Maintenance PDF

Service
Maintenance
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Amarok 2011 ➤
ise nte
or eo
h
aut ra
s c
s
Edition 01.2011
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.
Service Department. Technical Information

Service
Maintenance
Heading
1. Engine list
2. Service work
3. General
4. Descriptions of work
5. Exhaust emissions test
AG. Volkswagen AG d
6. Glossary 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
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.
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
agen G do
es n
olksw ot g
y V ua
b
thoris
ed
Contents ran
tee
or
au ac
ss
1 Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ce
e
nl
pt
du
an
2 Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
itte
y li
erm
2.1 Information on LongLife service and time or distance dependent service . . . . . . . . . . . . . . 2
ab
ility
ot p
2.2 Service tables, inland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
wit
, is n
2.3 Service tables, export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
h re
2.4 hole
Service tables, Argentina and Brazil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
spec
es, in part or in w
2.5 VW engine oil standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
t to the co
2.6 Delivery inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.7 Scopes of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
rrectness of i
2.8 Time or distance dependent additional work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.9 Market specific deviations - scope of work for Argentina and Brazil . . . . . . . . . . . . . . . . . . 17
l purpos
3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 Vehicle identification number (chassis number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
nform
ercia
3.2 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

m
at
3.3 Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
om
ion
c
3.4 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
in t
or
his
e
3.5 Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
at
do
riv
3.6 Entries in service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

p
cum
for
3.7 RME fuel (biodiesel) that does not conform with the standard . . . . . . . . . . . . . . . . . . . . . . 22
en
ng
t.
yi Co
op
4 Descriptions of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
C py
t. rig
gh ht
4.1 Lifting vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
pyri by
Vo
o
by c lksw
4.2 Swivel joints: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote
cted AG.
agen
44
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
gen G
4.53 Doors: Grease door arrester . . . . . . . . . . . . . . . . . . V.o.lk.sw. a. . . . . . . . . . . . . . . .d.oe. s.n.ot. . . . . . 128
y g
4.54 Paint: Perform visual check for damage and corrosion, ise
db interior and exterior when doorsuaand ran
bonnet/rear lid/flaps are open . . . . . . . . . . . .th.o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .te.e o128
r
u ra
4.55 Protective foil: Remove (if fitted) . . . . . . .ss.a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 c
ce
4.56 Underbody protection: Perform visual check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . 129
e
nl
pt
du
an
4.57 Clock: Set to correct time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
itte
y li
erm
4.58 Camshaft drive toothed belt and toothed belt tensioning roller: Renew . . . . . . . . . . . . . . 130
ab
ility
ot p
4.59 Camshaft drive toothed belt: Check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
wit
, is n
4.60 Coolant pump toothed belt sprocket and toothed belt: Renew . . . . . . . . . . . . . . . . . . . . . . 131
h re
hole
4.61 Spark plugs: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
spec
es, in part or in w
4.62 Removing and installing skid plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
t to the co
4.63 Steering: Check bellows for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5 Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
rrectness of i
5.1 General information for exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.2 Exhaust emissions test for petrol engines with engine code CFPA . . . . . . . . . . . . . . . . . . 135
l purpos
5.3 Exhaust emissions test for diesel engines with engine codes CDBA, CDCA . . . . . . . . . . 142
5.4 Exhaust emissions test with OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
nf
ercia
or
6 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
m
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.
ii Contents
Amarok 2011 ➤
1 Engine list
Diesel engines ⇒ page 1
Petrol engines ⇒ page 1
n AG. Volkswagen AG do
lkswage es n
o ot g
yV ua
Diesel engines ir se
d b ran
tee
tho
u or
a ac
ss
Note
ce
le
un
pt
an
d
itte
y li
To ease the search for an engine, the engine codes are listed in
rm
ab
alphabetical order.
pe
ility
ot
wit
, is n
h re
Engines: ⇒ Diesel engines Diesel engines
hole
spec
Capacity I 2,0 2,0
es, in part or in w
t to the co
Introduction WEEK 05/2010 ▶ WEEK 05/2010 ▶
Engine code CDBA CDCA
rrectness of i
No. of cylinders/valves per cylinder 4/4 4/4
l purpos
Output kW at rpm 90/3750 120/4000

Torque Nm at rpm 340/1750-2500 400/1500-2000
nform
ercia
Bore ∅ mm 81,0 81,0

m
a
Stroke mm 95,5 95,5
com
tion in
Compression ratio 16,5 16,5
r
te o
thi
s
iva
Injection/ignition TDI common rail TDI common rail

do
r
rp
cum
Diesel particulate filter yes/no1) yes/no1)
fo
en
ng
t.
yi Co
Camshaft drive t. Cop
Toothed belt py
rig Toothed belt
gh ht
yri
1)
by
Depending on vehicle equipment cop Vo
by lksw
cted agen
Prote AG.
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 ➤
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

AG. gen AG Volkswa
– Check vehicle data sticker to determine agen
whether the vehicle does no
olksw
has production control (PR) number d b „QG1“, „QG0“ or „QG2“.
yV t gu
ara
The PR number is decisive for rise service intervals
the nte
ho eo
⇒ page 5 . au
t ra
c ss
The vehicle data sticker -arrow- is attached to the left A-pillar low‐
ce
le
un
pt
er trim panel in the footwell.
an
d
itte
y li
erm
This vehicle data sticker is also found in the service schedule for ab
ility
ot p
the customer. wit

is n
h re
Vehicle ID with PR number
ole,
spec
urposes, in part or in wh
„QG1“ indicates „LongLife service“.

t to the co
„QG2“ or „QG0“ indicates „time or distance dependent“ service.

rrectness o
cial p
2.1.2 LongLife service

inform
mer
Vehicles with PR number „QG1“

atio
om
With the LongLife system, a new technology was introduced by

c
i
or
n thi
Volkswagen commercial vehicles whereby an interval service is

te
sd
a
only performed when the vehicle needs it.

iv
o
pr
cum
r
fo
What is so special about it is that individual conditions of use and

en
ng
t.
yi
personal driving style are taken into consideration when deter‐
Co
op py
mining the interval service. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
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 ➤
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
AG. Volksw agen AG (ESI)
agen does
(production control number QG0Volksw= without ESI, production not
control number QG2 = ESIed b cannot be activated)
y gu
ara
is nte
or eo
♦ When the extendedauservicing
th interval (ESI) was stopped ra
ss c
♦ or in which LongLife engine oil has not been used,
ce
le
un
pt
an
d
the time or distance dependent service applies.

itte
y li
rm
ab
These flexible service intervals are valid for all types of service
pe
ility
ot
including an engine oil change.

wit
, is n
h re

hole
spec
es, in part or in w
These vehicles are „not“ factory-fitted with components for Long‐

t to the co
Life service. For maintenance the time or distance dependent

intervals (non-flexible intervals) apply.
rrectness of i

l purpos
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
nform
ercia
dependent intervals (non-flexible intervals) are valid. These ve‐

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

n 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
3
c by lksw
cted agen
Prote AG. 2. Service work
Amarok 2011 ➤
AG. Volkswagen AG d
2.1.4 Service interval display Volkswagen oes
not
y gu
db ara
Introduction of extended servicing intervals
or
ise (ESI) nte
h eo
ut ra
Ask your importer if the extendedsservicing
sa interval (ESI) is avail‐ c
able for your country.
ce
le
un
pt
an
d
Flexible service interval display (only vehicles with LongLife serv‐
itte
y li
ice, production control number QG1) rm
ab
pe
ility
ot
Calculation of service intervals:
wit
, is n
h re
♦ 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
com
tion in
r
te o
For vehicles with LongLife service (PR number QG1) but which
thi
s
iva
are serviced according to time or distance dependent intervals,
do
r
the service interval display need not be recoded to „non-flexible“

rp
cum
fo
⇒ page 111 .
en
ng
t.
yi Co
Cop py
t. rig
Non-flexible service interval display (only vehicles with time or
gh ht
yri by
distance dependent service, PR number „QG0/QG2“)
op Vo
by c lksw
cted agen
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 ➤
– 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
agaenfew seconds or
AG
when
n AG d
oes button
-A- is pressed. o not
V gu
by a
ed ran
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
2.2 Service tables, inland
an
itte
y li
erm
ab
♦ Service intervals ⇒ page 5
ility
ot p
wit
, is n
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
ercia
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
te
sd
instance.
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh
Note
ht
pyri by
Vo
co lksw
by
cted agen
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 ➤
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
e
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
e
nl
pt
du
cles coded to fixed inter‐ 10,000 km 1) diesel en‐
an
itte
vals
y li
gines
erm
ab
ility
Oil change service every YES
ot p
wit
15,000 km, petrol engines
, is n
h re
hole
spec
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

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
do
riv
years
p
cum
for
en
ng
t.
yi
1) Vehicles with elevated sulphur content in diesel fuel.
Co
Cop py
t. rig
gh
2)
ht
Whichever occurs first yri
p by
co Vo
by lksw
cted agen
Prote AG.
2.3 Service tables, export

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

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 ➤
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
yV b gu
ara
ed
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
ce
le
un
pt
40,000km or 2 years2)
an
d
itte
y li
erm
ab
QG1 vehicles Interval service max. YES
ility
ot p
30,000km or 2 years2),
wit
is n
petrol engines
h re
ole,
spec
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
om
n
c
i
or
n thi
te
sd
2.3.2 Oil change intervals depending on sulphur content in fuel
iva
o
pr
cum
r
fo
en
ng
Oil change intervals depending on sulphur content in fuel

t.
yi Co
op py
Fuel quality (EN590) ◀ 500 ppm 500-2,000 ppm 2,000-4,000 ppm ▶ 4,000 ppm
t. C rig
gh ht
yri by
Change interval ESI 20,000 km 10,000 km 7,500 km 5,000 km
cop Vo
by lksw
cted agen
Prote
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 ➤

Mexico X
Chile X
Venezuela X
Columbia X
Ecuador X
Surinam X
Peru AG. Volkswagen AG d
X
agen oes
Bolivia yV
olksw
X not
gu
db ara
Paraguay orise X nte
eo
h
ut
Uruguay ss a X ra
c
France overseas territo‐ X
ce
e
nl
pt
du
ries and departments
an
itte
y li
erm
Caribbean X
ab
ility
ot p
Israel X
wit
, is n
h re
Bahrain X
hole
spec
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
l purpos
Africa X
nf
ercia
Kenya X
orm
Algeria
m
atio
om
n in
Libya X
or c
thi
e
Tunisia X 4) X 1)
t
sd
iva
o
r
rp
cu
Egypt X
o
m
f
en
ng
t.
Morocco Cop
yi
X
Co
py
Ivory Coast X
t. rig
gh ht
pyri by
Vo
Ghana X
o
by c lksw
cted agen
Prote AG.
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 ➤

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
olksw not
V gu
3) Eco diesel d by ara
ise nte
or eo
4) Podium h
aut ra
ss c
ce
le
2.4 Service tables, Argentina and Brazil

un
pt
an
d
itte
y li
♦ Service interval ⇒ page 9
rm
ab
pe
ility

ot
wit
, is n
h re
hole
spec

es, in part or in w
t to the co
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
iva
do
r
vals 10,000 km 1)
rp
cum
fo
en
g

n
t.
yi Co
op
10,000 km or 6 months 2)
C py
t. rig
gh ht
pyri by
1)
o Vo
Adapt service interval to respective distance-based interval.
by c lksw
cted agen
Prote AG.
2) Whichever occurs first
2. Service work 9
Amarok 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
wage oes
alternative 503 00 y Volks
alternative
not
gu 501 01 / 502
db ara
ir se nte 00
ho eo
DIESEL ENGINES aut ra
ss c
4-cylinder 507 00 1) 4-cylinder 507 00 1)
ce
e
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
ot p
4-cylinder 507 00 1) 4-cylinder 507 00 1)
wit
, is n
h re
(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
o
r
rp
cu
♦ The sequence of the individual service tasks has been tested

o
m
f
en
ng
and optimised. The sequence must be followed in order to

t.
yi Co
avoid unnecessary interruptions in work. Cop py
t. rig
gh ht
yri by
Work to be completed Page
cop Vo
by lksw
cted agen
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
y li
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
r
rp
cum
fo
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 ➤
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
olksw not
V
♦ 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
au ra
the brake fluid must be renewed. ss c
ce
e
nl
pt
du
an
♦ Brake fluid level: Check level is at maximum ⇒ page 69
itte
y li
erm
ab
ility
♦ Power assisted steering: Check fluid level ⇒ page 126
ot p
wit
, is n
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.
yi
♦ Road test: Perform ⇒ page 97
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
1) Service identification ⇒ page 2
c by lksw
cted agen
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 ➤
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
kswage es n
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
au ra
X ♦ Interior, luggage and glove compartment
ss lights, cigarette lighter, sockets, horn andc warn‐
ing lamps: Check function ce
e
nl
pt
du
an
itte
y li
X ♦ Battery: Perform visual check and check magic eye
erm
ab
ility
ot p
⇒ page 51
wit
, is n
h re
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.
yi Co
Tyres t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
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
ss c
ce
le
un
pt
an
d
itte
y li
erm
1) 2) 3)
ab
ility
ot p
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
en
ng
⇒ page 126 yi
t.
Co
♦ play, attachment and damage to boots/bellows t. Cop py
rig
gh ht
yri by
X ♦ CV joints, axial bearings, coupling rod bearings and anti-roll bar rubber bushes: Visual
op Vo
by c lksw
check for damage
cted agen
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 ➤

