of left-hand drives, on the right side of right-hand
nform
ercia

drives.
m

Attach second „vehicle data sticker“ in customer service schedule


a
com

tio

⇒ page 21
n in
r
te o

thi
s
iva

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cum
fo

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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

3. General 19
. Volkswagen AG
Amarok 2011 ➤ wage
n AG does
olks not
Maintenance - Editiond b01.2011
y V gu
ara
e nte
ris
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The sticker shows the following
au
t
vehicle data. ra
c
ss
1 - Vehicle identification number (chassis number)

ce
e
nl

pt
du

an
2 - Vehicle type, engine output, gearbox itte

y li
erm

ab
ility
3 - Engine and gearbox code letters, paint number, interior equip‐
ot p

wit
ment
, is n

h re
hole

4 - Optional equipment, PR numbers

spec
es, in part or in w

t to the co
rrectness of i
l purpos

3.3 Severe operating conditions


If the vehicle is used under severe operating conditions some jobs

nf
ercia

o
will have to be performed before the next service due or at shorter

rm
m

atio
service intervals.
om

n in
c

Severe operating conditions


or

thi
te

sd
a

• Regular short trips or stop and go operation in urban traffic


iv

o
r
rp

cu
o

m
f

• High percentage of cold starts

en
ng

t.
yi Co
op
• Vehicle is used in areas with extremely low temperatures over
C py
ht. rig
a long period
rig ht
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by lksw
• Regular long periods of idling (e.g. taxis)
cted agen
Prote AG.

• Vehicle is often driven at full throttle with high payload or whilst


towing a trailer
• Using diesel with elevated sulphur content
• Regular operation in areas with high levels of dust

3.4 Engine code and engine number


Engine code and engine number are located:
♦ On a sticker on toothed belt guard ⇒ Rep. gr. 00 ,
♦ On vehicle data sticker on left A-pillar lower trim panel in the
footwell ⇒ page 19 .
♦ On vehicle data sticker in service schedule for the customer.

3.5 Sticker
♦ Attaching service sticker „Your next service dates“
⇒ page 20 .
♦ Attaching „vehicle data sticker“ into customer service schedule
and in vehicle ⇒ page 21

3.5.1 Attaching service sticker „Your next


service dates“
Service sticker „Your next service dates“

20 3. General
Amarok 2011 ➤
Maintenance - Edition 01.2011

– Enter next service due: Enter a cross according to „service


interval display“ and enter date and odometer reading.

– Apply service sticker on driver side door pillar (B-pillar).

AG. Volkswagen AG d
agen oes
olksw not
byV gu
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aut ra
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nl

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du

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itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

3.5.2 Attaching „vehicle data sticker“ into cus‐


spec
es, in part or in w

tomer service schedule and in vehicle


t to the co

Perform the following jobs:


rrectness of i

– Attach upper vehicle data sticker -arrow- in customer service


schedule.
l purpos

Installation position of vehicle data sticker ⇒ page 19


nform
ercia

1 - Week of production
m

at
om

2 - Production control number (PR number)


ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3. General 21
Amarok 2011 ➤
Maintenance - Edition 01.2011

3.6 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‐
turer,
♦ the time period for the new replacement interval starts when
the replacement is carried out.
♦ Therefore it is very important, every time a component is
changed, to document this in the service schedule. This also
applies to components which were changed before the regular
change interval.
♦ There are more entries to be made in the service schedule
⇒ page 128 .
AG. Volkswagen AG d
agen oes
lksw not
Note by Vo gu
ara
d
rise nte
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When using genuine parts kits, it must be taken a into account
h
♦ u t ra
whether it is technically necessary to change all
s the compo‐
s c

ce
le

nents included in the genuine parts kits.


un

pt
an
d
itte

♦ If more components are renewed than is technically necessa‐

y li
erm

ab
ry, inform the customer before repair!

ility
ot p

wit
is n

h re
3.7 RME fuel (biodiesel) that does not con‐
ole,

spec
form with the standard
urposes, in part or in wh

t to the co
Note

rrectne
♦ RME fuel may only be used in vehicles which have been ap‐

s
proved by Volkswagen for this purpose with RME fuel - either

s o
in the standard version or in vehicles with optional equipment
cial p

f in
(PR number »2G0«).

form
mer

♦ The production control number »2G0« on the vehicle data

atio
m

sticker indicates RME compatibility.


o

n
c

i
or

n thi
e

♦ For vehicles with standard diesel particulate filter (DPF) RME


t

sd
va

fuel (biodiesel) must not be used.


i

o
pr

cum
r
fo

en
ng

t.
yi Co
op py
Caution t. C rig
gh ht
pyri by
Vo
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♦ When using RME (biodiesel) according to „DIN EN cted agen
Prote AG.
14214“, the fuel filter must be renewed every 10,000 km.
♦ When RME fuel is used and your vehicle is not suitable for
this, the fuel system can be damaged.
♦ When filling the tank with biodiesel, only use RME fuel
conforming to DIN EN 14214 (FAME)!
♦ Fuel that does not conform to DIN 14214 can result in fuel
filter blocking.

RME fuel must conform to DIN EN 14214 (FAME).


♦ RME means „Rapeseed Methyl Ester“.
♦ DIN stands for „Deutsches Institut für Normung e.V. (German
Standards Authority)“.
♦ EN stands for „European Norm (European standard)“.
♦ FAME means „Fatty Acid Methyl Ester“.

22 3. General
AG. Volkswagen AG d
agen oes Amarok 2011 ➤
olksw not
yV gu
ed b Maintenance ar-a Edition 01.2011
nte
ris
ho eo
aut ra
ss c

ce
le
Note

un

pt
an
d
itte

y li
♦ The RME compatibility of the vehicle is indicated by the pro‐

erm

ab
ility
duction control number »2G0« on the vehicle data sticker. If

ot p
the vehicle is not designed to run on biodiesel, the production

wit
is n

h re
control number »2G2« is noted in the vehicle data set

ole,

spec
urposes, in part or in wh
♦ and the message „Not for biodiesel“ is shown inside the fuel

t to the co
filler cap.

Characteristics of RME fuel

rrectne
♦ Performance can slightly be lower when using biodiesel.

s
♦ Fuel consumption can slightly be higher when using biodiesel.

s o
cial p

f in
♦ RME can be used in winter at temperatures to approx. -10 ℃.

form
mer

♦ At ambient temperatures below -10 °C, the use of winter diesel

atio
m

fuel is recommended.
o

n
c

i
or

n thi
te

sd
iva

o
r

Note
p

cum
r
fo

en
ng

t.
yi Co
♦ If standstill times of more than approx. 2 weeks are envisaged, Cop py
it is recommended that the petrol tank be first filled up with ht. rig
rig ht
conventional diesel fuel
py by
co Vo
by lksw
cted agen
♦ and that the vehicle be driven a distance of approx. 50 km in
Prote AG.

order to prevent damage to the injection system.

3. General 23
Amarok 2011 ➤
Maintenance - Edition 01.2011

4 Descriptions of work
♦ Swivel joints: Visual check ⇒ page 44
♦ Four-wheel drive: Insert fuse ⇒ page 77
♦ Lifting vehicle ⇒ page 25
♦ Reading ash mass (saturation level) of diesel particulate filter
⇒ page 45
♦ Battery: Check battery terminal clamps for secure seating
⇒ page 47 .
♦ Battery: Check magic eye ⇒ page 51
♦ Battery: Perform visual check ⇒ page 51
♦ Removing relay for battery disconnection ⇒ page 51
♦ Front passenger front airbag: Check key switch and „On/Off
function“ ⇒ page 55 .
♦ Checking tyres: Condition, wear pattern, tyre pressure, tread
depth ⇒ page 56
♦ Brake system: Perform visual check for leaks and damage
⇒ page 60
♦ Brake fluid level: Check ⇒ page 69
♦ Brake fluid: Change ⇒ page 65
♦ Climatronic: Set temperature to 22 °C ⇒ page 70
♦ Connecting vehicle diagnosis tester ⇒ page 71
♦ Window regulators: Check positioning (open and close func‐
tions) ⇒ page 71
♦ Performing vehicle system test ⇒ page 74
♦ Bonnet catch: Clean, ensure attachment is secure and lubri‐
cate ⇒ page 96 en AG. V
olkswagen AG
ag does
ksw not
♦ Protective bellows: Visual checkVol
by ⇒ page 80 d
gu
ara
ise nte
♦ Poly V-belt: Check condition
ut
ho ⇒ page 81
r eo
ra
sa c
♦ Control unit in dash panel
s insert -J285- in dash panel insert -
ce
e

K- at 5,000 km, 7,500 km or 10,000 km ⇒ page 112 : Code


nl

pt
du

an
itte

y li

♦ Fuel system: Bleed (diesel engine) ⇒ page 83


erm

ab
ility
ot p

♦ Fuel filter: Drain water (diesel engine) ⇒ page 84


wit
, is n

h re

♦ Fuel filter: Renew (diesel engine) ⇒ page 82


hole

spec

♦ Cooling system: Check frost protection and coolant level


es, in part or in w

t to the co

⇒ page 84
♦ Paint: Perform visual check for damage and corrosion, interior
and exterior when doors and bonnet/rear lid/flaps are open
rrectness of i

⇒ page 128
l purpos

♦ Steering: Check bellows/boots for leaks and damage


⇒ page 133
nf
ercia

♦ Air filter: Clean housing and renew filter element


rm
m

⇒ page 88
atio
om

n in
c

♦ Air filter with saturation indicator: Check saturation indicator


or

thi

⇒ page 90
te

sd
iva

o
r
rp

cu

♦ Engine and components in engine compartment (from above


o

m
f

and below): Perform visual check for leaks and damage


en
ng

t.
yi
⇒ page 95
Co
Cop py
t. rig
gh ht
pyri by
Vo
o

24
c by lksw
cted agen
4. Descriptions of work Prote AG.
Amarok 2011 ➤
Maintenance - Edition 01.2011

♦ Engine oil: Drain or extract; renew oil filter and replenish en‐
gine oil ⇒ page 91
♦ Oil level: Check ⇒ page 91
♦ Check breakdown set ⇒ page 96 .
♦ Performing road test ⇒ page 97
♦ Wheel securing bolts: Tighten to specified torque
⇒ page 98
♦ Reading radio code (only valid for vehicles without sticker with
serial number and radio code on vehicle data sticker)
⇒ page 99
♦ Radio / radio navigation system: Enter anti-theft coding PIN
⇒ page 101 .
♦ Radio navigation system: Insert navigation CD/DVD and per‐
form update ⇒ page 102
♦ Front and rear brake pads/linings: Check thickness
⇒ page 61 AG. Volkswagen n AG do
ks wage es
♦ Windscreen wash/wipe
Vol system and headlight
nowasher
t gu system:
by
Check function
ir se
d and settings ⇒ page 102 ara
nt ee
tho o
♦ Windscreen
sa
u wiper blades: Check park position ⇒ pager a105
c .
s
ce
e

♦ Headlight adjustment: Check, if necessary adjust


nl

pt
du

⇒ page 106
an
itte

y li
erm

ab

♦ Service interval display: Reset ⇒ page 109


ility
ot p

wit

♦ Service interval display: Recode (adapt) ⇒ page 111


, is n

h re
hole

♦ Power assisted steering: Check fluid level ⇒ page 126


spec
es, in part or in w

♦ Track rod ends: Check clearance, security and boots


t to the co

⇒ page 126
♦ Dust and pollen filter: Clean housing and renew filter element
rrectness of i

⇒ page 80
l purpos

♦ Clock: Set to correct time ⇒ page 129


♦ Underbody protection: Perform visual check for damage
nf
ercia

⇒ page 129
orm
m

atio

♦ Removing and installing skid plate ⇒ page 133


om

n in
or c

♦ Front doors: Grease door arrester ⇒ page 128


thi
te

sd
iva

♦ Camshaft drive toothed belt: Check condition ⇒ page 130


o
r
rp

cu
o

m
f

en
ng

♦ Camshaft drive toothed belt: Renew ⇒ page 130 yi


t.
Co
op py
♦ Spark plugs: Renew ⇒ page 131
t. C rig
gh ht
pyri by
Vo
o
4.1 Lifting vehicle
c by lksw
cted agen
Prote AG.

♦ Raising vehicle with wheel lifts as main support ⇒ page 26


♦ Raising vehicle under rear axle tube ⇒ page 29
♦ Raising vehicle before rear axle tube ⇒ page 33
♦ Alternative lift for front of vehicle ⇒ page 36
♦ Alternative lift for rear of vehicle ⇒ page 39
♦ Additional support of vehicle ⇒ page 42

4. Descriptions of work 25
Amarok 2011 ➤
Maintenance - Edition 01.2011

4.1.1 Raising vehicle with wheel lifts as main


support

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‐
missible lifting capacity of the platform.
♦ Vehicle may be lifted only at points indicated in figure to
avoid damaging vehicle underbody or tipping vehicle.
♦ Never start engine when vehicle is raised and do not en‐
gage a gear in gearbox even if only one driven wheel is
touching floor. Disregarding these warnings risks the dan‐
ger of an accident!
♦ Any fitter who raises a vehicle on a lifting platform must
check the lifting points and that the vehicle is standing se‐
curely prior to raising the vehicle, with regard to the loading
condition and the work to be performed.
♦ Laden vehicles are only allowed to be raised using wheel
lifts as main support. If wheels need to be removed, then
laden vehicles are also allowed to be raised under rear
axle tube using prismatic supports ⇒ page 33 . If this is
not possible because work is to be performed on rear axle
then vehicle must be unloaded.
♦ If vehicle is jacked up with a workshop jack in order to work
underneath then it must be securely a n AG. Volkswausing
gesupported
gen AG
suit‐
does
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able stands. by
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ed ran
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au ac
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Note
pt
an
d
itte

y li
rm

ab

♦ Raising vehicle with wheel lifts should mainly be done for all assembly work on vehicle.
pe

ility
ot

wit

♦ Only use support points listed in document when assembly work is performed on running gear or on axles.
, is n

h re
hole

♦ Vehicle must under no circumstances be raised on sills, otherwise its body will be seriously damaged.
spec
es, in part or in w

t to the co

Perform the following jobs:


– Reconfigure lifting platform so that existing 4 mounting plates
rrectness of i

are replaced by 4 wheel lift supports -1-.


l purpos

– Adjust distances of lifting platform in relation to one another so


that all 4 wheels fit precisely into wheel lifts -2-.
nform
ercia

– Drive vehicle onto lifting platform until vehicle is located ex‐


actly in wheel lifts.
m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

26 4. Descriptions of work
AG. Volkswagen AG d
agen
Volksw
oes
not Amarok 2011 ➤
by gu
ed Maintenance
ara
nte - Edition 01.2011
ris
tho eo
au ra
c
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Vehicle can now be raised and lowered to required working


height.

4. Descriptions of work 27
Amarok 2011 ➤ n AG. Volkswagen AG do
lkswage es n
Maintenance - Edition 01.2011 d byV
o ot g
ua
ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

28 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

4.1.2 Raising vehicle under rear axle tube

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‐
missible lifting capacity of the platform.
♦ Vehicle may be lifted only at points indicated in figure to
avoid damaging vehicle underbody or tipping vehicle.
♦ Never start engine when vehicle is raised and do not en‐
gage a gear in gearbox even if only one driven wheel is
touching floor. Disregarding these warnings risks the dan‐
ger of an accident!
♦ Any fitter who raises a vehicle on a lifting platform must
check the lifting points and that the vehicle is standing se‐
curely prior to raising the vehicle, with regard to the loading
condition and the work to be performed.
♦ Laden vehicles are only allowed to be raised using wheel
lifts as main support ⇒ page 26 . If wheels need to be re‐
moved, then laden vehicles are also allowed to be raised
under rear axle tube using prismatic supports
⇒ page 29 . If this is not possible because work is to be
performed on rear axle then vehicle must be unloaded.
♦ If vehicle is jacked up with a workshop jack in order to work
underneath then it must be securely supported using suit‐
able stands.

AG. Volkswagen AG d
Special tools and workshop equipment
olks
wage
n
required oes
not
V gu
by
♦ Tensioning strap -T10038-
ris
ed
ara
nte
ho eo
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

♦ Prismatic support with minimum opening angle 120°. Note that


l purpos

the versions differ from one lifting platform manufacturer to


another.
nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. Descriptions of work 29
Amarok 2011 ➤
Maintenance - Edition 01.2011

Note

♦ When assembly work is performed on running gear (front axle and rear axle) then raising vehicle under rear
axle should only be used as an alternative to main support ⇒ page 26 !
♦ The vehicle may only be lifted at points indicated in order to avoid damaging vehicle and to prevent vehicle
from tipping.
♦ Vehicle must always be lashed down additionally during all assembly work.
♦ Vehicle must under no circumstances be raised on sills, otherwise its body will be seriously damaged.

Perform the following jobs:


– Position rear support arms of lifting platform with prismatic
supports -1- as shown in illustration, exactly under rear axle
tube.
– Position front support arms of lifting platform with rubber plate
supports under front frame screw connection -2- and -3-.
– Additionally secure vehicles with tensioning straps -T10038-
-4- directly on frame of front and rear support arms of lifting
platform.

Note

To avoid damage, make sure that no electrical cables, brake lines or fuel lines become trapped.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

30 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

– Vehicle can now be raised and lowered to required working


wit
is n

height.
h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4. Descriptions of work 31
Amarok 2011 ➤
Maintenance - Edition 01.2011

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

32 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

4.1.3 Raising vehicle before rear axle tube

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‐
missible lifting capacity of the platform.
♦ Vehicle may be lifted only at points indicated in figure to
avoid damaging vehicle underbody or tipping vehicle.
♦ Never start engine when vehicle is raised and do not en‐
gage a gear in gearbox even if only one driven wheel is
touching floor. Disregarding these warnings risks the dan‐
ger of an accident!
♦ Any fitter who raises a vehicle on a lifting platform must
check the lifting points and that the vehicle is standing se‐
curely prior to raising the vehicle, with regard to the loading
condition and the work to be performed.
♦ Laden vehicles are only allowed to be raised using wheel
lifts as main support ⇒ page a26 gen.AIfGwheels need
. Volkswagen AG to be re‐
do s
moved, then laden vehicles Volksware also allowed to be eraised not
gu
under rear axle tube d using
by
prismatic supports ara
ise nte
⇒ page 29 . If this
thor is not possible because work is to be eo
performed ons arear axle then vehicle must be unloaded.
u ra
c
s
ce
le

♦ If vehicle is jacked up with a workshop jack in order to work


un

pt

underneath then it must be securely supported using suit‐


an
d
itte

y li

able stands.
erm

ab
ility
ot p

wit
is n

h re

Special tools and workshop equipment required


ole,

spec
urposes, in part or in wh

♦ Tensioning strap -T10038-


t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Note Cop py
t. rig
gh ht
pyri by
♦ For assembly work on vehicle, e.g. removal of front axle and rear axle, vehicle can be raised before rear
co Vo
by lksw
cted
axle tube as an alternative ⇒ page 33 .
agen
Prote AG.

♦ The vehicle may only be lifted at points indicated in order to avoid damaging vehicle and to prevent vehicle
from tipping.
♦ Vehicle must always be lashed down additionally during all assembly work.
♦ Laden vehicles must be unloaded before being raised.
♦ Vehicle must under no circumstances be raised on sills or front leaf spring supports, otherwise it will slip off
and its body could be seriously damaged.

4. Descriptions of work 33
Amarok 2011 ➤
Maintenance - Edition 01.2011

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.
– Additionally secure vehicles with tensioning straps -T10038-
-4- directly on frame of front and rear support arms of lifting
platform.