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
gu
by ara
ed
X X ♦ Road test: Perform thoris nte
eo
au ra
⇒ page 97 ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
2.8 Time or distance dependent additional
ility
ot p
wit
work
, is n
h re
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
o
r
rp
cu
• and has an elevated sulphur content (>2000 ppm)

o
m
f
en
ng
t.
yi
⇒ page 82
Co
Cop py
ht. rig
♦ Fuel filter: Drain water - if vehicle runs on diesel fuel Every 20,000 km
rig ht
py by
co Vo
by lksw
• 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
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
ise nte
or eo
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.
yi
Co
Cop py
ht. rig
⇒ page 130 rig ht
py by
co Vo
by lksw
♦ Poly V-belt: Check condition Prote
cted AG.
agen
⇒ page 81
• 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
⇒ 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
⇒ page 82
♦ Timing chain: Renew Every 300,000 km
⇒ page 102
16 2. Service work
Amarok 2011 ➤
Measure: Interval
♦ Camshaft drive toothed belt: Check Every 2 years
⇒ page 130
♦ Dust and pollen filter (cabin filter): Clean housing
and renew filter element swage
es n
olk ot g
yV
⇒ page 80 d b ua
ran
ir se tee
o
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
⇒ page 134
t to the co
♦ Fuel filter: Renew – if vehicle runs on diesel fuel Every 4 years
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
C py
t. rig
gh ht
yri by
• Conforming to „DIN EN 590“ cop Vo
by lksw
cted agen
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 ➤
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
y gu
⇒ page 65 ise
d b ara
nte
• Check if brakeuthor
fluid service is due. eo
a 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.
18 2. Service work
Amarok 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-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut ra
Significance of vehicle identification
ss a number c
ce
le
un
WV1 ZZZ 2H Z B D 000 234

pt
an
d
itte
y li
Manufacturer Filler charac‐ Type Filler charac‐ Model year Production lo‐ Serial number
rm
ab
pe
code ters ters 2011 cation

ility
ot
wit
, is n
h re
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
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.
3. General 19
. Volkswagen AG
Amarok 2011 ➤ wage
n AG does
olks not
Maintenance - Editiond b01.2011
y V gu
ara
e nte
ris
ho eo
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
py by
co Vo
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 ➤
– 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
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
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 ➤
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
o eo
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
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
co lksw
by
♦ 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
♦ 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 ➤
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

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 ➤
♦ 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 ➤
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
ksw
able stands. by
Vol
not
gu
a
ed ran
ris tee
tho or
au ac
ss
ce
le
un
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

– 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.
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.
Amarok 2011 ➤
4.1.2 Raising vehicle under rear axle tube
WARNING

ger of an accident!
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.
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.
Amarok 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.

– 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.
Amarok 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

wit
is n
height.
h re
ole,
spec
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.
Amarok 2011 ➤
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.
Amarok 2011 ➤
4.1.3 Raising vehicle before rear axle tube
WARNING

ger of an accident!
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

un
pt

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

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.
from tipping.
♦ 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.
Amarok 2011 ➤

– 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.
platform.
Note
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
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.
Amarok 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.
Amarok 2011 ➤
4.1.4 Alternative lift for front of vehicle
WARNING

ger of an accident!
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.
able stands.

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
nform

mercia
at
om
io
from tipping.
n
c
in t
or
his
ate
do
priv

um
for
en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Amarok 2011 ➤

– Front support arms -1- of lifting platform with rubber plate sup‐
member.
platform.
Note
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

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.
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.
Amarok 2011 ➤
4.1.5 Alternative lift for rear of vehicle
WARNING

ger of an accident!
♦ 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
pt
du
an
itte
y li
erm
ab
able stands.
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
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.
AG. Volkswagen AG d
agen oes
ksw not
Amarok 2011 ➤ by Vol
gu
ara
d
orise nte
eo
th
au ra
ss c
ce
e
nl
pt
Note
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
from tipping.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
– Front support arms of lifting platform with rubber plate sup‐
m
atio
m

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
C py
t. rig
gh
ht
pyri by
Vo
o
platform.
c by lksw
cted agen
Prote AG.
Note
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.

height.
AG. Volkswagen AG d
Amarok 2011 ➤ ksw
agen oes
not
Vol
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
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.

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

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.
Amarok 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.

♦ Vehicle diagnostic, testing and information system -VAS
5051B- or subsequent units
♦ Diagnosis cable -VAS 5051/5A-

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

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
Amarok 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
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

– 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.
Amarok 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:
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
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 .
Amarok 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
Amarok 2011 ➤
4.5 Battery: Perform visual check and check

magic eye
– 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.

♦ Torque wrench -V.A.G 1331- (5-50 Nm)
Procedure for all vehicles

– Switch off ignition and all electrical consumers.
Amarok 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.
Amarok 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.
– 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
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.
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.
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.
Amarok 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
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.
Amarok 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
– Check following areas of tyre for damage:
♦ »Tyre treads«
♦ »Tyre side walls«
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
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
– Check tyre tread depth.
Minimum tread depth: 1.6 mm
Amarok 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
♦ Tyre inflator -VAS 5216-
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
Amarok 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
♦ 245/65 R17,111 H 2,0 2,0 2,0 3,0

• Summer 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.
Amarok 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
• 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
ce
e
nl
pt
du
an
itte
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
es, in part or in w
t to the co
♦ 255/60 R18 112 H 2,0 2,0 2,0 3,0
rrectness of i
• Summer tyres
l purpos
nf
ercia
o
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
o
m
f
en
ng
t.
yi
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.
– 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.
Amarok 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
♦ Test pin -T40139-
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.
Amarok 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.
Amarok 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.
Amarok 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
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

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.
Amarok 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.
Amarok 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

– 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.
Amarok 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!

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.
Amarok 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)
Amarok 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‐
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!
Amarok 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.

– 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.
Amarok 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.

– 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 -
system -VAS 5052 A- and select functions ⇒ page 72
Amarok 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
♦ Diagnosis cable 5m -VAS 5051B/1- AG. Volkswagen AG d

agen oes
olksw not
V gu
Or d by ara
rise nte
ho eo
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.
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
an
itte
y li
A-
erm
ab
ility
ot p
wit
, is n
h re
Or
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Observe current operating instructions for vehicle diagnostic,
l purpos
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.
Amarok 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.
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
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.
Amarok 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.
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

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.
Amarok 2011 ➤
– Select Vehicle system test function -arrow- on display of
vehicle diagnostic, testing and information system -VAS
-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‐
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
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
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

Or
Or
A-
Or
– Switch off ignition, all electrical consumers and withdraw igni‐
tion key.
Amarok 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

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.
Amarok 2011 ➤

Note
♦ Observe current operating instructions for vehicle diagnostic,

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

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
es, in part or in w
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.
l purpos
– Select Read event memory function and then Erase event

memory .
nf
ercia
orm
m
Note
atio
om
n in
or c
If all faults have been cleared, it is shown on display.

thi
te
sd
iva
o
r
rp
cu
The vehicle system test is completed.

o
m
f
en
ng
t.
yi Co
– Switch off ignition and disconnect vehicle diagnosis, testing Cop py
and information system -VAS 5051B- or vehicle diagnosis and
t. rig
gh ht
yri by
service information system -VAS 5052 A- . op Vo
by c lksw
cted agen
Prote
– Remove vehicle diagnosis, testing and information system -
AG.

system -VAS 5052 A- from vehicle.
Amarok 2011 ➤
4.20 Protective bellows: Visual check

– Check outer and inner CV joint boots -arrows- for leaks and
damage.
4.21 Dust and pollen filter: Clean housing and

renew filter element
Note
Before installing the new filter, clean area around the dust and
pollen filter in the heater and air conditioner unit.
Removing
The filter is located in front passenger footwell.
– Unscrew bolts -1- and open cover -2- downwards.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
– Remove filter element -1- downwards.

spec
t to the co
Note
rrectne
Observe disposal regulations!

ss
Installing
o
cial p
f in

form
mer
atio
om
n
c
Note
i
or
n thi
te
sd
va
Note installation position.

i
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
80
AG.
Amarok 2011 ➤
Observe installation position of filter element -arrows-.
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
– Insert new filter -1-.
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
– Close cover -2- and bolt on with bolts -1-.

o
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.
4.22 Poly V-belt: Check condition

– Use a socket spanner to turn the engine at the vibration damp‐
er/pulley.
Amarok 2011 ➤
– Check poly V-belt -1- for:

♦ Substructure cracks (cracks, core ruptures, cross sectional
breaks)
♦ Layer separation (top layer, cord strands)
♦ Base break-up
♦ Fraying of cord strands
♦ Flank wear (material wear, frayed flanks, brittle flanks -glassy
flanks-, surface cracks)
♦ Traces of oil and grease
Note
If faults are found it is absolutely necessary to renew the poly V-

belt. This will avoid possible breakdowns or operating problems.
Renewing the poly V-belt is a repair measure.
4.23 High pressure pump: Check

– The procedure is described in workshop manual ⇒ Rep. gr.
24 .
4.24 Poly V-belt: Renew

13 .
AG. Volkswagen AG d
agen
4.25 Fuel filter: VRenew (diesel engine)
w es n o
olks ot g
by u ara
ed nte
ris
tho e or
Caution
au ac
ss
ce
le
un
pt
The fuel system must also be vented after replacement of the

an
d
itte
common rail high-pressure pump and all components that are

y li
rm
ab
upstream of the common rail high-pressure pump in the low-

pe
ility
pressure fuel system.

ot
wit
, is n
h re
For example, fuel filter, fuel lines etc.

hole
spec
The electric fuel pump must be activated once for at least 60

es, in part or in w
seconds when components that are upstream from the com‐

t to the co
mon rail high-pressure pump are replaced.

When the common rail high-pressure pump itself is replaced,
rrectness of i
the electric fuel pump should be activated for approx. 180 sec‐
onds.
l purpos
(to be done several times according to need).

nform
mercia
Fuel system: Bleed (diesel engine) ⇒ page 83 .

com
tion in
r
Removing
te o
thi
s
iva
do

r
rp
cum
fo
en
Fuel filter is located on inside of left longitudinal member under

ng
t.
yi Co
vehicle in area ahead of pedal floor. ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Amarok 2011 ➤
– To pull off lines -1- press release buttons on connecting pieces

of fuel filter -2-.
– To remove fuel filter -1-, press fuel filter from below

-movement arrow- upwards out of holder -2- and remove it
downwards.
Installing
Note
♦ Note installation position of fuel filter!

♦ Note fuel line identification
agen
AG. Volon
kswfuel
agen filter!
AG do
w es n
olks ot g
♦ Observe ddisposal
by
V regulations! ua
ran
e
ris tee
tho or
– Insert
ss
a new
u
fuel filter into bracket. ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
– Push fuel lines -1- onto fuel filter connection. When doing this
h re
ensure that fuel lines are seated securely on fuel filter.

hole
spec
– Fuel system: Bleed (diesel engine) ⇒ page 83 .

es, in part or in w
t to the co
– Start engine and conduct a visual check of fuel system on fuel

filter.
rrectness of i
l purpos
Note
To ensure the engine starts immediately after changing the fuel

nform
ercia
filter, bleed the fuel system using vehicle diagnostic, testing and
m
information system -VAS 5051B- or vehicle diagnostic and serv‐

at
om
io
ice information system -VAS 5052 A- ⇒ page 83 .

n
c
in t
or
his
ate
do
priv
4.26 Fuel system: Bleed (diesel engine)

um
for
en
ng
t.
yi Co
Using vehicle diagnostic, testing and information system -VAS
. Cop py
5051B- or vehicle diagnostic and service information system -
t rig
gh ht
yri by
VAS 5052 A- cop Vo
by lksw
cted agen
Prote
To ensure the engine starts immediately after changing the fuel
AG.
filter, bleed the fuel system using vehicle diagnostic, testing and
information system -VAS 5051B- or vehicle diagnostic and serv‐
ice information system -VAS 5052 A- .
Amarok 2011 ➤
. Volkswagen AG
Maintenance - Edition k01.2011
swa
gen AG does
n
ol ot g
yV ua
db ran
ris
e
tee
ho
ut or
– Connect vehiclessdiagnostic, testing
a
and information system - ac
ce
e
nl
pt
system -VAS 5052 A- with ignition switched off ⇒ page 71 .
du
an
itte
y li
erm
ab
ility
ot p
– Press the Guided functions button on the display.
wit
, is n
h re
hole
– Then perform vehicle identification.
spec
es, in part or in w
– Select following functions one after another:
t to the co
♦ „Systems capable of self-diagnosis“
♦ „Diesel direct injection and glow plug system“
rrectness of i
♦ „Functions“
l purpos
♦ „Bleeding fuel system“
nform
ercia
– Follow instructions on display of vehicle diagnostic, testing

m
at
om
i
on
c
in t
or
– After bleeding the fuel system, exit „Guided functions“ using
his
ate
do
riv
GoTo button.
p
cum
for
– Touch function End on display.