Note

To avoid damage, make sure that no electrical cables, brake lines or fuel lines become trapped.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
– Vehicle can now be raised and lowered to required working Prote AG.
height.

34 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4. Descriptions of work 35
Amarok 2011 ➤
Maintenance - Edition 01.2011

4.1.4 Alternative lift for front of vehicle

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‐
missible lifting capacity of the platform.
♦ Vehicle may be lifted only at points indicated in figure to
avoid damaging vehicle underbody or tipping vehicle.
♦ Never start engine when vehicle is raised and do not en‐
gage a gear in gearbox even if only one driven wheel is
touching floor. Disregarding these warnings risks the dan‐
ger of an accident!
♦ Any fitter who raises a vehicle on a lifting platform must
check the lifting points and that the vehicle is standing se‐
curely prior to raising the vehicle, with regard to the loading
condition and the work to be performed.
♦ Laden vehicles are only allowed to be raised using wheel
lifts as main support ⇒ page 26 . If wheels need to be re‐
moved, then laden vehicles are also allowed to be raised
under rear axle tube using prismatic supports
⇒ page 29 . If this is not possible because work is to be
performed on rear axle then vehicle must be unloaded.
♦ If vehicle is jacked up with a workshop jack in order to work
underneath then it must be securely supported using suit‐
able stands.

Special tools and workshop equipment required


AG. Volkswagen AG d
agen oes
♦ Tensioning strap -T10038- Volksw not
gu
by ara
d
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

Note
l purpos

♦ For assembly work on vehicle, e.g. removal of front axle and rear axle, vehicle can be raised before rear
nform

axle tube as an alternative ⇒ page 33 .


mercia

♦ The vehicle may only be lifted at points indicated in order to avoid damaging vehicle and to prevent vehicle
at
om

io

from tipping.
n
c

in t
or

♦ Vehicle must always be lashed down additionally during all assembly work.
his
ate

do
priv

♦ Laden vehicles must be unloaded before being raised.


um
for

en
ng

t.
♦ Vehicle must under no circumstances be raised on sills or front leaf spring supports, otherwise it will slip off
yi Co
op
and its body could be seriously damaged.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

36 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

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.
– Additionally secure vehicles with tensioning straps -T10038-
-2- directly on frame of front and rear support arms of lifting
platform.

Note

To avoid damage, make sure that no electrical cables, brake lines or fuel lines become trapped.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
e

– Vehicle can now be raised and lowered to required working


t

sd
iva

height.
o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. Descriptions of work 37
AG. Volkswagen AG d
Amarok 2011 ➤ lksw
agen oes
not
o
Maintenance - Edition 01.2011 d by
V gu
ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

38 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

4.1.5 Alternative lift for rear of vehicle

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‐
missible lifting capacity of the platform.
♦ Vehicle may be lifted only at points indicated in figure to
avoid damaging vehicle underbody or tipping vehicle.
♦ Never start engine when vehicle is raised and do not en‐
gage a gear in gearbox even if only one driven wheel is
touching floor. Disregarding these warnings risks the dan‐
ger of an accident!
♦ Any fitter who raises a vehicle on a lifting platform must
check the lifting points and that the vehicle is standing se‐
curely prior to raising the vehicle, with regard to the loading
condition and the work to be performed.
♦ Laden vehicles are only allowed to be raised usingAGwheel . Volkswagen AG
lifts as main support ⇒ page 26 . If wheelslkneed swage to be re‐
n does
not
moved, then laden vehicles are also allowed byV
o to be raised gu
ara
under rear axle tube using prismatic ris supports
ed
nte
⇒ page 29 . If this is not possible because
o
auth work is to be eo
ra
performed on rear axle then vehicle
ss must be unloaded. c

ce
e
nl

♦ If vehicle is jacked up with a workshop jack in order to work

pt
du

an
itte

underneath then it must be securely supported using suit‐

y li
erm

ab
able stands.

ility
ot p

wit
, is n

h re
Special tools and workshop equipment required
hole

spec
es, in part or in w

♦ Tensioning strap -T10038-

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
g

♦ Anti-slip discs -V.A.G 1994-


n

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. Descriptions of work 39
AG. Volkswagen AG d
agen oes
ksw not
Amarok 2011 ➤ by Vol
gu
ara
d
Maintenance - Edition 01.2011
orise nte
eo
th
au ra
ss c

ce
e
nl

pt
Note

du

an
itte

y li
erm

ab
♦ For assembly work on vehicle, e.g. removal of front axle and rear axle, vehicle can be raised before rear

ility
ot p
axle tube as an alternative ⇒ page 33 .

wit
, is n

h re
♦ The vehicle may only be lifted at points indicated in order to avoid damaging vehicle and to prevent vehicle
hole

spec
from tipping.
es, in part or in w

t to the co
♦ Vehicle must always be lashed down additionally during all assembly work.
♦ Laden vehicles must be unloaded before being raised.

rrectness of i
♦ Vehicle must under no circumstances be raised on sills or front leaf spring supports, otherwise it will slip off
and its body could be seriously damaged.
l purpos

Perform the following jobs:

nf
ercia

orm
– Front support arms of lifting platform with rubber plate sup‐
m

atio
m

ports are positioned in area of front bolted gearbox cross


o

n in
c

member.
or

thi
te

sd
a

– The rear support arms of the lifting platform with anti-slip discs
iv

o
r
rp

cu
-V.A.G 1994- -1- are positioned in front of the front leaf spring
o

m
f

support -2- under the vehicle frame.

en
ng

t.
yi Co
op
– Additionally secure vehicles with tensioning straps -T10038-
C py
t. rig
gh
-3- directly on frame of front and rear support arms of lifting
ht
pyri by
Vo
o
platform.
c by lksw
cted agen
Prote AG.

Note

To avoid damage, make sure that no electrical cables, brake lines or fuel lines become trapped.

40 4. Descriptions of work
AG. Volkswagen AG d
agen oes
olksw not
V gu
by
nte Amarok 2011 ➤
d ara
ise
r
tho Maintenance e- oEdition 01.2011
s au ra
c
s

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Vehicle can now be raised and lowered to required working


height.

4. Descriptions of work 41
AG. Volkswagen AG d
Amarok 2011 ➤ ksw
agen oes
not
Vol
Maintenance - Edition 01.2011
db
y gu
ara
e nte
ris
tho eo
au ra
c
ss

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4.1.6 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- .
♦ To avoid damage, make sure that no electrical cables, brake
lines or fuel lines become trapped.

Perform the following jobs:


– Place height-adjustable stands -1- for supporting vehicle un‐
der rear longitudinal member -arrows-.

42 4. Descriptions of work
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
horis nte
eo Amarok 2011 ➤
aut ra Maintenance - Edition 01.2011
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Alternatively, height-adjustable stands -2- can be positioned


under rear leaf spring bracket -1- on rear axle tube.

4. Descriptions of work 43
Amarok 2011 ➤
Maintenance - Edition 01.2011

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

4.2 Swivel joints: Visual check


rrectness of i

Perform the following jobs:


l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

44 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011
AG. Volkswagen AG d
agen oes
lksw n
– Check boots y V -arrow- of lower swivel jointsotfor
o gu leaks and dam‐
d b ara
age. orise nte
eo
th
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Check boots -arrow- of upper swivel joints for leaks and dam‐

rrectness of i
age.
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
4.3 Reading ash mass (saturation level) of
co Vo
by lksw
cted agen
Prote
diesel particulate filter
AG.

Note

♦ The ash mass test provides information on the saturation level


of the particulate filter volume.
♦ After a certain running time diesel particulate filters must be
exchanged, because of ash deposits.
♦ This running time mainly depends on the filter size, oil and fuel
consumption and engine output.

Special tools and workshop equipment required


♦ Vehicle diagnostic, testing and information system -VAS
5051B- or subsequent units

♦ Diagnosis cable -VAS 5051/5A-


Or
♦ Diagnosis cable 5m -VAS 5051B/1-
Or

4. Descriptions of work 45
Amarok 2011 ➤
Maintenance - Edition 01.2011

♦ Vehicle diagnostic and service information system -VAS 5052


A-
♦ Diagnosis cable, 2 m -VAS 5052/3 A-
Or
♦ Diagnosis cable, 5 m -VAS 5052/3 A-1-
Perform the following jobs:
– Pull on handbrake.
– Manual gearbox: Gear lever in neutral
– Connect vehicle diagnostic, testing and information system -
VAS 5051B- or vehicle diagnostic and service information
system -VAS 5052 A- with ignition switched off ⇒ page 71 .
– Press the Guided functions button -arrow- on display of
vehicle diagnostic, testing and information system -VAS
5051B- or vehicle diagnostic and service information system
-VAS 5052 A- .

Indicated on display:

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
o
– Select engine on vehicle diagnostic, testingaand
ut
h information eo
ra
system -VAS 5051B- or vehicle diagnosticssand service infor‐ c
mation system -VAS 5052 A- -arrow-.
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

– Press Read motor control unit -J623- -arrow-.


ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

46 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

– Select „Measured value block 68 - ash mass DPF“ -arrow- on


screen and confirm with Done button.
– Follow instructions of vehicle diagnostic, testing and informa‐
tion system -VAS 5051B- or vehicle diagnostic and service
information system -VAS 5052 A- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

– Press Read button -arrow- to display the ash mass measured

wit
, is n

values.

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
The ash mass is displayed in the result column -arrow-.
c

in t
or

his
ate

do
priv

Note
um
for

en
ng

t.
yi Co
op
♦ If the limit value of 95 grams is reached the diesel particulate C py
t. rig
filter must be renewed ⇒ Rep. gr. 26 .
gh ht
pyri by
Vo
o
by c lksw
♦ If the indicated ash mass limit value is not reached, the vehicle cted agen
Prote AG.
can be driven further 40,000 km.
♦ The ash mass (saturation level) of the diesel particulate filter
must be read every 40,000 km.

– Follow instructions of vehicle diagnostic, testing and informa‐


tion system -VAS 5051B- or vehicle diagnostic and service
information system -VAS 5052 A- and end „Guided functions“
operating mode with No button -arrow-.
– Switch off ignition and then disconnect vehicle diagnostic,
testing and information system -VAS 5051B- or vehicle diag‐
nostic and service information system -VAS 5052 A- from
vehicle.

4.4 Battery: Check battery terminal clamps


for secure seating
♦ Specified torques: Battery ⇒ page 50
♦ Battery: Check battery terminal clamps for secure seating
⇒ page 48 .
♦ Battery terminal connections ⇒ page 50

4. Descriptions of work 47
Amarok 2011 ➤
Maintenance - Edition 01.2011

Note

♦ The battery terminal clamps must only be connected by hand


without using force, to ensure the battery housing is not dam‐
aged.
♦ Battery terminals must not beagreased.
gen AG
. Volkswagen AG
do w es n
olks ot g
♦ Always adhere to theedsequence
by
V
of work steps. ua
ran
ris te
♦ Disconnecting the
au
thobattery earth cable ensures safe working e or a
on the electrical
ss system. c

ce
e
nl

pt
du

an
Special tools and workshop equipment required
itte

y li
erm

ab
♦ Torque wrench -V.A.G 1331/- (5-50 Nm)

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

io

4.4.1 Battery: Check battery terminal clamps


n
c

in t
or

his

for secure seating


ate

do
priv

cum
for

en
ng

t.
yi
Note
Co
Cop py
ht. rig
rig ht
by
♦ In all vehicles a battery with „magic eye“ and covered-over cell copy Vo
by lksw
sealing plugs or without cell sealing plugs is installed. cted agen
Prote AG.

♦ A securely seated battery clamp ensures trouble free function


and long service life of the battery.
♦ The battery is located in engine compartment.

– 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.

48 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011
AG. Volkswagen
– Check whether wbattery
agen clamps areAsecure
G do
es n on battery terminals
olks
by moving d bybattery negative cable -1- and battery
V ot g
ua positive cable
-2- back
o
ir se and forth.
ran
te
th eo
au ra
c
ss
WARNING

ce
le
un

pt
an
d
itte

y li
If the battery terminal clamp is not seated securely on the pos‐
rm

ab
itive terminal, first disconnect battery terminal clamp from bat‐
pe

ility
tery negative terminal.
ot

wit
, is n

h re
hole

spec
If the battery terminal clamp is not seated securely on positive
es, in part or in w

t to the co
terminal:
Perform the following jobs:

rrectness of i
– Disconnect battery terminal clamp -1- from battery negative
terminal first.
l purpos

– Open battery positive terminal cover.

nform
ercia

– Tighten battery terminal clamp -2- on battery positive terminal


m

a
to specified torque ⇒ page 50
com

tion in
r

– Close battery positive terminal cover.


te o

thi
s
iva

do
– Reconnect battery terminal clamp -1- on battery negative ter‐
r
rp

cum

minal and tighten to specified torque ⇒ page 50 .


fo

en
ng

t.
yi Co
If the battery terminal clamp on negative terminal is not seated
. Cop py
securely:
t rig
gh ht
pyri by
Vo
co
Perform the following jobs:
by lksw
cted agen
Prote AG.

– Tighten battery terminal clamp -1- on battery positive terminal


to specified torque ⇒ page 50 .

Note

If the battery has been reconnected, observe procedures descri‐


bed in ⇒ Electrical system; Rep. gr. 27 .

4. Descriptions of work 49
Amarok 2011 ➤
Maintenance - Edition 01.2011

4.4.2 Battery terminal connections

Caution

To prevent damage to the battery terminal clamps eandAGthe


. Volkbat‐
swagen AG
tery terminals, observe the following: ag n does
olksw not
V gu
by ara
♦ The battery terminal clamps must risonly be connected by
ed nte
hand (without using force). autho eo
ra
ss c
♦ Battery terminals must not be greased.

ce
e
nl

pt
du

an
♦ Install battery terminal clamps so that the battery terminal
itte

y li
is flush with clamp or it projects through it.
erm

ab
ility
ot p

♦ When connecting the battery, always follow the procedure

wit
, is n

described in workshop manual ⇒ Rep. gr. 27

h re
hole

spec
♦ After tightening the battery terminal clamps to the prescri‐
es, in part or in w

bed torque, they must not be retightened!

t to the co
For specified torques of battery terminal clamps -1- and additional

rrectness of i
clamps -2-, refer to table „Specified torques: Battery“
l purpos

⇒ page 50 .

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4.4.3 Specified torques: Battery

Caution

♦ After tightening the battery terminal clamps to the prescri‐


bed torque, they must not be retightened.

Follow notes regarding battery terminal connections ⇒ page 50 .


Threaded connections Specified torques
Battery -A-: Battery terminal clamps on battery terminals M6 6 Nm
Battery -A-: Securing bolt for battery carrier M8x35 23 Nm

50 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

4.5 Battery: Perform visual check and check


magic eye
Perform the following jobs:
– Visual inspection of battery as well as a battery check using
AG. Volkswagen AG d
„magic eye“ ksw
agen oes
n ol ot g
yV ua
♦ Battery: Perform visual check ⇒ Electrical
ed
b system; Rep. gr. ran
ris
27 ut
ho tee
or
sa ac
♦ Battery: Check magic eye ⇒ Electrical
s system; Rep. gr. 27

ce
e
nl

pt
du

4.6 Removing relay for battery disconnec‐

an
itte

y li
erm

tion

ab
ility
ot p

wit
, is n

On vehicles with transport equipment, a battery cut-off relay is

h re
fitted on the battery positive terminal in left engine compartment.
hole

spec
es, in part or in w

On RHD vehicles an additional adapter cable is installed to extend

t to the co
the 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

rrectness of i
electrical consumers not required during transportation from man‐
l purpos

ufacturer to dealer.
♦ The battery cut-off relay and the adapter cable for RHD vehi‐

nform
ercia

cles must be removed for delivery inspection, if still fitted.


m

at
♦ Collect removed battery cut-off relay and, if necessary, adapt‐
om

io
er cable for RHD, and send back to manufacturer

n
c

in t
or

⇒ page 54 .

his
ate

do
priv

cum
for

Note

en
ng

t.
yi Co
Cop py
t. rig
♦ The battery terminal clamps must only be connected by hand yri
gh by
ht
without using force, to ensure the battery housing is not dam‐ cop Vo
by lksw
aged. cted agen
Prote AG.

♦ Battery terminals must not be greased.


♦ Disconnecting the battery earth cable ensures safe working
on the electrical system.

Special tools and workshop equipment required


♦ Torque wrench -V.A.G 1331- (5-50 Nm)

Procedure for all vehicles


Perform the following jobs:
– Switch off ignition and all electrical consumers.

4. Descriptions of work 51
Amarok 2011 ➤
Maintenance - Edition 01.2011

– Disconnect battery terminal clamp -1- on battery negative ter‐


minal first.
– Separate connector -1- between vehicle side cable and wiring
harness to battery cut-off relay.

– Separate connector -2- of wiring harness for battery cut-off


relay from brake fluid reservoir.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

– Secure vehicle side cable -1- back on brake fluid reservoir

h re
connection.
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
e

– Unscrew securing bolt (10 mm) -1- of battery cut-off relay from
at

do
riv

jump start point for battery positive terminal and remove.


p

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

52 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

– Loosen hexagon flange nut (10 mm) -1- from battery cut-off
relay and remove cable to main fuse box -2- from connection.
Procedure for RHD vehicles
On RHD vehicles an additional adapter cable is installed to extend
the wiring harness of the battery cut-off relay to connect the brake
fluid reservoir in right engine compartment.
Perform the following jobs:
– Open cable tie -1- on centre of bulkhead and remove wiring
harness of battery cut-off relay -2- with adapter cable -3- from
cable tie.

– Remove cable tie by unscrewing it from stud.


Procedure for all vehicles
Perform the following jobs:
olkswagen AG
en AG. V
– Remove battery cut-off relay with wiring harness and, if nec‐ ksw
ag does
not
Vol
essary, adapter cable for RHD. db
y gu
ara
e nte
ris
utho eo
ra
a c
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
– Unscrew jump start point (17 mm) -1- from battery positive
hole

terminal and remove.

spec
es, in part or in w

– Route cable to main fuse box -2- to battery positive terminal.

t to the co
– Place the cable in the envisaged position -arrow- in the termi‐
nal protector on the battery positive terminal.

rrectness of i
– Now secure cable to main fuse box -2- with jump start point
l purpos

-1- to battery positive terminal.

nform
mercia

at
om

ion
c

in t
or

his
te

Specified torque: 8 ± 1 Nm
a

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. Descriptions of work 53
AG. Volkswagen AG d
agen oes
olksw not
Amarok 2011 ➤ d by
V gu
ara
e nte
Maintenance - Edition 01.2011 horis
eo
aut ra
ss c
– Remove red terminal cap -1- from ashtray and insert it into

ce
le
un
thread of jump start point -2-.

pt
an
d
itte

y li
– Reconnect battery terminal clamp to battery negative terminal.

erm

ab
ility
ot p
– Tighten securing bolt of terminal clamp to specified torque

wit
is n
⇒ page 50 .

h re
ole,

spec
– Install battery cover.
urposes, in part or in wh

t to the co
Note

rrectne
If the battery has been reconnected, observe procedures descri‐
bed in ⇒ Electrical system; Rep. gr. 27 .

ss o
cial p

f inform
4.6.1 Parts dispatch
mer

atio
om

n
c

i
or

n thi
Note
te

sd
iva

o
pr

cum
r

♦ The battery cut-off relay and/or the RHD adapter cables are
fo

en
ng

so-called rotatable parts and are urgently required for the ve‐
t.
yi Co
op
hicle production. C py
t. rig
gh ht
yri by
♦ The parts must be packed in a cardboard box in order to pre‐ op Vo
by c lksw
vent damage to the battery cut-off relay and the adapter cable cted agen
Prote AG.
during transport.
♦ If they are dispatched with other parts, intermediate layers of
cardboard or bubble plastic are to be used.