en
ng
t.
yi Co
op py
– Select function End in „End menu“.
. C rig
ht ht
rig by
opy Vo
– Switch off ignition. by c lksw
cted agen
Prote AG.
– Disconnect diagnosis connector from vehicle.
Bleeding the fuel system is finished.
4.27 Fuel filter: Drain water (diesel engine)

– Unscrew drain plug from bottom end of filter and collect ap‐
prox. 100 ml of fuel into a suitable container.
– Screw drain plug back in, if necessary first fitting it with a new
seal if the old one was damaged.
Note
4.28 Cooling system: Check frost protection

and coolant level
Caution
Only distilled water may be used for mixing G12 plus-plus. The
use of distilled water enables the optimal level of corrosion
protection to be reached.
Amarok 2011 ➤
Note AG. Volkswagen AG d

agen oes
o lksw not
yV
♦ From model year 2008 all engines are filled e d with coolant ad‐
b gu
ara
ditive G 12 Plus Plus (purple). G 12 Plus
thoris
Plus can be mixed nte
eo
with coolant additives G 11 (green),s G 12 (red) and G 12 Plus
au ra
c
(purple)! But because of its positive characteristics, ensure
s
ce
le
that only G 12 Plus is used when replenishing.
un
pt
an
d
itte
y li
♦ G 12 Plus Plus is suitable as a filled-for-life filling for cast iron
erm
ab
and all-aluminium engines and gives optimum protection
ility
against frost, corrosion damage, scaling and overheating. ot p
wit
is n
h re
♦ G 12 Plus Plus raises the boiling point and ensures better heat
ole,
spec
dissipation.
t to the co
♦ The coolant concentration must be at least 40 % (frost pro‐
tection to -25 °C) and should never exceed 60 % (frost pro‐
tection to -40 °C). Otherwise both frost protection and cooling
rrectne
efficiency will be reduced.
♦ Frost protection must be assured to about -25 °C (in arctic
ss
climatic countries to about -35 °C).
o
cial p
f inform
mer
♦ Check frost protection, if necessary replenish coolant additive
atio
⇒ page 85
om
n
c
i
or
n
♦ Check coolant level, replenish coolant if necessary
thi
e
⇒ page 87
t
sd
iva
o
pr
cum
r
♦ Mixture ratio ⇒ page 87

fo
en
ng
t.
yi Co
♦ Mixing coolants ⇒ page 86 . Cop py
rig
ht ht
rig
4.28.1 Checking frost protection, if necessary
py by
co Vo
by lksw
replenish coolant additive
cted agen
Prote AG.

♦ Refractometer -T10007-
Note
Read precise value for the following tests at bright/dark boundary.

Using a pipette, place a drop of water on the glass to improve the
readability of the bright/dark boundary. The bright/dark boundary
can be clearly recognised on the „WATERLINE“.

– Check concentration of coolant additive using refractometer -
T10007- (note).
Amarok 2011 ➤
The scale -1- of the refractometer is calibrated for coolant addi‐

tives G 11, G 12; G 12 Plus and G 12 Plus Plus.
The scale -2- is only calibrated for coolant additive G 13 (initially
L80).
Note
♦ Frost protection must be assured to about -25 °C (in arctic

climatic countries to about -35 °C). swage
es n
olk ot g
yV
♦ If a stronger form of frost protection is srequired
d b for climatic ua
ran
ir e
reasons, the percentage of G 12 Plus tho Plus can be increased. tee
or
au ac
♦ But only up to 60 % (frost protection down to about -40 °C), as
ss
ce
le
otherwise frost protection will be reduced again and cooling

un
pt
effectiveness is also reduced.
an
d
itte
y li
erm
ab
ility
– If frost protection is insufficient, drain required quantity shown
ot p
wit
in frost protection table and add coolant additive G 12 Plus
is n
h re
Plus.
ole,
spec
t to the co
Note
rrectness
Frost protection to °C Quantity to drain (in litres)
o
cial p
f in
Actual value Specified value 4-cylinder diesel engine
form
mer
0 -25 3,5
atio
om
n
c
-35 4,5
i
or
n thi
e
-5 -25 3,0
t
sd
iva
o
pr
-35 4,0
um
r
fo
en
ng
t.
-10 -25 2,5
yi Co
Cop py
-35 3,5
t. rig
gh ht
pyri by
Vo
-15 -25 2,0
co lksw
by
cted agen
Prote AG.
-35 2,5
-20 -25 1,5
-35 2,5
-25 -35 2,0
-30 -35 1,0
-35 -40 1,0
– Check coolant additive concentration after road test again.
4.28.2 Mixing coolants

Refer to the table to glean which coolants can be mixed and which
coolant can be added to the standard filling.
Note
Use distilled water to mix the coolant.
n AG. Volkswagen AG do Amarok 2011 ➤
lkswage es n
byV
o
Maintenanceot g
uara Edition 01.2011
-
ed nte
oris eo
th
Initial filling / standarda filling
u ra
c
ss
ce
le
Can be G11 G12 G12+ G12++
un
pt
mixed from 1994 from 1996 from 2000 from 2005
an
d
itte
y li
with …
rm
ab
pe
ility
G11 X 0 0 0
ot
wit
, is n
G12 0 X 0 0
h re
hole
spec
G12+ X 1.) X X 0
es, in part or in w
t to the co
G12++ X 1.) X X X
Key
rrectness of i
♦ „X“ May be mixed
l purpos
♦ „0“ May NOT be mixed

♦ 1.) Becomes discoloured after mixing (brown)
nform
mercia
a
com
tio
Note
n in
r
te o
thi
s
iva
If „G11“ is mixed with „G12+“ or „G12++“, the coolant will become
do
r
rp
c
brown in colour.
um
fo
en
ng
t.
yi Co
op
4.28.3 Checking coolant level, replenish cool‐
C py
t. rig
gh ht
yri by
ant if necessary cop Vo
by lksw
cted agen
Prote AG.
– Check coolant level in expansion tank with engine cold.
Recommended coolant level at delivery inspection:
♦ Coolant level above „Min. marking“ -arrow-.
Recommended coolant level at inspection service
• Slightly above area -arrow-.
– If coolant is too low, add required amount according to mixture
ratio.
Note
If fluid loss is greater than can be expected through normal use,

determine source and rectify (repair measure).
4.28.4 Mixture ratio

Frost protection to Coolant additive G 12 Plus Plus Water
-25 °C approx. 40 % approx. 60 %
Amarok 2011 ➤
Note
♦ Coolant additive G 12 Plus Plus prevents frost and corrosion

damage, scaling and also raises boiling point of coolant. For
these reasons, the cooling system must be filled all-year-
round with a coolant and corrosion protection additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The
antifreeze portion must be at least 40 %.
4.29 Air filter: Clean housing and renew filter

element
Note
♦ When replacing air filter, make sure that no dirt gets into intake
hose, air mass meter -G70- and air filter cover.
♦ Following each air filterwachange,
gen AG programmed
. Volkswagen AG values of engine
doe
control unit -J623- must
Volks be reset using Guideds nfault
ot g finding
by
with vehicle diagnostic, testing and information system ran -VAS
d ua
e
ris
5051B- orutvehicle
ho diagnostic and service information system
tee
or
-VAS 5052
ss
a A- ⇒ page 90 . ac
ce
e
nl
pt
du

an
itte
y li
erm
ab
♦ Spring-type clip pliers -VAS 5024/A-

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

on
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.
Amarok 2011 ➤

Removing
– Before changing air filter, clean outside of components with
compressed air.
– Seal all openings of components using caps or hood covers
immediately after removal.
– Pull connector -1- off intake air temperature sender -G42- andgen AG. Volkswagen AG d
a
connector -2- from air mass meter -G70- . Vol
ksw
oes
not
g y ua
db ran
– Remove vacuum hose -3- from air filter cover -6-.orise tee
th or
au
– Remove clamp -4- from intake hose -5- and pull
ss off intake hose
ac
-5-.
ce
e
nl
pt
du
an
– Loosen bolts -arrows- of air filter cover.
itte
y li
erm
ab
– Raise air filter upper part and remove upwards.
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
ercia
– Remove air filter element -1-.

m
at
om
i
– Clean air filter housing if necessary.
on
c
in t
or
Installing
his
ate
do
riv

p
cum
for
en
ng
t.
– Install new air filter insert -1-.
yi Co
Cop py
t. rig
– Remove all caps or hood covers from sealed components. gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
When installing ensure the air filter element -1- is properly seated
in housing and check if seal is seated securely and completely.
Note
When installing air filter upper part, ensure that the seal of air filter
element is not moved or trapped and that both parts of housing
are flush.
– Tighten bolts -arrows- of air filter cover.

Torque setting: 2 Nm.
– Push on intake hose -5- and secure clamp -4-.
Torque setting: 5.5 Nm.
– Push vacuum hose -3- onto air filter cover -6-.
Amarok 2011 ➤
– Then push connector -1- onto intake air temperature sender -

G42- and connector -2- onto air mass meter -G70- .
4.30 Air filter with saturation indicator in dash

panel insert:
Note
When rectifying a saturated filter as a separate job, clean air filter

housing and renew filter element.

Saturation indicator is located in dash panel insert -K- and dis‐
plays contamination of filter element inc. filter housing.
– Clean air filter housing and renew filter element ⇒ page 88 .
– Resetting programmed values in engine control unit -J623- got
saturation indicator ⇒ page 90 .
4.31 Resetting programmed values in engine

control unit
Perform the following jobs: AG. Volkswagen AG d
agen oes
ksw not
– Connect vehicle diagnostic, testing and information
byV
ol
system - gu
ara
VAS 5051B- or vehicle diagnostic andrisservice information
ed
nte
system -VAS 5052 A- with ignition aswitched
ut
ho
off ⇒ page 71 . eo
ra
ss c
ce
le
un
pt
Note
an
d
itte
y li
erm
ab

ility
ot p

wit
is n

h re
ole,

spec
Operating manual .
t to the co
– Select „Guided fault finding“ on display of vehicle diagnostic,

rrectne
nostic and service information system -VAS 5052 A- and

identify vehicle.
ss o
– Select „Powertrain“, „Engine“ and then „Functions“.

cial p
f inform
– Select function „01 Reset programmed value“.

mer
atio
m
– Follow menu instructions to reset programmed values of en‐

o
n
c
gine control unit -J623- .

i
or
n thi
te
sd
a
– Switch off ignition and disconnect vehicle diagnostic, testing

iv
o
pr

um
r
fo

en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
90
cted agen
Prote AG.
Amarok 2011 ➤
4.32 Engine oil level: Check
Note
In engines with engine codes CFPA, CDBA and CDCA, it is only

possible to assess and check oil level when engine is at operating
temperature.

G. Volkswage
– After shutting off engine, wait at least 3 minutes
lksw
agenso that the oil AG does
A n
not
can flow back into the sump. by
Vo gu
a d ran
ise
– Pull out dipstick and wipe with authclean
or cloth and then push tee
or
dipstick in again to limit stop. ss a ac
ce
e
– Pull dipstick out again and read oil level.

nl
pt
du
an
itte
y li
For dipstick as illustrated:
erm
ab
ility
ot p
-A- Oil must not be replenished.
wit
, is n
h re
-B- Oil may be replenished. It may happen that the
hole
oil level afterwards is in the -A- region.
spec
es, in part or in w
-C- Oil must be replenished. It is sufficient if the oil
t to the co
level is in the -B- region (hatched area) after‐
wards.
rrectness of i
There is a danger of damaging the catalytic converter if the oil
level is above the -A- marking.
l purpos
– If the oil level is below the -C- mark, replenish oil up to the
-A- mark.
nform
mercia
at
4.33 Engine oil: Drain or extract; renew oil fil‐
om
ion
c
in t
ter and replenish engine oil
or
his
ate
do
riv
In the case of difficult operating conditions such as operation

p
cum
for
en
ng
t.
yi Co
op py
Note
t. C rig
gh ht
pyri by
Vo
co lksw
by
♦ with fuel containing sulphur, cted agen
Prote AG.
♦ with frequent short trips,

♦ in areas with high levels of dust,
♦ with frequent trips carrying a full load or pulling a trailer,
♦ with a high number of cold starts,
♦ and when the vehicle is used for a long time in areas with ex‐
tremely low temperatures,
the engine oil should be changed more often than indicated in the
service schedule.
Furthermore extreme operating conditions for vehicles with diesel
particulate filter are stop and go operation, such as in urban traffic.
Use, in these conditions is an additional load on the engine oil
which is taken into account by the flexible service interval system.
– Draining or extracting engine oil ⇒ page 92
– Renewing oil filter ⇒ page 92 .
– Replenishing engine oil ⇒ page 95 .
Amarok 2011 ➤
4.33.1 Draining or extracting engine oil

lkswage es n
o ot g
Note d byV ua
ran
ir se tee
tho
or
For engines with standing
ss
au
oil filter the oil filter must be renewed ac
before changing the engine oil. When removing the filter element
ce
le
a valve is opened, the oil in the filter housing automatically flows

un
pt
an
d
into crankcase.
itte
y li
erm
ab
ility
ot p
wit
is n
h re
♦ Used oil collection and extraction unit -VAS 6622-
ole,
spec
♦ Oil filter strap wrench
t to the co
♦ Oil spill cloth -VAS 6204/1-
Draining or extracting engine oil
rrectnes
Note
s o
cial p
f inform
For engines with standing oil filter the oil filter must be renewed
mer
before changing the engine oil. When removing the filter element
atio
m
a valve is opened, the oil in the filter housing automatically flows

o
n
c
into crankcase.
i
or
n thi
te
sd
iva
o
r

p
cum
r
fo
en
ng
t.
– Extract engine oil using used oil collection and extraction unit op
yi Co
-VAS 6622- .
C py
t. rig
gh ht
yri by
Or cop Vo
by lksw
cted agen
Prote AG.
– Removing and installing skid plate ⇒ page 133 .
– Remove oil drain plug.
– Let engine oil drain.
Note
The oil drain plug and seal are one unit and must be renewed
together.
– Screw in oil drain plug together with seal hand-tight and then
tighten to specified torque.
Specified torques for oil drain plug
♦ Diesel engines: 30 Nm
♦ Petrol engines: 30 Nm
WARNING
♦ Torque specifications must not be exceeded.