Parts dispatch, notes on packaging and dispatch for export mar‐


kets
To avoid delays if the battery cut-off relay and the adapter cable
(if there is one) for right-hand drives have to be sent back,
make sure that the removed parts are immediately sent to the
importer's collecting point.
Parts dispatch, notes on packaging and dispatch for German
market
Make warranty/warranty claim immediately after removing the
battery cut-off relay and/or the RHD adapter cable. Forward the
part according to PDC guidelines.
Fill in section „Non-genuine parts“ completely and enter part num‐
ber of the removed battery cut-off relay.
Type of dispatch Parts recipient/location
OT Logistics Via TSC to K-QS-62 Regresse GTR
Halle 18 - Abt. 1958/4
38436 Wolfsburg

Notes on invoicing
Dispatch and labour costs are to be invoiced using special dam‐
age number „S 289 010 WWO“. For removing the battery cut-off
relay and/or the RHD adapter cable 20 time units are credited.

54 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

4.7 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.

WARNING

It is only permissible to deactivate the front passenger airbags


if, in exceptional cases, a child's seat has to be used on the
front passenger seat AG. Volkswagen AG d
agen oes
ksw n
Vol ot g
with the child sitting facing backwards. d by ua
ran
e
ris tee
utho or
a ac
ss

ce
le
un

pt
an
Note
d
itte

y li
rm

ab
pe

ility
The „PASSENGER AIRBAG ON/OFF“ switch is located on the
ot

wit
right end of dash panel.
, is n

h re
hole

spec
Perform the following jobs:
es, in part or in w

t to the co
– Check „ON/OFF function“ of key switch as follows:
Deactivating front passenger airbags (deactivated)

rrectness of i
– Switch off ignition.
l purpos

– Using the ignition key, turn key switch to position -1- „PAS‐
SENGER AIRBAG OFF“.

nform
ercia

The key slot must point in the direction of travel (forwards).


m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

If ignition is switched on, warning lamp in dash panel „PASSEN‐


GER AIRBAG OFF“ -arrow- must light up continuously.
– Switch off ignition.

4. Descriptions of work 55
Amarok 2011 ➤
Maintenance - Edition 01.2011

4.8 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
should be fitted on a vehicle!

♦ Check tyre age ⇒ page 56


♦ Tyre pressures (including spare wheel): Check, correct if nec‐
essary ⇒ page 58
♦ Checking wear pattern ⇒ page 57
♦ Tyre tread depth (including spare wheel): Check and enter
⇒ page 57
♦ Check condition ⇒ page 56

4.8.1 Check tyre age agen


AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
ris nte
o
Note aut
h eo
ra
ss c

ce
e

We recommend that summer or winter tyres older than 6 years


nl

pt
du

should be taken out of service.

an
itte

y li
erm

ab
ility
ot p

wit
, is n

Note

h re
hole

spec
The DOT number -arrow- is a number sequence stamped on at
es, in part or in w

t to the co
least one side of the tyre wall on motor vehicles which indicates
the production date of the tyre.

rrectness of i
The first two digits are for the calendar week (KW); shown as „02“
in this example.
l purpos

The last two digits indicate the year of manufacture; shown as


„04“ in this example.
nf
ercia

orm

In this case, therefore, „0204“ means that the tyre was produced
m

atio
m

in the second week of 2004.


o

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4.8.2 Checking condition of tyre


Tests at delivery inspection
Perform the following jobs:
– Check following areas of tyre for damage:
♦ »Tyre treads«
♦ »Tyre side walls«

56 4. Descriptions of work
agen
AG. Volkswagen AG d
oes Amarok 2011 ➤
ksw
gMaintenance - Edition 01.2011
ol not
V
d by ua
ran
ise
or tee
th or
au ac
ss
Note

ce
le
un

pt
an
d
itte
If damage is determined, always check to see if a new tyre should

y li
erm

ab
be fitted.

ility
ot p

wit
is n
Tests at interval service

h re
ole,

spec
Perform the following jobs:
urposes, in part or in wh

t to the co
– Check following areas of tyre for damage:
♦ »Tyre treads«

rrectne
♦ »Tyre side walls«

s
– Remove foreign bodies from tyres such as nails and glass

s o
splinters if necessary.
cial p

f inform
– In addition, check the tyres for:
mer

atio
m

♦ »Cupping«
o

n
c

i
or

n
♦ »One-sided tread wear«

thi
te

sd
iva

o
r

♦ »Porous side walls«


p

cum
r
fo

en
ng

♦ »Cuts«
t.
yi Co
Cop py
t.
♦ »Punctures«
rig
gh ht
pyri by
Vo
o
by c
♦ »Tyre age« „DOT identification“ 1.)
lksw
cted agen
Prote AG.
1.)
Tyres that are more than 6 years old should be renewed (rec‐
ommendation to customer)

Note

The customer must be informed of any faults found.

4.8.3 Checking wear pattern


The wear pattern on the front tyres will indicate, for example, if
toe and camber settings should be checked:
♦ Feathering on tread indicates incorrect toe setting.
♦ One-sided tread wear is mainly attributed to incorrect toe and
camber.
If wear of this nature is detected, determine cause by checking
alignment (repair measure).

4.8.4 Tyre tread depth (including spare


wheel): Check and enter
Perform the following jobs:
– Check tyre tread depth.
Minimum tread depth: 1.6 mm

4. Descriptions of work 57
Amarok 2011 ➤
Maintenance - Edition 01.2011

Note

♦ This value may vary according to different legislation in indi‐


vidual countries.
♦ 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,
inform the customer.

4.8.5 Tyre pressure (including spare wheel):


Check using tyre inflator -VAS 5216- ,
correct tyre pressure if necessary
Special tools and workshop equipment required
♦ Tyre inflator -VAS 5216-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
Note au ac
ss
ce
e
nl

pt

♦ „Checking tyre inflation pressure“ also applies to the spare


du

an
itte

wheel, if a spare wheel with standard tyres is fitted.


y li
erm

ab
ility

♦ The pressures in the table apply to cold tyres. Do not reduce


ot p

increased pressures of warm tyres.


wit
, is n

h re
hole

♦ Winter tyres and summer tyres may be used with the same
spec

tyre sizes - check suitability for use with chains.


es, in part or in w

t to the co

♦ Tyre pressures for the relevant model can also be found on a


sticker attached to the inside of fuel tank flap.
rrectness of i

♦ Values for pressure are indicated in „bar“.


l purpos

♦ Adjust the tyre pressure to suit the vehicle load.


♦ Tyre pressures apply for all tyre sizes fitted in the factory.
nform
ercia

♦ The tyre pressures indicated are valid when towing a trailer up


m

at

to a speed of 130 km/h (if permitted).


om

ion
c

in t
or

his
e

Explanation for speed indexes used in the table:


at

do
priv

♦ Q: up to 160 km/h
um
for

en
ng

t.
yi
♦ R: up to 170 km/h
Co
Cop py
t. rig
♦ S: up to 180 km/h
gh ht
pyri by
Vo
co lksw
by
♦ T: up to 190 km/h cted agen
Prote AG.

♦ H: up to 210 km/h

58 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

♦ 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 front rear
1370 / 1860 ♦ 205 R16 C 110/108 T 2,5 2,5 2,8 4,5
• Summer tyres
• M&S (winter tyres)
• All Season (all-season tyres)

♦ 245/70 R16,111 T 2,0 2,0 2,0 3,0


• Summer tyres
• M&S (winter tyres)
• All Season (all-season tyres)

♦ 245/65 R17,111 H 2,0 2,0 2,0 3,0


• Summer tyres
• M&S (winter tyres)
• All Season (all-season tyres)

♦ 255/60 R18,112 H 2,0 2,0 2,0 3,0


• Summer tyres

♦ 255/55 R19,111 H 2,0 2,0 2,0 3,5


. Volkswagen AG
• gen AG
waSummer tyres does
olks not
byV gu
ris
ed • M&S (winter tyres) ara
nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. Descriptions of work 59
Amarok 2011 ➤
Maintenance - Edition 01.2011

Permitted axle load Type of tyre Half payload Full payload


Full load: FA / RA
(kg)
1420 / 1860 ♦ 205 R16 C 110/108 T 2,7 2,7 3,0 4,5
• Summer tyres
• M&S (winter tyres)
• All Season (all-season tyres)agen AG. Volkswagen AG d
w oes
olks not
yV g
♦ 245/70 R16,111 Tise d b 2,0 2,0 2,0 uaran 3,0
r tee
ho
• Summer tyres aut or
ac
ss
• M&S (winter tyres)

ce
e
nl

pt
du

an
itte
• All Season (all-season tyres)

y li
erm

ab
ility
ot p

♦ 245/65 R17,111 H 2,0 2,0 2,0 3,0

wit
, is n

h re
• Summer tyres
hole

spec
• M&S (winter tyres)
es, in part or in w

t to the co
• All Season (all-season tyres)

♦ 255/60 R18 112 H 2,0 2,0 2,0 3,0

rrectness of i
• Summer tyres
l purpos

• M&S (winter tyres)

nf
ercia

o
• All Season (all-season tyres)

rm
m

atio
om

♦ 255/55 R19 111 H 2,0 2,0 2,0 3,0

n in
or c

thi
e

• Summer tyres
t

sd
iva

o
r
rp

cu
• M&S (winter tyres)
o

m
f

en
ng

t.
yi
• All Season (all-season tyres)
Co
Cop py
t. rig
gh ht
pyri by
Spare wheel with standard tyres
o Vo
by c lksw
cted agen
Prote AG.
The spare wheel should have the highest tyre pressure deter‐
mined for the vehicle.

4.9 Brake system: Perform visual check for


leaks and damage
– Check following components for leaks and damage:
♦ Brake servo,
♦ for anti-lock brake system: hydraulic unit,
♦ Brake calipers,
♦ Brake master cylinder.
Perform the following jobs:
– Make sure that brake hoses are not twisted ⇒ Brake hydraulic
system, regulator, booster; Rep. gr. 47 .
– In addition, make sure that brake hoses do not contact other
components across entire steering range.
– Check brake hoses for porosity or brittleness.
– Check brake hoses and lines for chafing.

60 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

– Check brake connections and fastenings for correct seating,


leaks and corrosion.

WARNING

Faults found must always be rectified (repair measure).

4.10 Front brake pads/linings: Check thick‐


ness
Special tools and workshop equipment required
♦ Test pin -T40139-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec

♦ Torque wrench -V.A.G 1332-


es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
or

and, if necessary, if anti-theft wheel bolts are installed:


f

en
ng

t.
yi Co
♦ Adapter set for tamper-proof wheel bolts -T10101- Cop py
t. rig
gh ht
yri
Or p by
co Vo
by lksw
cted agen
Prote AG.

4. Descriptions of work 61
Amarok 2011 ➤
Maintenance - Edition 01.2011

♦ Adapter set for tamper-proof wheel bolts -T10190-


♦ Electric hand torch and mirror

4.10.1 Front brake pads


Check thickness using test pin -T40139-

Note

♦ The wheel rim geometry of some vehicles may make it im‐


possible to
♦ insert the test pin through the wheel rim far enough to reach
the brake disc or brake pad.
♦ In this case, determine the thickness of the brake
agen
pads
AG. Voby
lkswagen AG
do
means of a visual check Vol
ksw es n
ot g
d by ua
ran
♦ or remove the wheel on the driver's orside to make it easier
ise to tee
assess or measure the remaining auththickness of the pads. or
ac
ss
ce
le
un

Perform the following jobs: pt


an
d
itte

y li
– To measure the brake pad thickness push the movable ring in
rm

ab
pe

direction of test probe onto stop.


ility
ot

wit
, is n

– Insert the test probe of the test pin through the wheel rim until
h re
hole

it touches the brake disc.


spec
es, in part or in w

– Push the test pin towards the brake pad until the pin touches
t to the co

the rear plate of the brake pad.


– Then remove test pin -T40139- and read off value on scale
rrectness of i

identified with brake symbol.


l purpos

Note
nform
ercia

♦ Ensure the movable ring is not moved when removing the test
m

pin after the measurement. Otherwise this will lead to an in‐


com

tion in

correct measurement!
r
te o

thi

♦ The second scale (tyre symbol) on the test pin can be used to
s
iva

do
r

measure the tyre tread depth.


rp

cum
fo

en
ng

t.
yi Co
a - Pad thickness „with“ backplate Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

62 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

Wear limit: 9 mm

WARNING

The brake pads have reached their Awear limit at a brake pad
G. Volkswagen AG d
thickness of 9 mm (value shownlkswagon
en test pin) (including
oes back‐
not
plate) and must be renewed.
d by V Inform customer!
o gu
a
e ran
ris tee
utho or
a ac
ss

ce
le
un

pt
Note

an
d
itte

y li
rm

ab
When replacing disc brake pads, always check brake discs for
pe

ility
wear! Checking and if necessary replacing the brake discs is a
ot

wit
, is n

repair measure.

h re
hole

spec
Checking brake disc for wear ⇒ Rep. gr. 46 .
es, in part or in w

t to the co
Check thickness by visual check

rrectness of i
Note
l purpos

One some vehicles it may be very difficult to ascertain or measure


the thickness of the pad due to the geometry of the wheel rim. If

nform
ercia

this is the case, remove the wheel on driver side for better eval‐
m

uation of the remaining pad thickness.

a
com

tion in
r
te o

thi
Perform the following jobs: s
iva

do
r

– Measure outer and inner brake pad thickness by visually


rp

cum
fo

checking through the holes of wheel rim (depending on type).


en
ng

t.
yi Co
op
– If necessary, remove the wheel on the driver's side to make it
C py
t. rig
gh
easier to assess or measure the remaining thickness of the
ht
pyri by
Vo
pads.
co lksw
by
cted agen
Prote AG.
– Mark position of wheel in relation to brake disc, in order to
avoid imbalances on vehicle wheel.
– Unscrew wheel securing bolts and remove wheel.

4. Descriptions of work 63
Amarok 2011 ➤
Maintenance - Edition 01.2011

– 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). Inform customer!

Note

When replacing disc brake pads, always checksbrakeagen discs for


AG. Vo agen AG lksw
does
k w
wear! Checking and if necessary replacingbythe
V brake discs is a
ol not
gu
repair measure. ris
ed ara
nte
tho eo
au ra
c
Checking brake disc for wear ⇒ Rep.
ss
gr. 46 .

ce
le
un

pt
Perform the following procedure:

an
d
itte

y li
erm

ab
– If necessary, secure wheel in marked position.

ility
ot p

– Tighten wheel securing bolts diagonally across to following

wit
is n

h re
specified torque:
ole,

spec
urposes, in part or in wh

Specified torque: 180 Nm

t to the co
– Push on wheel trims if necessary.

4.11 Rear drum brake linings: Check thick‐

rrectne
ness
Special tools and workshop equipment required ss o
cial p

f inform

♦ Fluorescent lamp, 13 watts -VAS 6485-


mer

atio
m

Or
o

n
c

i
or

n thi

♦ Conventional torch
te

sd
iva

o
pr

Perform the following procedure:


cum
r
fo

en
ng

t.
– Remove inspection hole cover.
yi Co
Cop py
ht. rig
– Check brake lining thickness through inspection holes rig ht
py by
-arrow- in brake backplates. co Vo
by lksw
cted agen
Prote AG.
Wear limit: 1.5 mm (lining thickness only).

Note

Check linings for brake fluid or grease contamination.

64 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

4.12 Brake system and shock absorbers:


Perform visual check for leaks and dam‐
age
Check following components for leaks and damage:
♦ Brake master cylinder
♦ Hydraulic unit
♦ Brake calipers
♦ Shock absorber
♦ Presence of dust caps on brake fluid bleeder valves
– Ensure that brake hoses are not twisted.
– Additionally ensure that brake hoses do not touch any vehicle
components when steering is at full lock.
– Check brake hoses for porosity or brittleness.
– Check brake hoses and lines for chafing.
– Also check brake connections
gen AG
. Volksand fastenings
wagen AG
does for correct seat‐
swa
ing, leaks andy Vcorrosion.
olk not
gu b ara
ed nte
oris e
th or
au WARNING ac
ss
ce
e
nl

Faults found must always be rectified (repair measure).


pt
du

an
itte

y li
erm

ab
ility
ot p

4.13 Brake fluid: Change


wit
, is n

h re
hole

♦ Observe brake fluid specification ⇒ page 69


spec
es, in part or in w

t to the co

WARNING

♦ Brake fluid must under no circumstances come into con‐


rrectness of i

tact with fluids containing mineral oils (oil, petrol, cleaning


l purpos

solutions). Mineral oils will damage seals and sleeves of


brake system.
nform
ercia

♦ Brake fluid is poisonous. In addition, due to its corrosive


nature, it must not come into contact with paint.
m

at
om

io

♦ Brake fluid is hygroscopic, i.e. it attracts moisture from the


n
c

in t
r

surrounding air and therefore must always be stored in air-


o

his
te

tight containers.
a

do
priv

cum
or

♦ Wash away spilt brake fluid using plenty of water.


f

en
ng

t.
yi Co
♦ Do not reuse extracted (used) brake fluid! ht. Cop py
rig
rig ht
♦ Observe disposal regulations! py by
co Vo
by lksw
cted agen
Prote AG.

Special tools and workshop equipment required

4. Descriptions of work 65
Amarok 2011 ➤
Maintenance - Edition 01.2011

♦ Brake filling and bleeding equipment -VAS 5234-

AG. Volkswagen AG d
agen oes
olksw not
♦ Brake pedal actuator -V.A.G 1869/2- d by
V gu
ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
♦ Upgrade kit and extraction unit -V.A.G 1869/4-
l purpos

Perform the following procedure:


– Unscrew sealing cover -1- from brake fluid reservoir -2-.

nform
mercia

a
com

t
Note

ion in
r
te o

thi
The strainer in brake fluid reservoir must not be removed.

s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

66 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

– Extract as much brake fluid as possible using suction hose


from brake filling and bleeding equipment -VAS 5234- .

WARNING

Do not reuse extracted (used) brake fluid!


n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Screw adapter -1- onto brake fluid reservoir -2-.
– Fit brake pedal actuator -V.A.G 1869/2- between driver seat

rrectness of i
and brake pedal and pretension.
l purpos

– Connect filler hole from brake filling and bleeding equipment -


VAS 5234- to adapter.

nform
mercia

at
Note
om

ion
c

in t
or

Observe ⇒ operating instructions for brake filling and bleeding


his
ate

equipment -VAS 5234- !


do
priv

cum
for

en
ng

t.
yi Co
op
WARNING
C py
t. rig
gh ht
pyri by
Vo
co
Use an appropriate bleeder hose. It must seat tightly on bleed‐
by lksw
cted agen
Prote
er valve so that no air can enter the brake system.
AG.

Change brake fluid in clutch slave cylinder.


Bleeder valve for clutch slave cylinder is located on left side of
gearbox.

– 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 cm3 to
flow out.
– Close bleeder valve and quickly operate foot pedal 10 to 15
times from stop to stop.
– Open bleeder valve and allow another 0.05 litre or 50 cm3 of
brake fluid to flow out.
– Close bleeder valve and push on cover cap.
– Press clutch pedal rapidly several times.
– Remove caps from bleed valves of brake calipers.
Changing brake fluid at rear.