♦ Excessive torque can cause leaks in the area of the oil
drain plug or even damage.
4.33.2 Renewing oil filter

♦ Renewing oil filter, engine with engine codes CDBA, CDCA
⇒ page 93
Amarok 2011 ➤
♦ Renewing oil filter, engine with engine code CFPA

⇒ page 94
4.33.3 Renewing oil filter, engine with engine

codes CDBA, CDCA
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
Removing
wit
is n
h re
ole,
spec
t to the co
Note
♦ Before draining or extracting release threaded cap, so that the
rrectne
engine oil can flow out of filter housing.
♦ Prevent engine oil from dripping onto components in engine
ss
compartment.
o
cial p
f inform
♦ Observe disposal regulations!
mer
atio
m
♦ Oil new O-rings before installing.

o
n
c
i
or
n thi
e
– Loosen threaded cover -1- on hexagonal flats or along perim‐

t
sd
iva
o
eter and remove.
pr
cum
r
fo
en
ng
– Clean sealing surfaces on threaded cap and oil filter housing.

t.
yi Co
Cop py
Installing
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
– Renew filter element -5-.
– Renew O-rings -2-, -3- and -4-.
– Fit threaded cover -1- and tighten.
Specified torque: 25 Nm
Amarok 2011 ➤
4.33.4 Renewing oil filter, engine with engine

code CFPA
Note

♦ Oil filter tool -VAS 3417-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
Or aut ra
c
ss
♦ Oil filter with tensioning strap Hazet - 2171-1
ce
e
nl
pt
du
an
itte
♦ Oil spill cloth -VAS 6204/1-

y li
erm
ab
Or
ility
ot p
wit
, is n
♦ Universal cloth -VAS 6385-

h re
hole
spec
Removing
es, in part or in w
t to the co

– Loosen oil filter -arrow- with oil filter tool -VAS 3417- and re‐
move filter.
rrectness of i
– Clean sealing surface for example with universal cloth -VAS

l purpos
6385- .
Installing
nf
ercia
orm

m
atio
om
n in
c
– Oil rubber seal lightly on new oil filter.

or
thi
te
sd
a
– Screw on new filter and tighten.

iv
o
r
rp
cu
o
Specified torque: 22 ± 2 Nm
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
94
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes Amarok 2011 ➤
olksw not
V
d by gu
ara Maintenance - Edition 01.2011
rise nte
tho eo
4.33.5 Replenishing engine oil
au ra
ss c
ce
e
nl
pt
VW engine oil standards ⇒ page 10
du
an
itte
y li
Engine oil capacities see ⇒ Engine lubrication; Rep. gr. 17
erm
ab
ility
ot p
General notes
wit
, is n
h re
hole
spec
es, in part or in w
– After replenishing with oil, wait at least 3 minutes and then
t to the co
check oil level.
rrectness of i
Note
l purpos
It is absolutely necessary to perform oil level check with the en‐

gine warm in order to ensure correct assessment of the oil level.
nform
mercia
– Pull out dipstick, wipe with a clean cloth and push dipstick in
at
om
io
again to limit stop.
n
c
in t
or
his
e
– Pull dipstick out again and read oil level.

at
do
priv
c
For dipstick as illustrated:
um
for
en
ng
t.
yi
-A- Oil must not be replenished.
Co
Cop py
t. rig
-B- Oil may be replenished. It may happen that the
gh ht
yri by
oil level afterwards is in the -A- region.
cop Vo
by lksw
cted agen
-C- Oil must be replenished. It is sufficient if the oil
Prote AG.
level is in the -B- region (hatched area) after‐

wards.
There is a danger of damaging the catalytic converter if the oil
level is above the -A- marking.
– If the oil level is below the -C- mark, replenish oil up to the
-A- mark.
VW engine oil standards ⇒ page 10
4.34 Engine and components in engine com‐

partment (from above and below): Per‐
form visual check for leaks and damage
– Check engine and components in engine compartment for
leaks and damage.
– Check lines, hoses and connections of
♦ Fuel system
♦ Cooling and heating system
♦ And brake system
for leaks, abrasions, porosity and brittleness.
Note
♦ Arrange for defects to be rectified as repair measures.

♦ If fluid loss is greater than can be expected through normal
use, determine source and rectify (repair measure).
Amarok 2011 ➤
4.35 Bonnet catch: Clean, ensure attach‐

ment is secure and lubricate
♦ Universal cloth -VAS 6385-
– Clean bonnet catch -arrow- with cleaning gen AGsolution -D
. Volkswagen A009
G do 401
swa es n
04- and, for example, a universal
y Volk cloth -VAS 6385- . Also useot g
ua
„compressed air“ to clean
ris
eif
d necessary.
b ran
t ee
tho or
s au ac
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
– Lubricate bonnet catch -arrow- with grease -G 000 150- .
mer
atio
m
– Ensure bonnet catch is seated securely with »back and forth«

o
n
c
movement; retighten screws if necessary ⇒ Lids, flaps, cab,

i
or
n thi
e
central locking; Rep. gr. 55 ; Removing and installing bonnet

t
sd
va
catch .
i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4.36 Check breakdown set

♦ Breakdown set location ⇒ page 96
♦ Check minimum use-by date ⇒ page 97
4.36.1 Breakdown set location

Model Location
2H In drawer under driver or front passenger seat
Amarok 2011 ➤
Note
If the breakdown set is not found at the fitting location described,

this can be found in ⇒ vehicle wallet .
4.36.2 Check minimum use-by date

The breakdown set consists of the compressor and a tyre filler
bottle with sealant .
Because the sealant in the tyre filler bottle has a limited expiry
date, this date is indicated on the bottle -arrow-.
– Check the expiry date and renew the tyre filler bottle with seal‐
ant , if the expiry date is reached.
This example shows that the expiry date 05/2003. The tyre filler
bottle with sealant must be renewed.
The tyre filler bottle with sealant is available as replacement part.
The part number can be found in ⇒ Electronic parts catalogue
„ETKA“ .
AG. Volkswagen AG d
agen oes
Caution olksw not
byV gu
ara
ed
ris nte
If the tyre filler bottle with sealant was opened e.g.ut at a "flat
ho eo
ra
tyre", it must be renewed. ss a c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
Note
ot p
wit
is n
h re
♦ Residual tyre sealant or bottles which are filled and the expiry
ole,
spec
date has been exceeded, must be disposed of.
t to the co
♦ Old tyre sealant or residual sealant must not be mixed and
disposed of with other fluids.
rrectne
Disposing of tyre sealant ⇒ Handbook Service Organisation; En‐
vironment protection and disposal practice; Chapter 3 Funda‐
s
mentals; Chapter. 6.5 .
s o
cial p
4.37 Performing road test f inform

mer
atio
om
Which of the following can be checked depends on vehicle equip‐

n
c
i
or
ment and local conditions (urban/country).

thi
te
sd
va
Check the following during a road test:

i
o
pr
cum
r
fo
en
ng
– Engine: Output, misfiring, idling speed, acceleration.

t.
yi Co
Cop py
– Clutch: Pulling away, pedal pressure, odours. ht. rig
rig ht
py by
o Vo
– Gear selection: Ease of operation, stick position. by c lksw
cted agen
Prote AG.
– Braking to clear brake discs: drive approx. 500 m in 2nd gear
at 50 to 60 km/h. Brake slightly several times, then brake
strongly 3 times. It is also possible to allow the brakes to drag
for approx. 4 minutes for each vehicle axle on the single-axle
roller dynamometer.
– Foot brake and handbrake: Function, free travel and effec‐
tiveness, pulling to one side, juddering, squeal.
– ABS function: Pulsing must be felt at the brake pedal during
ABS-regulated braking.
Amarok 2011 ➤
– Steering: Function, steering free clearance, steering wheel

centred when vehicle is travelling straight ahead
– Radio/radio navigation system: Function, reception, GALA, in‐
terference noise
– Multi-function indicator (MFI): Functions
– Air conditioning system: Function
– Vehicle: Pulling to one side when travelling straight-ahead
(level road)
– Imbalance: Wheels, drive shafts, propshaft
– Wheel bearings: Noises AG. Volkswagen AG d
agen oes
ksw
– Engine: Hot starting behaviour by Vol not
gu
ara
d
ise nte
4.38 Wheel securing bolts: Tighten to speci‐ or eo
th
au ra
fied torque ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Torque wrench -V.A.G 1332/- (40-200 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
and if necessary, if anti-theft wheel bolts are installed:
n
c
in t
or
his
e

at
do
priv
Or cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Pulling off wheel hub trim.
The puller hook -1- to remove the cover caps is located with the
vehicle tool kit.
Amarok 2011 ➤
– Hook puller hook into one drilling of wheel hub trim and pull off
in -direction of arrow-.
Pulling off wheel bolt caps.
Note
Before removing wheel bolts, remove the cover caps.
The puller hook to remove the cover caps is located with the ve‐
hicle tool kit.
– Insert wire hoop through opening in cover cap.
– Pull off cap with wire hoop.
Loosening anti-theft wheel bolts.
Note
To loosen the theft-resistant wheel bolts a special adapter is re‐

quired, located in vehicle tool kit or use adapter set for tamper-
proof wheel bolts -T10101- or adapter set for tamper-proof wheel
bolts -T10190-
– Push adapter -2- into anti-theft wheel bolt -1- onto stop.
– Push wheel brace onto adapter -2- onto stop.
– Unscrew wheel bolt by about one turn.
Tighten wheel bolts.
lkswage es n
o ot g
Note d byV ua
ran
ir se tee
tho
or
Ensure that wheel bolts are tightened diagonallyss aand
u
alternately ac
to the following specified torque: ce
e
nl
pt
du
an
itte
Specified torque: 180 Nm y li

erm
ab
ility
ot p
– Place puller hooks and adapter with vehicle tool kit after com‐ wit
pleting work.
, is n
h re
hole
spec
4.39 Reading radio code

es, in part or in w
t to the co
Note
rrectness of i
Only valid for vehicles without sticker with serial number and radio
l purpos
code on vehicle data sticker.

nf
ercia
Reading radio code using vehicle diagnostic, testing and infor‐

rm
m
mation system -VAS 5051B- or vehicle diagnostic and service

atio
m
information system -VAS 5052 A-

o
n in
or c
thi
e
Authorization prerequisites for reading radio code

t
sd
iva
o
r
rp
cu
• The vehicle diagnostic, testing and information system -VAS

o
m
f

en
ng
t.
yi Co
-VAS 5052 A- is connected via the „Central Partner Cop py
Network“ (CPN) with the central database (Carport, Fazit).
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Amarok 2011 ➤
• Available access for the user of the system „GeKo“ (secrecy

and component protection)
Note
♦ The radio codes are read in the central database (Carport,

Fazit) and are indicated on display of vehicle diagnostic, test‐
♦ To activate the anti-theft coding the radio code must be en‐
tered using radio buttons, as previously ⇒ page 101 .
AG. Volkswagen AG d
agen
Perform the following jobs: Volksw
oes
not
by gu
d ara
– Connect vehicle diagnostic, testing oand
ris information system -
e nte
eo
VAS 5051B- or vehicle diagnosticauand
th service information ra
system -VAS 5052 A- with ignition
ss switched off ⇒ page 71 . c
ce
e
nl
pt
du
an
itte
y li
– Press the Guided functions button on display of vehicle di‐
erm
ab
ility
agnostic, testing and information system -VAS 5051B- or ve‐
ot p
wit
hicle diagnostic and service information system -VAS 5052
, is n
h re
A- .
hole
spec
– Press > button to confirm selection.
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Brand
nf
ercia
♦ Type
orm
m
atio
m
♦ Model year
o
n in
or c
♦ Version
thi
te
sd
iva
♦ Engine code
o
r
rp
cu
o
m
f
en
ng

t.
yi Co
firm with > button. Cop py
t. rig
gh ht
yri by
– Select one after another: op Vo
by c lksw
cted agen
Prote
♦ Radio system
AG.
♦ Reading radio code

information system -VAS 5052 A- to read the radio code ac‐
cording to „Guided functions“.
Exit radio code reading as follows:
– Select function GoTo on display.
– Press function End on display.
– Switch off ignition and separate diagnosis connection from
vehicle.

Amarok 2011 ➤
Note
Inform the customer about the radio code.
Reading radio code using „ElsaWin“ (Electronic Service Informa‐

tion System) and Vehicle Individual Service Notes „FISH“
Reading the radio code was integrated with „ElsaWin“ (Electronic
Service Information System) version 3.0 into Vehicle Individual
Service Notes „FISH“. Currently this function is only valid for
Volkswagen and Commercial vehicles.
Note
♦ Radio codes cannot be read in „FISH“ with the previous ac‐

cess authorization for radio codes. Reading only functions with
the access authorization for „GeKo“ (secrecy and component
protection).
♦ The access authorization for „GeKo“ (secrecy and component
protection) for reading the radio code using vehicle diagnostic,
nostic and service information system -VAS 5052 A- is also
valid for reading the radio code in Vehicle Individual Service
Notes „FISH“. . Volkswag
AG en AG
agen does
olksw not
Authorization prerequisites for reading radio codeed by V gu
ara
ris nte
• Available access for the user of the system utho„GeKo“ (secrecy eo
ra
a
and component protection) ss c
ce
le
un
pt
an
d
itte
y li
– Follow the instructions of Vehicle Individual Service Notes
erm
ab
ility
„FISH“ in Electronic Service Information System „ElsaWin“.
ot p
wit
is n
h re
ole,
spec
Note
t to the co
♦ To read the radio code the radio serial number must be en‐
tered fully. This can be entered using vehicle diagnostic, test‐
and service information system -VAS 5052 A- via „Guided rrectne
functions“ and „Measured value block 81“. For this follow in‐
s
structions of vehicle diagnostic, testing and information sys‐

s o
tem -VAS 5051B- or vehicle diagnostic and service informa‐

cial p
f in
tion system -VAS 5052 A- .

form
mer
♦ To enter the radio serial number the 17-digit chassis number

atio
m
is taken from the order.

o
n
c
i
or
n thi
e
♦ If you are authorized to read the radio code via „GeKo“ (se‐
t
sd
va
crecy and component protection), you will obtain the 4-digit

i
o
pr
cum
r
radio code to the radio serial number.

fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note cop Vo
by lksw
cted agen
Prote AG.
Inform the customer about the radio code.
4.40 Radio / radio navigation system: Enter

anti-theft coding PIN
The anti-theft coding electronically prevents unauthorized per‐
sons from operating the unit after it has been removed from
vehicle. The anti-theft codes are also called radio codes or se‐

Amarok 2011 ➤
curity codes. Security code means that each unit with an anti-theft
coding is programmed with its own code number. This security
code is not active when leaving the factory. The security code is
found on the unit card, if fitted. If the unit card is not fitted, the
security code can be read from a central database using vehicle
diagnosis tester.
Note
If an incorrect code number is entered when releasing the elec‐

tronic lock, the whole procedure can be repeated once. If an
incorrect code number is entered again, the unit is locked for
about one hour. That means, it cannot be used. After one hour,
during which time the unit must remain switched on, the display
extinguishes. The electronic lock can be released as described
above. The cycle, two attempts, one hour lock, applies again.
Procedure
Deactivating anti-theft coding ⇒ Infotainment; Rep. gr. 91 .
4.41 Radio navigation system: Insert naviga‐

tion CD/DVD and perform update
If no navigation CD/DVD is inserted in the CD/DVD slot, after en‐
tering the radio code it can be displayed that no navigation CD/
DVD is inserted.
In this case, insert the navigation CD/DVD according to ⇒ Oper‐
ating instructions .
Note
swage es n
When the navigation CD is inserted bthe y V first time, the radio navi‐
olk ot g
ua
gation system performs an update, ir se which can take up to 5 mi‐
d ran
tee
nutes. Do not pull off ignition switch
utho
and radio navigation system or
during this process, because ss the radio navigation system then
a ac
switches off and the update will be interrupted!
ce
e
nl
pt
du
an
itte
y li
4.42 Timing chain: Renew

erm
ab
ility
ot p
wit

, is n
h re
15 .
hole
spec
4.43 Windscreen wash/wipe system and

es, in part or in w
t to the co
headlight washer system: Check func‐

tion and settings
rrectness of i
♦ Check antifreeze content of Windscreen Clear with G 052 164,

l purpos
replenish with fluid if necessary ⇒ page 102

♦ Window wash/wipe system: Check spray jet settings and ad‐
nf
ercia
just if necessary ⇒ page 104

orm
m
atio
4.43.1 Checking Windscreen Clear with anti‐

om
n in
or c
freeze for windscreen wash/wipe sys‐

thi
te
sd
a
tem, replenish with fluid if necessary

iv
o
r
rp
cu
o
m
f
en
ng
Checking antifreeze concentration .

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

Amarok 2011 ➤
♦ Refractometer -T10007-
Read precise value for the following tests at bright/dark boundary.

Using a pipette, place a drop of water on the glass to improve the
readability of the bright/dark boundary. The bright/dark boundary
can be clearly recognised on the „WATERLINE“.
– Check concentration of antifreeze additive using refractometer
-T10007- (note).
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
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
Prote AG.

Amarok 2011 ➤
The scale -1- of the refractometer is calibrated for Genuine Volks‐

wagen Windscreen Clear with antifreeze G 052 164.
The scale -2- is designed for commercially available windscreen
cleanser as well as a mixture of commercially available wind‐
screen cleanser and genuine Volkswagen Windscreen Clear with
antifreeze G 052 164.
Mixture ratio
Frost protection to Windscreen Clear Water
with antifreeze
G 052 164
-17/-18 °C 1 part 3 parts
-22/-23 °C 1 part 2 parts
-37/-38 °C 1 part 1 part
Replenishing with fluid.
The fluid reservoir of the window washer system must be filled
completely.
Starting immediately, use only Genuine Volkswagen Windscreen
Clear with antifreeze G 052 164 all-year-round when replenishing
window wash/wipe system.
Note
♦ On vehicles with fan-type spray jets,

en AG. V
olksthe
wagreservoir
en AG must be fil‐
led with Windscreen Clear ksw with antifreeze G 052es164,
ag do
not as this
Vol
fluid has a low viscosity
d by at temperatures below freezing.
gu Oth‐
ara
erwise the complicated
horise spray jet system can become blocked
nte
eo
by the crystallised
aut washer fluid, which affects the spray pattern ra
s jet. Windscreen Clear with antifreeze G 052 164 c
of the sprays
ce
e
ensures that the fan-type spray jets remain fully functional

nl
pt
du
even at low temperatures.

an
itte
y li
erm
ab
♦ Genuine Volkswagen Windscreen Clear with antifreeze G 052

ility
ot p
164 protects the spray jets, fluid reservoir and connecting ho‐
wit
, is n
ses from freezing.

h re
hole
spec
♦ Also use Genuine Volkswagen Windscreen Clear with anti‐

es, in part or in w
freeze G 052 164 in the warmer periods of the year. The

t to the co
powerful cleanser removes wax and oil residue from the glass.
♦ Frost protection must be guaranteed to approx. -25 °C (ap‐
rrectness of i
prox. -35 °C in countries with an arctic climate) in the wind‐

screen wash/wipe system.
l purpos
4.43.2 Window wash/wipe system: Check

nform
ercia
spray jet settings and adjust if necessary

m
at
om
ion
c
in t

or
his
ate
♦ Commercially available Torx screwdriver „T 10“

do
priv
cum
for
en
ng
t.
yi Co
op
Note C py
t. rig
gh ht
pyri by
Vo
The spray jets may be cleaned in both directions, also opposite
o
by c lksw
cted agen
to direction of spray with compressed air or water. Prote AG.

Amarok 2011 ➤
Windscreen spray jet settings:

The washer jets are preset. However, small height differences
can be compensated for.
– If spray field is not at correct height, adjust spray direction up‐
wards or downwards as follows:
– Adjust spray jet by turning with a commercially available Torx
screwdriver „T10“ at adjuster -1-.
♦ „Clockwise“ lower.
♦ „Anti-clockwise“ higher.
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
4.44 Windscreen wiper blades: Check park
rm
ab
pe
ility
position
ot
wit
, is n
h re
hole
♦ Windscreen wiper blades: Check park position ⇒ page 105 .
spec
es, in part or in w
4.44.1 Windscreen wiper blades: Check park
t to the co
position
rrectness of i
Windscreen of LHD vehicles
l purpos
Note
nform
ercia
For RHD vehicles the wiper blades are aligned as a mirror image.
m
a
com
tion in
Driver side
r
te o
thi
s
iva
do

r
rp
cum
fo
– Check park position.

en
ng
t.
yi Co
op py
Wiper blade tips should be located at marked position -arrow- on t. C rig
gh ht
windscreen. yri
p by
o Vo
by c lksw
cted
– Adjust park position by moving wiper arm if necessary.
agen
Prote AG.
Adjusting windscreen wiper blades ⇒ Electrical system; Rep. gr.

92 ; Windscreen wiper blades - park position .
Front passenger side

Amarok 2011 ➤
Wiper blade tips should be located at marked position -arrow- on

windscreen.
– Adjust park position by moving wiper arm if necessary.
– Switch windscreen wiper on and off and let it move into park
position.
– Switch off ignition. 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
4.45 Headlight adjustment: Check, if neces‐
erm
ab
ility
ot p
sary adjust
wit
is n
h re
ole,
♦ Adjusting halogen headlights ⇒ page 108 .
spec
♦ Adjusting fog lights and other additional lights ⇒ page 109 .
t to the co
♦ Test prerequisites ⇒ page 106
♦ Checking headlight adjustment (using new test screen without
rrectne
15° setting line) ⇒ page 107
s
4.45.1 Test prerequisites
s o
cial p
f in
form
mer
atio
♦ Headlight adjustment unit -VAS 5046-

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.
Or
♦ Headlight adjustment unit -VAS 5047-
Test and adjustment conditions
♦ Tyre pressure OK
♦ Lenses must not be damaged or dirty.
♦ Reflectors and bulbs OK
♦ Vehicle must be loaded.
Loading: With one person or 75 kg on the driver seat and the
vehicle otherwise unloaded (unladen weight).
The unladen weight is the weight of vehicle ready for operation
with a full fuel tank (at least 90 %) including weight of all equip‐
ment normally carried (e.g. spare wheel, tools, jack, fire extin‐
guisher etc.).
If the fuel tank is not at least 90 % full, then load as follows:

Amarok 2011 ➤

– Read fuel level in fuel tank on fuel gauge. Determine additional
weight from following table and place weight in luggage com‐
partment.
Fuel gauge table
Fuel level of Additional weight
fuel gauge in kg
1/4 30
1/2 20
3/4 10
Full 0
Example:
When the fuel tank is half full, an additional weight of 20 kg must
be placed in the luggage compartment. G. Volkswage
A n AG d
agen oes
olksw not
yV gu
db ara
Note rise nte
tho eo
s au ra
c
♦ A fuel can filled with water is the best
s way of adding additional
ce
le
weight.
un
pt
an
d
itte
y li
♦ A fuel can filled with 5 litres of water weighs approx. 5 kg.
rm
ab
pe
ility
ot
wit
The vehicle must be rolled forward or backward several metres
, is n
h re
or front and rear springs must be bounced fully several times so
hole
that springs settle.
spec
es, in part or in w
t to the co
♦ Vehicle and headlight adjuster must be on a level surface ⇒
of headlight adjustment unit -VAS 5046- or ⇒ of headlight ad‐
justment unit -VAS 5047-
rrectness of i
♦ Vehicle and headlight adjuster must be aligned.
l purpos
♦ Inclination must be set.

Inclination information in „%“ is stamped into trim above headlight.
nform
ercia
Headlights must be adjusted according to this information. Per‐

m
centage given is based on a projection distance of 10 metres. For

a
com
tio
example: inclination of 1.0 % converts to approx. 10 cm.

n in
r
te o
thi
Vehicles with manually regulated headlight range control

s
iva
do
r
rp
♦ Headlight range control thumb wheel must be in basic setting

um
fo
-0-.
en
ng
t.
yi Co
op py
4.45.2 Checking headlight adjustment (using
t. C rig
gh ht
yri by
new test screen without 15° setting line)
cop Vo
by lksw
cted agen
Prote AG.
Headlights
♦ Whether, with the dipped beam switched on, the horizontal
bright/dark boundary touches the dividing line -1- of the test
area
♦ Whether the breaking point -2- between the horizontal part of
the bright/dark boundary on the left and the rising part on the
right lies on the vertical line of the central point -3-.