4. Descriptions of work 67
Amarok 2011 ➤
Maintenance - Edition 01.2011

– Push collector bottle bleed hose -1- onto rear right bleed valve.
– Open bleeder valve and let appropriate quantity of brake fluid
run out (see table).

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
– Close bleeder valve again.ut
ho eo
ra
s a c
s
Repeat procedure on rear left of vehicle.

ce
e
nl

pt
du

an
Change brake fluid at front.
itte

y li
erm

ab
– Push collector bottle bleeder hose -1- onto front right-hand

ility
ot p

bleeder valve, open bleeder valve and allow appropriate

wit
, is n

amount of brake fluid to flow out out (see table).

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

– Close bleeder valve again.


l purpos

Repeat procedure on front left of vehicle.


nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Sequence Recommended quantity of brake fluid to be changed
On clutch slave cylinder 1) approx. 0.15 litre
Rear right approx. 0.25 litre
Rear left approx. 0.25 litre
Front right approx. 0.25 litre
Front left approx. 0.25 litre

1) Only vehicles with manual gearbox


• Brake fluid quantity to be changed: approx. 1.0 to 1.15 litre
(depending on vehicle equipment)

68 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

Final checks
– Fit cover caps on bleeder valves of brake calipers.
– Set fill lever of brake filling and bleeding equipment -
VAS 5234- to position „B“ (see ⇒ operating instructions ).
– Remove filler hose from adapter.
– Unscrew adapter from brake fluid reservoir.
– Check brake fluid level and correct it if necessary.
– Screw on sealing cover -1- of brake fluid reservoir -2-.
– Remove brake pedal actuator.
– Check pressure and free travel of brake pedal.
Free play: max. 1/3 of pedal travel. ksw
agen
AG. Volkswagen AG d
oes
ol not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
4.13.1 Brake fluid specification
is n

h re
ole,

spec
The brake fluids are available as replacement part. The part num‐
urposes, in part or in wh

ber can be found in ⇒ Electronic parts catalogue „ETKA“ .

t to the co
Permissible brake fluid specifications

rrectne
♦ Volkswagen recommends using new brake fluid acc. to VW
Standard 501 14 for optimum function of brake system.

s
♦ Alternatively, a brake fluid acc. to requirements of US standard

s o
cial p

FMVSS 116 DOT4 or DIN ISO 4925 Class 4 can be used.

f inform
mer

♦ Specification is stated on brake fluid packaging.

atio
m

4.14 Brake fluid level: Check


o

n
c

i
or

n thi
te

sd
♦ Checking brake fluid level at delivery inspection ⇒ page 70
iva

o
pr

cum
r

♦ Checking brake fluid level at interval service and inspection


fo

en
ng

service ► 2010 ⇒ page 70


t.
yi Co
Cop py
t. rig
♦ Observe brake fluid specification ⇒ page 69 opyri
gh by
Vo
ht
by c lksw
cted agen
Prote
WARNING
AG.

♦ 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.
♦ Brake fluid is hygroscopic, i.e. it attracts moisture from the
surrounding air and therefore must always be stored in air-
tight containers.
♦ Wash away spilt brake fluid using plenty of water.
♦ Observe disposal regulations!

4. Descriptions of work 69
Amarok 2011 ➤
Maintenance - Edition 01.2011

4.14.1 Checking brake fluid level at delivery in‐


spection
At delivery inspection the fluid level must be at MAX. marking
-1-.

Note

In order that brake fluid does not overflow the reservoir, MAX
marking -1- must not be exceeded.

4.14.2 Checking brake fluid level at interval


service and inspection service

Note

♦ The fluid level must always be judged


gen AG
in conjunction
. Volkswagen AG with lin‐
d
ing/pad wear. olks
wa oes
not
byV gu
ar
When vehicle is in use, ed
♦ ris fluid level tends to drop slightly due to antee
ho
lining/pad wear andau automatic adjustment.
t or
ac
ss
ce
e
nl

Recommended brake fluid level „BEFORE“ brake pads are at


pt
du

an

wear limit:
itte

y li
erm

ab

• „At MIN marking or just above“, -2-


ility
ot p

wit
, is n

Then „REPLENISHING IS NOT REQUIRED!“


h re
hole

spec

Recommended brake fluid level, brake pads new or well within


es, in part or in w

wear limit:
t to the co

• „Between MIN. and MAX. marking“


rrectness of i

WARNING
l purpos

If fluid level is below MIN marking -2-, the brake system must
be checked before fluid is topped up, „Repair measure“!
nform
mercia

at
om

ion
c

in t

4.15 Climatronic: Set temperature to 22 °C


or

his
ate

do
priv

cum
for

en

Note
ng

t.
yi Co
Cop py
ht. rig
The automatic air conditioning system „Climatronic“ only func‐ rig ht
py by
tions when engine is running and the blower is switched on.
co Vo
by lksw
cted agen
Prote AG.

Perform the following jobs:


– Switch on ignition.
– Check the temperature controllers -2- and -3- to see whether
the temperature has been set to 22 °C.
If temperature is not set to 22 ℃, then correct it.

70 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

– Press AUTO -1- The „AUTO High“


n AG. Vfunction
olkswagen(high
AG do blower output)
has been activated.VThe wage
olks right-hand warning lamps nin ot the button
e
gu
lights up. ed
by ara
n is tee
or
– Press AUTO ut -1- again. The „AUTO Low “ function (low blower
h or
ac
sa
output) has been activated. The left-hand warning lamp in the
s

ce
e

button lights up.


nl

pt
du

an
itte

y li
– Turn the temperature controllers -2- and -3- to set the desired
erm

ab
temperature for the left-hand and right-hand sides of the inte‐

ility
ot p

rior.

wit
, is n

h re
22 °C is recommended.
hole

spec
es, in part or in w

t to the co
Note

In the automatic mode the air temperature, air quantity and air

rrectness of i
distribution are regulated automatically so that a specified tem‐
l purpos

perature level is attained as quickly as possible and is maintained


constantly.

nform
mercia

at
om

ion
c

in t
or

his
ate

4.16 Window regulators: Check positioning


do
priv

cum
or

(open and close functions)


f

en
ng

t.
yi Co
Cop py
ht. rig
WARNING
rig ht
py by
co Vo
by lksw
cted agen
Prote
After batteries have been disconnected and reconnected the
AG.

roll-back function of the window regulators is disabled. Severe


pinching injuries could result!

Note

♦ The automatic opening and closing functions of the electric


windows do not work after the batteries have been discon‐
nected and reconnected.
♦ Therefore, with immediate effect, before a new vehicle is de‐
livered, the window regulators must be reactivated.
♦ Once the windows have been repositioned, the batteries must
not be disconnected again.

Perform the following jobs:


– Close all doors and windows completely.
– Insert key in driver's door lock and lock vehicle from outside.
– Unlock vehicle again.
– Lock vehicle again from outside and hold key in lock position
for at least 1 second.
The one-touch opening and closing function is now ready for use.

4.17 Connecting vehicle diagnosis tester


♦ Connect vehicle diagnostic, testing and information system -
VAS 5051B- or vehicle diagnostic and service information
system -VAS 5052 A- and select functions ⇒ page 72

4. Descriptions of work 71
Amarok 2011 ➤
Maintenance - Edition 01.2011

4.17.1 Connect vehicle diagnostic, testing and


information system -VAS 5051B- or ve‐
hicle diagnostic and service information
system -VAS 5052 A- and select func‐
tions
Special tools and workshop equipment required
♦ Vehicle diagnostic, testing and information system -VAS
5051B- or subsequent units

♦ Diagnosis cable 5m -VAS 5051B/1- AG. Volkswagen AG d


agen oes
olksw not
V gu
Or d by ara
rise nte
ho eo
♦ Diagnosis cable -VAS 5051/5A-
aut ra
c
ss
Or
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

72 4. Descriptions of work
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
tho Amarok tee
o2011 ➤
u ra
ss
a
Maintenance - Edition 01.2011 c

ce
e
nl

pt
du
♦ Vehicle diagnostic and service information system -VAS 5052

an
itte

y li
A-

erm

ab
ility
ot p
♦ Diagnosis cable, 2 m -VAS 5052/3 A-

wit
, is n

h re
Or

hole

spec
♦ Diagnosis cable, 5 m -VAS 5052/3 A-1-

es, in part or in w

t to the co
Note

rrectness of i
♦ Observe current operating instructions for vehicle diagnostic,
l purpos
testing and information system -VAS 5051B- or vehicle diag‐
nostic and service information system -VAS 5052 A- , which
are shown on display after selecting the functions Adminis-

nform
ercia

tration and Operating manual .


m

at
om

io
♦ For diagnosis only use the diagnosis cable indicated above,

n
c

in t
r

because this is fitted with CAN bus cables and allows a CAN
o

his
te

diagnosis or CAN communication.


a

do
priv

cum
or

♦ For a road test use diagnostic cable -VAS 5051/5A- , to guar‐


f

en
g

antee the voltage supply of the vehicle diagnostic, testing and


n

t.
yi Co
op
information system -VAS 5051B- . C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
WARNING
AG.

♦ If the vehicle diagnosis tester is placed within the range of


action of an airbag during a test or measuring run,
♦ there is a risk of severe or fatal injury should an airbag be
triggered!
♦ During the road test, take another person with you who
can operate the vehicle diagnosis tester from the rear
seat.
♦ Always secure testing and measuring equipment on the
rear seat during a road test.