Amarok 2011 ➤
The bright core of the light beam must be to the right of the vertical
line.
Note
lkswage es n
o ot g
♦ To simplify determination by V of the breaking point -2-, cover uand
ar
ed
uncover left (fromhodriver
ris perspective) half of the headlight a antee
few times. Thenaucheck dipped beam again.
t or
ac
ss
♦ After correct adjustment of dipped beams, the centre point of
ce
le
un
pt
the main beam must lie on the centre mark -3-.
an
d
itte
y li
erm
♦ For the previous test screens with 15° setting line, adjust as
ab
ility
for new test screen. To avoid incorrect settings, ignore the 15°
ot p
wit
setting line.
is n
h re
ole,
spec
Fog lights
t to the co
– Check whether the upper light-dark border touches the setting

line and runs horizontally over the entire width of the test
rrectne
screen.
Other additional lights
ss o
Additionally retrofitted lights of other systems must be checked

cial p
f in
and set according to valid guidelines.

form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
4.45.3 Adjusting halogen headlights
C py
t. rig
gh ht
pyri by
Vo
co
Left headlight
by lksw
cted agen
Prote AG.
– Check headlight setting and adjust headlights if necessary.
The adjustment bolts for the right headlight are a mirror image.

Amarok 2011 ➤
♦ Height adjustment bolt -1-

♦ Height/lateral adjustment bolt -2-
– For height adjustment, turn adjustment screws -1- and -2- with
same number of turns.
– For lateral adjustment, only turn adjuster screw -2-.
4.45.4 Adjusting fog lights and other additional

lights
Fog light on left in bumper
Location of adjustment screw on right fog light is a mirror image.
Inclination:
♦ Fog lights 20 cm
Adjustment screw for setting fog lights can only be accessed from
rear.
– Move adjustment screw -arrow- to regulate headlight range.
A lateral adjustment is not possible.
Other additional lights
Additionally retrofitted lights of other systems must be checked
and set according to valid guidelines.
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
4.46 Service interval display: Reset

pt
du
an
itte
y li
erm
ab
Using vehicle diagnostic, testing and information system -VAS

ility
ot p
5051B- or vehicle diagnostic and service information system -

wit
, is n
VAS 5052 A-
h re
hole
spec
es, in part or in w
Note
t to the co
The procedure to reset the service interval display without vehicle

diagnostic, testing and information system -VAS 5051B- or vehi‐
rrectness of i
cle diagnostic and service information system -VAS 5052 A- is

l purpos
described in ⇒ Booklet „Controls and Equipment“ in the vehicle

literature.
nform
ercia
Service interval display must be reset (adapted) in the handover

m
at
inspection and during each service!

om
ion
c
in t

or
his
ate

do
priv

um
for
en
g

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
109
cted agen
Prote
AG.
Amarok 2011 ➤
Note

Operating manual .

– Touch the Guided functions field on the screen.
♦ Brand
♦ Type
♦ Model year
♦ Version
♦ Engine code
– Confirm vehicle identification.
firm with > button.
♦ „Dash panel insert“ -ARROW-
AG. Volkswagen AG d
agen oes
♦ „Resetting the service interval display“
Vol
ksw not
gu
y
db ara
Perform the following jobs: orise nte
eo
th
s au ra
c
s
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
– Perform adaptation according to the information of „Guided

functions“.
rrectness of i
End adaptation.
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.

Amarok 2011 ➤
– Select function GoTo -arrow- on display.
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
– Touch function End -arrow- on display.
ility
ot p
wit
, is n
h re
hole
spec
– Switch off ignition and separate diagnosis connections.
es, in part or in w
t to the co
After the ignition is switched on, the type of service is no longer
rrectness of i
displayed in the distance display in the dash panel insert.
l purpos
nform
ercia
4.47 Service interval display: Recode (adapt)

m
at
om
io
n
c
in t
or
his
e

at
do
riv

p
cum
or

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Note yri
p by
co Vo
by lksw
cted agen
Prote
AG.

Operating manual .
♦ Brand
♦ Type
♦ Model year
♦ Version
♦ Engine code
firm with > button.

Amarok 2011 ➤

♦ „Dash panel insert“ -arrow-
♦ „Adapting service interval extension“.
– Perform adaptation according to the information of „Guided
functions“.
Ending adaptation.
– Select function GoTo -arrow- on display.
– Touch function End -arrow- on display.
AG. Volkswagen AG d
– Select function End in „End menu“. lksw
agen oes
not
Vo gu
by ara
– Switch off ignition and separate diagnosis connections.
rise
d
nte
tho eo
– Switch on ignition. ss au ra
c ce
e
After the ignition is switched on, the type of service is no longer

nl
pt
du
an
displayed in the distance display in the dash panel insert.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
4.48 Service interval: Adjusting (inland)

es, in part or in w
t to the co
Code control unit in dash panel insert -J285- in dash panel insert
-K- to 5,000 km, 7,500 km or 10,000 km.
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.

Amarok 2011 ➤
Or
Or
AG. Volkswagen AG d
A- kswagen oes
n ol ot g
yV ua
♦ Diagnosis cable,ise2d bm -VAS 5052/3 A- ran
r tee
ho
Or aut or
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
♦ Battery charger -VAS 5903-
rrectness of i
Or
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.

Amarok 2011 ➤
♦ Battery charger, 60A -VAS 5904-

Note

Operating manual .
♦ Brand
♦ Type
♦ Model year
♦ Version
♦ Engine code
firm with > button. agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
– Select one after another: ed by ua
ran
ris tee
utho or
– Select „17 - Dash panel insert“ -arrow- ss
a ac
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
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
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
– Select „17 - Adapt service interval“ -arrow-

AG. Volkswagen AG d
agen oes
olksw not
V
Note ed by gu
ara
ris nte
h o eo
ut
♦ With this function, the service
ss a interval display is adapted for ra
c
vehicles without LongLife service (production control number
ce
e
nl
„QG0/G1“.
pt
du
an
itte
y li
♦ If this function is performed on vehicles with LongLife service,
erm
ab
the extended service interval (ESI) is deactivated.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Press button -arrow-.
– If necessary, connect battery charger -VAS 5903- or battery
charger, 60A -VAS 5904- .
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
– Press „Done“ button -arrow-.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Select service with „1 - Delivery inspection“ ⇒ page 115

-arrow- or „2 - Other service work“ ⇒ page 116 button.
„1“ Delivery inspection

Amarok 2011 ➤
– Confirm vehicle market query with „Yes“ or „No“ -arrow-.

AG. Volkswagen AG d
agen oes
olksw not
V gu
Note d by ara
rise nte
tho eo
u ra
Keep confirming
ss a the vehicle market query with „Yes“ or „No“ until
c
the desired country appears on the display.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Confirm end of „Adapt interval“ routine with „Done“ button
-arrow-.
– Exit „Guided functions“.
rrectne
ss
o
cial p
f i
nform
mer
atio
m
„2“ Other service work

o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
– Select „km“ in next window with -1 to 4- button. Cop
yi Co
py
t. rig
– The chosen setting is adopted by pressing the -Yes- button gh ht
yri by
-arrow-. cop Vo
by lksw
cted agen
Prote AG.
– The service selection window is activated again by pressing

the -No- button -arrow-.

Amarok 2011 ➤

-arrow-. agen
AG. Volkswagen AG d
oes
olksw not
– Exit „Guided functions“. ed byV gu
ara
ris nte
– Switch off ignition. aut
ho eo
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
4.49 Service interval: Adjusting (export)
rrectness of i
-K- to 5,000 km, 7,500 km or 10,000 km.
l purpos
Caution
nform
ercia

m
at
om
io
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Special tools and workshop equipment required Cop py
ht. rig
rig ht
♦ Vehicle diagnostic, testing and information system -VAS py by
co Vo
by lksw
cted agen
Prote AG.

Or
Or
A-
Or

Amarok 2011 ➤
Maintenance - Edition 01.2011 AG. Volkswagen AG d
agen oes
olksw not
y V gu
♦ Diagnosis cable, 5 m -VAS 5052/3 A-1- d b ara
rise nte
ho eo
♦ Battery charger -VAS 5903- 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
Perform the following jobs: l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e
Note
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
C py
t. rig
gh
ht
pyri by
Vo
o
Operating manual .
c by lksw
cted agen
Prote AG.
♦ Brand
♦ Type
♦ Model year
♦ Version
♦ Engine code
firm with > button.

Amarok 2011 ➤
– Select „17 - Dash panel insert“ -arrow-
Note
♦ With this function, the service interval display is adapted for

„QG0/G1“.
♦ If this function is performed on vehicles with LongLife service, AG. Volkswagen AG d
the extended service interval (ESI) is deactivated. olksw
agen oes
not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
– Press button -arrow-.
ce
le
un
pt
an
d
itte
– If necessary, connect battery charger -VAS 5903- or battery
y li
rm
ab
charger, 60A -VAS 5904- .
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
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
– Select service with „1 - Delivery inspection“ ⇒ page 120

Note
Keep confirming the vehicle market query with „Yes“ or „No“ until

AG. Volkswagen AG d
-arrow-. lksw
agen oes
not
Vo gu
by
– Exit „Guided functions“. ised ara
nte
or eo
h
– Switch off ignition. aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
„2“ Other service work
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Select „km“ in next window with -1 to 4- button.
– The chosen setting is adopted by pressing the -Yes- button rrectness of i
-arrow-.
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.

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes Maintenance - Edition 01.2011
olksw not
V gu
by a
ed ra
– The service selectionhoris window is activated again by pressing ntee
the -No- button s-arrow-.
au
t or
ac
s
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
-arrow-.
nf
ercia
or
m
m
atio
m

o
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
4.50 Service interval: Adjusting (Argentina
Prote AG.
and Brazil)
-K- to 5,000 km, 7,500 km or 10,000 km.
Caution



Or

Amarok 2011 ➤
Or
A-
Or

♦ Battery charger -VAS 5903-
Or
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
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.

Amarok 2011 ➤

Note

Operating manual .
ing and information system -VAS 5051B- n AG. Volkswagen AG do
lkswageor vehicle diagnostic es n
and service information systemby-VAS
Vo 5052 A- . ot g
ua d ran
ise tee
– Select one after another:uthor or
a ac
♦ Brand ss
ce
le
un
pt
♦ Type
an
d
itte
y li
rm
ab
♦ Model year
pe
ility
ot
wit
♦ Version
, is n
h re
hole
♦ Engine code
spec
es, in part or in w

– If the vehicle identification has been performed correctly, con‐ t to the co
firm with > button. rrectness of i

l purpos
– Select „17 - Dash panel insert“ -arrow-

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
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
Note
♦ With this function, the service interval display is adapted for

„QG0/G1“.
♦ If this function is performed on vehicles with LongLife service,
the extended service interval (ESI) is deactivated.
wage es n
– Press button -arrow-. yV
olks ot g
b ua
ed ran
– If necessary, connect battery charger -VAS 5903- horor battery
is tee
charger, 60A -VAS 5904- . aut or
ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
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
yri
– Select service with „1 - Delivery inspection“ ⇒ page 124 p by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
Note
Keep confirming the vehicle market query with „Yes“ or „No“ until

-arrow-.
olksw
– Remove vehicle diagnosis, testing and information
agen AG. V systemdo-es
agen AG
ksw
VAS 5051B- or vehicle diagnosis
by Voand
l service information not
gu
system -VAS 5052 A- fromrivehicle.
se
d ara
nte
tho eo
„2“ Other service work s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Select „km“ in next window with -1 to 4- button.
wit
, is n
h re
– The chosen setting is adopted by pressing the -Yes- button
hole
-arrow-.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
– The service selection window is activated again by pressing

n
c
in t
or
the -No- button -arrow-.

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.

Amarok 2011 ➤

-arrow-.
4.51 Track rod ends: Check clearance, se‐

curity and boots
– With vehicle raised (wheels hanging free), check clearance by
moving track rods and wheels:
Clearance: Zero clearance
– Check mountings. n AG. Volkswagen AG do
lkswage es n
o ot g
yV ua
– Check that boots -arrow- are not damaged and are seated ir se
d b ran
tee
correctly. utho
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
4.52 Power assisted steering: Check fluid
l purpos
level
♦ Oil at operating temperature (from approx. 50 °C)
nf
ercia
⇒ page 127 orm

m
atio
m
♦ Fluid cold ⇒ page 126

o
n in
or c
thi
4.52.1 Fluid cold

te
sd
iva
o
r
rp
cu
Test prerequisites
o
m
f
en
ng
t.
yi
• Engine switched off
Co
Cop py
t. rig
gh ht
• Front wheels in straight-ahead position yri
p by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
AG. Volkswagen AG d
lksw
agen oes
not Maintenance - Edition 01.2011
Vo gu
d by ara
e
Performhorthe
is following jobs: nte
eo
aut ra
– Unscrew
ss sealing cover -arrow- with built-in dipstick from c tank.
ce
e
nl
– Wipe off dipstick using a clean cloth.
pt
du
an
itte
y li
– Screw sealing cover on until finger tight and then unscrew
erm
ab
again. Following this, fluid level can be checked.
ility
ot p
wit
, is n
The oil level must be in area of „cool“ marking.
h re
hole
spec
Tolerance: 2 mm above or below marking.
es, in part or in w
t to the co
Note
rrectness of i
♦ If the fluid level is above the area specified, the excessive fluid
l purpos
must be extracted.
♦ If fluid level is below specified area, hydraulic system must be
nf
ercia
checked for leaks (repair measure).
orm
m
atio
♦ If the hydraulic system is not leaking, replenish required quan‐
om
tity of hydraulic oil -G 002 000- .
n in
or c
thi
te
sd
iva
– Screw sealing cover onto tank until finger tight.

o
r
rp
cu
o
m
f
en
ng
t.
4.52.2 Fluid at operating temperature (from ap‐
yi Co
Cop py
t. rig
prox. 50 ℃)
gh ht
pyri by
Vo
o
by c lksw
cted
Test prerequisites
agen
Prote AG.
• Engine switched off

• Front wheels in straight-ahead position
– Unscrew sealing cover -arrow- with built-in dipstick from tank.
– Wipe off dipstick using a clean cloth.
– Screw sealing cover on until finger tight and then unscrew
again, after which fluid level can be checked.
The oil level must be between the „cool“ and the „hot“ marking.
Note
♦ If the fluid level is above the area specified, the excessive fluid
must be extracted.
♦ If fluid level is below specified area, hydraulic system must be
checked for leaks (repair measure).
♦ If the hydraulic system is not leaking, replenish required quan‐
tity of hydraulic oil -G 002 000- .
– Screw sealing cover onto tank until finger tight.

Amarok 2011 ➤
4.53 Doors: Grease door arrester

– Lubricate door arrester at positions marked -arrows-. lkswage es n
o ot g
byV ua
d
– Use lubricating paste -G 000 150- or lock cylinder lubricating
o
ir se
ran
tee
spray -G 052 778 A2- . auth or
ac
ss
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
4.54 Paint: Perform visual check for damage
rrectness of i
and corrosion, interior and exterior when
l purpos
doors and bonnet/rear lid/flaps are open

nform
ercia
– Visual check on paint for damage and corrosion, interior and

m
a
com
ti
exterior when bonnet/rear lid/doors and flaps are open.
on in
r
te o
thi
– After the visual check, tick the corresponding field in the serv‐
s
iva
ice record.
do
r
rp
cum
fo
If damage is determined during visual check, make entries in the
en
ng
t.
yi
service schedule:
Co
Cop py
t. rig
gh
– Put a cross in „Repair recommendation“ on „Service record“
ht
pyri by
Vo
o
page in service schedule.
c by lksw
cted agen
Prote AG.
– Additionally describe exactly what part of vehicle is affected or
damaged etc. in field „Notes“ below „Workshop comments“ in
the service schedule.
Note
♦ Inform the customer when faults are found during visual check
and repair measures are necessary.
♦ Faults found must always be rectified (repair measure). There‐
fore, further damage and corrosion and rusting through can be
avoided.
4.55 Protective foil: Remove (if fitted)
Note
The foil must „NOT“ be removed from the rear bumper on Amarok
models in „Russia“ with chrome bumpers.
Reason:
In Russia, the roads are gritted with calcium chloride in winter.
This aggressive substance could corrode the chrome coating.

Amarok 2011 ➤
4.56 Underbody protection: Perform visual

AG. Volkswagen AG d
check for damage Vo lksw
agen oes
not
y gu
db ara
During visual check, also check floor pan, wheel housings
ris and
e nte
sills. utho eo
ra
a c
ss
ce
le
un
pt
Note
an
d
itte
y li
erm
ab
ility
Faults found must always be rectified (repair measure). This in‐
ot p
hibits corrosion and rusting through.
wit
is n
h re
ole,
spec
4.57 Clock: Set to correct time
t to the co
Vehicles without digital tachograph
– Setting buttons -A and B- are located in dash panel insert -K- .
rrectnes
Note
s o
cial p
f inform
Clock -B- can only be set when the time is displayed in the dash
mer
panel insert -K- and is not overlaid with another display.
atio
om
n
c
i
or
n
thi
te
sd
va
i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
– To access hour display -B- in dash panel insert -K- , press
p by
co Vo
by lksw
button -A-. Prote
cted AG.
agen
– Briefly pressing 0.0 / SET -A- changes time by one hour for
every press.
– Pressing 0.0 / SET -A- for longer changes hour value quick‐
ly.

Amarok 2011 ➤
– Press button -A- again to mark the minute display.

– Briefly pressing 0.0 / SET -A- changes time by one minute
for every press.
– Pressing 0.0 / SET -A- for longer changes minute value

quickly.
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
– Pressing -A- button again finishes time setting.

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
r
4.58 Camshaft drive toothed belt and toothed

o
his
ate
belt tensioning roller: Renew

do
priv
cum
for
en
g

n
t.
yi Co
op
15 . C py
t. rig
gh ht
yri by
4.59 Camshaft drive toothed belt: Check con‐
op Vo
by c lksw
cted agen
dition
Prote AG.
Applicable to
♦ Diesel engines in „dusty“ regions
♦ Diesel engines
– Remove toothed belt guard ⇒ Rep. gr. 15 .

Amarok 2011 ➤
– Check toothed belt condition, looking for:

♦ -A- Cracks, cross-sectional breaks, cracks (coating)
♦ -B- Side contact
♦ -C- Fraying of cord strands
♦ -D- Cracks (in teeth base)
♦ Layer separation (toothed belt body, draw strands)
♦ Surface cracks (synthetic coating)
swage es n
♦ Traces of oil and grease yV
olk ot g
ua
d b ran
ir se tee
tho
u or
Note ss
a ac
ce
le
un
pt
If faults are found always renew toothed belt. This will avoid pos‐
an
d
itte
y li
sible breakdowns or operating problems. The replacement of a erm
ab
toothed belt is a repair measure.
ility
ot p
wit
is n
h re
ole,
4.60 Coolant pump toothed belt sprocket and
spec
toothed belt: Renew
t to the co
19 .
rrectne
4.61 Spark plugs: Renew
ss o
cial p
f inform
Note
mer
atio
om
n
c
i
or
n thi
te
sd
va

i
o
pr
cum
r
fo
♦ Torque wrench -V.A.G 1331/-
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Spark plug socket and extension -VAS 3122B-

Amarok 2011 ➤
♦ Puller -T40039-
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
Removing
rrectness of i
– Pull out all ignition coils with final output stage from cylinder
head approx. 30 mm using puller -T40039- .
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
– Release connector -arrows- and simultaneously pull all con‐ Prote
cted AG.
agen
nectors off ignition coils with final output stage.
– Remove ignition coil with output stage.
– Unscrew spark plugs using spark plug socket and extension -
VAS 3122B- .
Installing
– Install new spark plugs using spark plug socket and extension
-VAS 3122B- .
Specified torques: 30 Nm
– Insert all ignition coils with output stages loosely into spark
plug shaft.
– Align ignition coil with final output stage to connector

-arrows- and fit simultaneously.
Note
Do not strike with a hammer or other types of tools.
– Evenly push ignition coils with final output stages onto spark
plugs by hand.

Amarok 2011 ➤
4.62 Removing and installing skid plate

Torque wrench -V.A.G 1331- (6-50 Nm)
Note
Get a second mechanic to help you to remove and install skid

plate.
– Unscrew bolts -2-, -3- and -4- one after another.

– Remove skid plate -1- in -direction of arrow-.
Note
AG. Volkswagen AG d
agen oes
ksw
The assembly steps are basically a reverse of the by
Vdismantling
ol not
gu
procedure. rised ara
nte
ho eo
aut ra
c
– Tighten bolts. ss
ce
le
un
pt
Specified torques: 20 Nm
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
4.63 Steering: Check bellows for leaks and
damage
ss o
cial p
f
inform
mer
– Check bellows of steering -arrow- for leaks and damage on

atio
respective side.
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.

Amarok 2011 ➤
5 Exhaust emissions test
Note
The following exhaust emissions test description is applicable

only in countries where no specific exhaust emission regulations
have to be adhered to.
Exhaust emissions test intervals in Germany:

Vehicles with regulated catalytic converter or vehicles with diesel
engine:
♦ 3 years after initial registration and then every 2 years.
♦ Vehicles for commercial passenger transport, e.g. taxis: every
12 months
General for exhaust emissions test ⇒ page 134
Exhaust emissions test for petrol engines with engine code CFPA
⇒ page 135
Exhaust emissions test for diesel engines with engine codes
CDBA, CDCA ⇒ page 142
Exhaust emissions test with OBD ⇒ page 144
5.1 General information for exhaust emis‐

sions test
AG. Volkswagen AG d
agen oes
5.1.1 d by
VExhaust emissions test intervals
olksw not
gu
ara
ise nte
r
Vehicles with petrol
ut
ho and diesel engine and OBD: eo
ra
s a c
s
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
♦ Observe country-specific legal regulations.

ility
ot p
wit
, is n
♦ Exhaust emissions test badges are omitted as of 1 January

h re
2010; only the main inspection badges are then available.

hole
spec
es, in part or in w
♦ Existing exhaust emissions test badges will be removed from

t to the co
the vehicle by the test centres at the next main inspection or

so-called "repair badges" will be affixed over them.
rrectness of i
♦ If the OBD test is carried out, the inspector must issue an ex‐
haust emissions test record according to Annex VIII No.
l purpos
3.1.1.1 German vehicle licensing regulations.

♦ No obligation of storage and submission exists for the exhaust
nf
ercia
emissions test records if the exhaust emissions test record has

orm
been transferred to the main inspection test report by the offi‐

m
atio
m
cially recognised expert.

o
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.
134 5. Exhaust emissions test

Amarok 2011 ➤
5.2 Exhaust emissions test for petrol en‐

gines with engine code CFPA
AG. Volkswagen AG d
agen oes
lksw not
Note d by Vo gu
ara
rise nte
ho eo
♦ The following description srefers
aut
to vehicles fitted with „On‐ ra
c
board diagnosis“ (OBD) sand regulated catalytic converter.
ce
e
nl
pt
du
♦ The OBD monitors all components and part systems influenc‐
an
itte
y li
ing the exhaust emissions quality.
erm
ab
ility
ot p
wit
, is n
h re
hole
♦ Emissions testing station -VAS 6300-
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
c
♦ OBD adapter cable -VAS 5052/16-
um
for
en
ng
t.
♦ Data sheets for exhaust emissions test
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Note
by lksw
cted agen
Prote AG.
♦ It is only possible to carry out an exhaust emissions test when

all units of the emissions testing station -VAS 6300- are con‐
nected properly and combined with each other according to
the ⇒ operating instructions .
♦ All work to be performed is displayed by the emissions testing
station -VAS 6300- .
Test prerequisites
• All test conditions and data required for exhaust emissions test
⇒ Data sheets for exhaust emissions test for respective engine
• For bar code reading the EET data sheet must be printed out.
• Manual gearbox: Gear lever in neutral
• Handbrake pulled on
– Perform exhaust emission test according to instructions on
display.
5. Exhaust emissions test 135

Amarok 2011 ➤
Initial screen
– Select Exhaust emissions test -arrow- button.
An overview is displayed to select the respective EET type.
– Select EET petrol -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
s c
The display for warm-up phase appears. s ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
– Continue exhaust emission test according to instructions on

o
cial p
display.
inform
mer
– If the EET specification selection is displayed, select respec‐

atio
m
tive „EET specification selection“ -arrow-.

o
n
c
i
or
♦ „Standard values“ when an EET is performed for the first time,

thi
te
sd
iva
♦ Select „Last vehicle“ when an EET is to be carried out again.

pr
cum
r
fo
en
ng
– Select Continue on display, see -item 1-.

t.
yi Co
Cop py
t.
The vehicle data input menu is displayed.
rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
autho eo
ra Amarok 2011 ➤
ss Maintenance - Edition 01.2011
c
ce
le
un
pt
an
d
Vehicle data input
itte
y li
rm
ab
♦ Vehicle manufacturer -A-
pe
ility
ot
wit
, is n
♦ Key number -B-
h re
hole
♦ Vehicle type -C-
spec
es, in part or in w
t to the co
♦ Key number -D- (the first 3 digits)
♦ For vehicle identification number (chassis number) -E-
rrectness of i
l purpos
nform
ercia
– Enter items -1…7- of vehicle data from vehicle registration

m
a
certificate.
com
tion in
♦ -1- Vehicle manufacturer: „e.g. VOLKSWAGEN - VW“
r
te o
thi
s
iva
do
♦ -2- Vehicle type: „e.g. 2H“
r
rp
cum
fo
♦ -3- Key number to 2 (old) or 2.1 (new): „e.g. 0603“
en
ng
t.
yi Co
op
♦ -4- Key number to 3 (old) or 2.2 (new): „e.g. 358“
C py
t. rig
gh ht
yri by
♦ -5- Engine code „e.g. CFPA“ cop Vo
by lksw
cted agen
Prote AG.
♦ -6- Registration number: „e.g. WOB-HH 1234“
♦ -7- Vehicle identification number: „e.g.
WV1ZZZ2HZYW123456“
♦ -8- Odometer reading: „e.g. 32000“
Note
♦ Further functions can be called up using GoTo button.

♦ The test can be interrupted using GoTo button.
– Select with OBD -arrow-.

Specified data input for EET
Note
♦ If specifications are not available as bar code, they are to be

entered manually.
♦ All test conditions and data required for exhaust emissions test
Manual specified data input for EET:

– Perform manual data input according to instructions on dis‐
play.