Perform the following jobs:

4. Descriptions of work 73
Amarok 2011 ➤
Maintenance - Edition 01.2011

– Connect diagnosis cable connector to diagnosis connection


with ignition switched off.gen AG. Volkswagen AG
a does
lksw not
– Switch on tester.
db
yV
o gu
ara
e nte
ris
– Switch on uignition.
tho eo
ra
sa c
– Touch the
s
field on the screen for Guided fault finding or

ce
e
nl

Guided functions .

pt
du

an
itte

y li
– Select one after another:
erm

ab
ility
ot p

♦ Brand

wit
, is n

h re
♦ Type
hole

spec
es, in part or in w

♦ Model year

t to the co
♦ Version
♦ Engine code

rrectness of i
– Confirm entered data.
l purpos

nf
ercia

Note

orm
m

atio
m

Wait until tester has read all control units in vehicle.


o

n in
or c

thi
e

– Press GoTo button and select Function/component selec-


t

sd
iva

o
r

tion function.
rp

cu
o

m
f

en
ng

t.
Now follow screen display to start desired functions.
yi Co
Cop py
t. rig
gh ht
yri
4.18 Performing vehicle system test
p by
co Vo
by lksw
cted agen
Prote AG.
– Connect vehicle diagnostic, testing and information system -
VAS 5051B- or vehicle diagnostic and service information
system -VAS 5052 A- ⇒ page 71 .

Note

Observe current operating instructions for vehicle diagnostic,


testing and information system -VAS 5051B- or vehicle diagnostic
and service information system -VAS 5052 A- , which are shown
on display after selecting the functions Administration and
Operating manual .

WARNING

♦ If the vehicle diagnostic, testing and information system -


VAS 5051B- or the vehicle diagnostic and service infor‐
mation system -VAS 5052 A- is placed in the range of
action of an airbag during a test or measuring run,
♦ there is a risk of severe or fatal injury should an airbag be
triggered!
♦ During the road test take another person with you who can
operate the vehicle diagnostic, testing and information
system -VAS 5051B- or vehicle diagnostic and service in‐
formation system -VAS 5052 A- from the rear seat.
♦ Always secure testing and measuring equipment on the
rear seat during a road test.

74 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

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
A- in operating mode Guided fault finding , the device reads
the event memories again. The vehicle diagnosis, testing and in‐
formation system -VAS 5051B- or vehicle diagnosis, testing and
information system -VAS 5052 A- can generate a test plan for
„Guided fault finding“ but only if the faults are still stored in the
event memory.
Perform the following jobs:
– Pull on handbrake.
– Manual gearbox: Gear lever in neutral
gen AG
. Volkswagen AG
d
wa oes
olks not
– Switch on ignition. d byV gu
ara
ise nte
r
– Select Guidedutfunctions
ho operating mode -arrow- on display eo
ra
of vehicle diagnostic,
ss a
testing and information system -VAS c
5051B- or vehicle diagnostic and service information system ce
e
nl

pt
du

-VAS 5052 A- . an
itte

y li
erm

Indicated on display: ab
ility
ot p

– Then perform vehicle identification on vehicle diagnostic, test‐


wit
, is n

ing and information system -VAS 5051B- or vehicle diagnostic


h re
hole

and service information system -VAS 5052 A- .


spec
es, in part or in w

– Select one after another:


t to the co

♦ Brand
rrectness of i

♦ Type
l purpos

♦ Model year
♦ Version
nf
ercia

♦ Engine code
rm
m

atio
m

– Confirm vehicle identification


o

n in
or c

thi

– If the vehicle identification has been performed correctly, con‐


te

sd
a

firm with > button.


iv

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4. Descriptions of work 75
Amarok 2011 ➤
Maintenance - Edition 01.2011

Indicated on display:
– Select Vehicle system test function -arrow- on display of
vehicle diagnostic, testing and information system -VAS
5051B- or vehicle diagnostic and service information system
-VAS 5052 A- .
– Start system test by selecting function Start system test
on display of vehicle diagnostic, testing and information sys‐
tem -VAS 5051B- or vehicle diagnostic and service informa‐
tion system -VAS 5052 A- .
Now the event memories of all control units for this type of vehicle
are automatically read and any faults stored will be listed. n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
Note utho
or
a ac
ss
♦ If any stored faults are listed, it is useful at this point to change

ce
e
nl

pt
to the Guided troubleshooting mode du

an
itte

y li
erm

ab
♦ in order to continue working with the vehicle diagnostic, testing

ility
ot p

and information system -VAS 5051B- or vehicle diagnostic

wit
, is n

and service information system -VAS 5052 A- and avoid the

h re
tester having to perform a second vehicle identification check.
hole

spec
es, in part or in w

♦ When the system test indicates the need for a repair measure

t to the co
(fault finding) and this is to be performed immediately, change
to operating mode Guided fault finding .

rrectness of i
♦ If the repair measure is to be carried out at a later date, e.g.
after completing servicing, end operating mode Guided
l purpos

functions . The event memory will not be cleared.

♦ Follow the instructions of the vehicle diagnosis, testing and

nf
ercia

information system -VAS 5051B- or vehicle diagnosis and

orm
service information system -VAS 5052 A- on how to proceed
m

atio
m

for „Guided find finding“ or „Guided functions“.


o

n in
or c

thi
te

sd
a

– End the system test via function GoTo and End or continue
iv

o
r
rp

cu
„Guided fault finding“ after changing the operating mode.
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
Caution
gh ht
pyri by
Vo
co lksw
by
cted agen
The vehicle must always be delivered to the customer with Prote AG.

event memory cleared.

Static faults
If one or more static faults have been stored in the event memory,
it is advisable to rectify these faults with the help of „Guided trou‐
bleshooting“ in consultation with the customer.
Sporadic faults
If only sporadic faults or notes have been stored in the event
memory
and the customer makes no complaints regarding an electronic
vehicle system, the event memory is to be erased.
Clear event memory.
– Start operating mode Vehicle self-diagnosis in the sys‐
tem start mask of the vehicle diagnostic, testing and informa‐
tion system -VAS 5051B- or vehicle diagnostic and service
information system -VAS 5052 A- .

76 4. Descriptions of work
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
c
Amarok 2011 ➤
s
s Maintenance - Edition 01.2011

ce
e
nl

pt
du

an
itte
There are two ways to clear the event memory:

y li
erm

ab
♦ Clearing event memory by selecting individual control units:

ility
ot p

wit
, is n
Perform the following jobs:

h re
hole

spec
– Select control unit in question individually in overview, select
es, in part or in w
Read event memory and then press Delete event memo-

t to the co
ry .

♦ Clearing event memory via function Collection services :

rrectness of i
Perform the following jobs:
l purpos

– Call up Collection services on display,

nf
ercia

– and then select Delete event memory function.

orm
m

atio
om

n in
c

Note
or

thi
te

sd
iva

o
r

♦ If all faults have been cleared, it is shown on display.


rp

cu
o

m
f

en
ng

♦ The diagnosis log can be sent automatically »online«.


t.
yi Co
Cop py
t. rig
gh ht
yri
The vehicle system test is completed. p by
o Vo
by c lksw
cted agen
Prote AG.

4.19 Four-wheel drive: Insert fuse


Insert fuse 46 on fuse holder C -SC46- „4 x 4“ four-wheel drive
control unit
Special tools and workshop equipment required
♦ Vehicle diagnostic, testing and information system -VAS
5051B- or subsequent units

♦ Diagnosis cable 5m -VAS 5051B/1-


Or
♦ Diagnosis cable -VAS 5051/5A-
Or
♦ Vehicle diagnostic and service information system -VAS 5052
A-
♦ Diagnosis cable, 2 m -VAS 5052/3 A-
Or
♦ Diagnosis cable, 5 m -VAS 5052/3 A-1-
Perform the following jobs:
– Switch off ignition, all electrical consumers and withdraw igni‐
tion key.

4. Descriptions of work 77
Amarok 2011 ➤
Maintenance - Edition 01.2011

– 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- .

– Place fuse 46 on fuse holder C -SC46- in fuse holder C -SC- en AG. Volkswagen AG
-1- -arrow-, using removed insertion aid if necessary. olkswag does
not
V gu
by ara
– Replace insertion aid where it belongs if it has been
or
ise removed.
d
nte
h eo
ut ra
– Fold up fuse holder C -SC- and lock in place.
ss
a c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

– Switch on ignition and check if both warning lamps „4 x 4 high /


4 x 4 low“ -arrow- in dash panel insert -K- no longer light up.
rrectness of i

– Switch off ignition.


l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

78 4. Descriptions of work
Amarok 2011 ➤
Maintenance - Edition 01.2011

– Connect vehicle diagnostic, testing and information system -


VAS 5051B- or vehicle diagnostic and service information
system -VAS 5052 A- ⇒ page 71 .

Note

♦ Observe current operating instructions for vehicle diagnostic,


testing and information system -VAS 5051B- or vehicle diag‐
nostic and service information system -VAS 5052 A- , which
are shown on display after selecting the functions Adminis-
tration and Operating manual .

♦ For diagnosis only use the diagnosis cable indicated above,


because this is fitted with CAN bus cables and allows a CAN
diagnosis or CAN communication.

WARNING

♦ If the vehicle diagnosis tester is placed within the range of


action of an airbag during a test or measuring run,
♦ there is a risk of severe or fatal injury should an airbag be
triggered!
♦ During the road test, take another person with you who
can operate the vehicle diagnosis tester from the rear
seat.
. Volkswagen AG
♦ Always secure testing and measuring equipment on the lkswagen AG does
rear seat during a road test. by
Vo
not
gu
ara
ed nte
oris eo
th
au ra
– Switch on ignition. ss c

ce
e
nl

pt
– Connect vehicle diagnosis, testing and information system -
du

an
itte

VAS 5051B- or vehicle diagnosis and service information

y li
erm

ab
system -VAS 5052 A- .

ility
ot p

wit
– Start operating mode Vehicle self-diagnosis in the sys‐
, is n

h re
tem start mask of the vehicle diagnostic, testing and informa‐
hole

spec
tion system -VAS 5051B- or vehicle diagnostic and service
es, in part or in w

information system -VAS 5052 A- .

t to the co
– Select respective control unit „03 - Brake electronics“, „17 -
Dash panel insert“ and „19 - Gateway / data bus“ individually

rrectness of i
in the overview.