Amarok 2011 ➤
– Enter displayed values on EET data sheet under „Test values

for exhaust emissions test“ on display in following sequence:
1- Test speed (idling speed)
2- Warm-up phase for catalytic converter
3- Engine temperature
4- Increased idling speed
5- CO content at increased idling speed
6- Lambda at increased idling speed
7- Idling speed
8- Select regulating probe type, either „step-type probe“, or
„broad-band probe“ -item 1-.
AG. Volkswagen AG d
9- Lambda probe value agen oes
olksw not
V gu
d by ara
– When all data have been entered properly, press Continue orise nte
eo
button -arrow-. aut
h
ra
ss c
ce
le
un
Specified data input for EET as bar code:
pt
an
d
itte
y li
– If EET nominal data is present in bar code format then read in
erm
ab
bar code of EET data sheet using reader pen.
ility
ot p
wit
is n
All data required are shown on display.
h re
ole,
spec
– Press ► -button- to continue procedure.
t to the co
rrectness o
cial p
f i
Visual check
nform
mer
– Follow instructions on display.
atio
om
n
c
– Perform visual checks.
i
or
n thi
te
sd
a
– If visual check is OK press OK button. Press -arrow-.

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Note t. Cop py
rig
gh ht
yri by
When not OK button is pressed a check will be carried out.
op Vo
by c lksw
cted agen
Prote AG.
The visual check is displayed with the request to connect the di‐
agnosis connector -arrow A- and to check the MI lamp
-arrow B-.

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
lksw not
– Connect diagnosis line connector to EOBD connection.byV
o gu
ara
ed
is nte
– Switch on ignition. ut
hor eo
a ra
s c
– Perform visual check of „MI lamp“. s
ce
le
un
pt
– If lamp lights up, press Lamp On button -arrow C-.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
– Follow instructions on display, see -arrow C- and -arrow A-.
n
c
i
or
n thi
e
♦ Start engine.
t
sd
iva
o
pr
cum
♦ Perform visual check of MI lamp.
r
fo
en
ng
t.
yi Co
– Insert emission probe in exhaust tail pipe. . Cop py
rig
ht ht
rig by
copy Vo
by lksw
Note cted agen
Prote AG.
The exhaust emissions test is only continued when the test probe
is in the exhaust tail pipe.
It is automatically switched to test for readiness of operation.

It is checked here if all tests for readiness of operation supported
by the control unit have been performed.
Note
♦ If all display values have been set to „0“, a regulating probe

test is not performed.
♦ If not all display values have been set to „0“, a regulating probe
test will be performed later.
– Confirm status of „MI lamp“ -arrow B-.

Catalytic converter conditioning
It is automatically switched to warm-up phase of catalytic con‐
verter.

Amarok 2011 ➤

Measurement starts when the engine speed has reached the re‐
quired level.
– Keep engine speed within required rpm range.
The remaining time to perform the warm-up phase is displayed
- arrow A -.
Warm-up phase
It is automatically switched to display for measuring engine tem‐
perature.
Note AG. Volkswagen AG d

agen oes
olksw not
yV gu
This is only indicated on display if engine temperature isedhas not
b ara
nte
reached 80 ℃. ut
hor eo
ra
s a c
s
ce
– Bring engine to required temperature.
le
un
pt
an
d
itte
y li
erm
Measurement at increased idling speed:
ab
ility
ot p
It is automatically switched to display for measuring increased
wit
is n
idling speed.
h re
ole,
spec
t to the co
quired level.
rrectne
Note
ss o
cial p
♦ Measurement can be skipped using ► button, i.e. the exhaust f inform

emissions test has failed.
mer
atio
♦ Measured values are reset using the ← button and the test can
om
n
c
be repeated.
i
or
n thi
te
sd
iva
– Keep engine speed within required rpm range.

pr
cum
r
fo
en
ng
The remaining time to perform measurement is displayed

t.
yi Co
op
-arrow A-. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
Measuring idling speed and CO content

It is automatically switched to display for measuring the idling
speed and CO content.
quired level.
The remaining time to perform measurement is displayed
-arrow A-.
Regulating probe test
Note
The regulating probe test is only performed if „NOT“ all display

values have been set to „0“.
It is automatically switched to display for regulating probe test.
Note
The regulating probe test is performed for every lambda probe

individually.
quired level.
– Keep engine speed within required rpm range. . Volkswagen AG
gen AG does
swa
The remaining time to perform measurement by V is displayed
o lk not
gu
-arrow A-. rised ara
nte
ho eo
aut ra
Evaluation ss c
ce
le
un
pt
When the exhaust emissions test has been performed, the log is an
d
itte
shown on display. y li
rm
ab
pe
ility
The test result is displayed.
ot
wit
, is n
Now remarks concerning the exhaust emissions test can be en‐

h re
hole
tered -arrow A-. These will then be included in the test log.
spec
es, in part or in w
– When the exhaust emissions test is classed as passed, select

t to the co
-arrow B- EET sticker issued in drop-down menu and date.

– Then confirm with Yes , see -arrow C-.
rrectness of i
l purpos
After confirmation, the „2“ „TEST CERTIFICATES“ are printed out

automatically.
nform
ercia
– If further test certificates are required, press -arrow A-

m
Print button.
com
tion in
r
te o

thi
s
iva
do
– Remove exhaust probe from exhaust tailpipe.

r
rp
cum
fo
en
g
– Then press ► button -arrow B-.

n
t.
yi Co
Cop py
The exhaust emissions test is completed, a new exhaust emis‐
ht. rig
rig ht
by
sions test can be performed. copy Vo
by lksw
cted agen
Prote AG.

olkswagen AG
wag en AG. V
Amarok 2011 ➤ olks
does
not
yV gu
se
d b ara
nte
ri
ho eo
ut ra
5.3 Exhaust emissions test for diesel en‐
a c
ss
ce
le
gines with engine codes CDBA, CDCA
un
pt
an
d
itte
y li
erm
ab
ility
ot p
♦ Diesel tester -V.A.G 1743-
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n
♦ Engine speed adapter -VAS 6296-
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
Prote AG.
♦ Data sheets for exhaust emissions test
Note
♦ All test conditions and data required for exhaust emissions test
♦ If possible, the test should be completed outdoors following a
road test. If this is not possible for various reasons (weather,
excessive noise in residential areas), then the test can be car‐
ried out in a workshop.
♦ To reduce noise levels, the bonnet should be closed on first
catch during tests.

Performing visual check of components that influence pollution.
⇒ Data sheets for exhaust emissions test
– Perform visual check for:
♦ Installation
♦ Completeness
♦ Leakage
♦ Damage

Amarok 2011 ➤
Note
Faults found are to be rectified.
With ignition switched off, connect testers as follows:

– Connect diesel tester -V.A.G 1743- according to ⇒ operating
instructions with ignition
wage
n AGswitched
. Volkswageoff.
n AG d
oe
ks s no
Vol t
– Connect engine
ed
by speed adapter -VAS 6296- . guara
ris nte
ho eo
aut ra
ss c
Note
ce
le
un
pt
an
d
itte
♦ Follow ⇒ operating instructions for engine speed adapter -
y li
erm
ab
VAS 6296- !
ility
ot p
♦ Strictly follow the safety precautions in the operating instruc‐
wit
is n
h re
tions!
ole,
spec
– Start engine and run at idling speed.
t to the co
The engine speed must now be displayed on diesel tester -V.A.G
1743- . rrectne
If the engine speed is displayed incorrectly or not at all, use ⇒
operating instructions for VAS 1743 or ⇒ operating instructions
ss
for VAS 6296 to rectify the cause.

o
cial p
f in
Perform exhaust emissions test according to instructions on die‐

form
mer
sel tester -V.A.G 1743- display.

atio
om
If the following is indicated on display:

c
i
or
n rpm mode k 1/m T °C

n thi
XXX XXXX B X.XX XX

te
sd
iva
o
r
Unit ready to carry out measurements.

p
cum
r
fo
en
ng
Check idling speed.

t.
yi Co
Cop py
t. rig
Idling speed not within specified range: opyri
gh by
Vo
ht
by c lksw
cted agen
Prote AG.
Note
The idling speed and maximum speed can be checked but not
adjusted.
– If the values are not within specified range, a repair measure

must be made.
Performing acceleration test.
– Press „button for acceleration test“.
First, a fresh air comparison is performed.
If the following is indicated on display: n rpm tB s k 1/m Gas T °C M
XXX XXXX -.- X.XX 0 XX -
Current values for temperature and speed are displayed.

The arrow pointing upwards indicates that the unit is waiting for
the throttle burst.
– Depress accelerator pedal fully and hold for specified time.
– Check maximum engine speed (not adjustable).

Amarok 2011 ➤
WARNING
If the governed speed (maximum speed) is exceeded, lift off

accelerator pedal immediately and perform repair measures.
– If the values are not within specified range, a repair measure

must be made.
If the unit detects a valid throttle burst (the speed increases con‐
tinually during measuring period „tx“), the following is indicated on
display:
If the following is indicated on display: n rpm tB s k 1/m Gas T °C M
XXX XXXX -.- -.- 1 XX -
The display remains „frozen“ during the evaluation phase (ap‐

prox. 15 seconds).
After the evaluation phase, the display changes to: n rpm tB s k 1/m Gas T °C M
XXX XXXX X.XX X.XX 1 XX -
The arrow pointing upwards indicates that the unit is waiting for
the next throttle burst.
Repeat test 4 times.
The following is indicated on display after each throttle burst: n rpm tB s k 1/m Gas T °C M
XXX XXXX X.XX X.XX X XX -
In this way, the unit measures and registers at least four throttle
bursts. After the fourth and for each further throttle burst se‐
quence, an average of the last three measurements is performed.
The following is indicated on display after each throttle burst: n rpm tB s k 1/m Gas T °C M
AG. Volkswagen AG dXXX XXXX X.XX X.XX X XX -
agen oes
olksw not
yV gu
After 10 seconds, this display changes to: ise
db ara tB s k 1/m
nte band width M
or Average X.XX
eo X.XX X.XX -
th
au ra
ss c
After 5 seconds, this display changes to:
ce
le
tB s k 1/m band width M

un
pt
Average X.XX X.XX XX -

an
d
itte
y li
The display remains until a further throttle burst is performed or

rm
ab
pe
another measurement is called up.

ility
ot
wit
, is n
If the opacity figures are equal to or less than the prescribed fig‐
h re
hole
ures, cease measurements.

spec
es, in part or in w
If the determined opacity figure is above the prescribed figure,

t to the co
locate fault within repair measure framework ⇒ Fault finding en‐

gine
rrectness of i
5.4 Exhaust emissions test with OBD

l purpos
Note
nform
mercia
♦ The following exhaust emission test description is only appli‐

a
com
tio
cable in countries where specific exhaust emission regulations

n in
have to be adhered to.

r
te o
thi
s
iva
do
♦ In motor vehicles with spark ignition engine or compression

r
rp
cum
ignition engine which were initially registered for use on the

fo
en
g
road as of 01.01.2008, measurement and processing of the

n
t.
yi Co
exhaust emissions behaviour are omitted if all readiness co‐ Cop py
t. rig
des are set. gh ht
pyri by
Vo
co lksw
by
♦ If „NOT“ all readiness codes are set, an exhaust emissions test Prote
cted AG.
agen
must be performed ⇒ page 134 .

lkswage es n
d byV
o
Amarok 2011
ot g
ua ➤
ran
ho
ir se Maintenance - Edition 01.2011 tee
ut or
a ac
ss
ce
le
un
pt
an
d
itte
y li
5051B-
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
♦ Diagnosis cable 5m -VAS 5051B/1- mercia
a
com
tio
n in
r
A-
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.
♦ Diagnosis cable -VAS 5052/3-
Carry out the following procedure:

– Perform visual check:
♦ Crankcase breather system connected,
♦ Exhaust system must be leaktight,
♦ Catalytic converter and particulate filter present and undam‐
aged.
Checking and adjusting prerequisites:
♦ Electrical consumers switched off,
♦ Air conditioner switched off,
♦ As of an engine oil temperature of at least 60°C, warm the
engine to at least 80°C by revving freely 10 times up to the rev.
limit.

Amarok 2011 ➤
Note
Faults found are to be rectified.
– Manual gearbox: Gear lever in neutral.
– Connect diagnosis cable connector to diagnosis connection
with ignition switched off.
system -VAS 5052- ⇒ page 71 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
– Press Guided functions button -arrow-
ss on display. c
ce
le
un
pt
Vehicle identification begins.
an
d
itte
y li
erm
– Select brand, vehicle model, model year, etc.

ab
ility
ot p

wit
is n
h re
ole,
spec
t to the co
rrectnes
– Select „Engine“ -arrow- in vehicle diagnostic system guided

s o
cial p
menu.
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
Prote AG.

Amarok 2011 ➤
– Select „Generate readiness code“ -arrow-.

information system -VAS 5052- .
Evaluation: 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
After running through readiness code, result appears on screen.
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ Exhaust emissions test is PASSED when all „ACTUAL values“
correspond to „SPECIFICATIONS“.
rrectness of i
♦ If not all readiness codes are set, an exhaust emissions test
l purpos
must be carried out ⇒ page 134 .
– Print out the evaluation with Print .
nf
ercia
orm
– End programme.
m
atio
om
n in
c
– Remove vehicle diagnostic, testing and information system -

or
thi
te
sd
a
system -VAS 5052- .

iv
o
r
rp
cu
o
m
f
– Complete exhaust emissions test record according to Annex

en
ng
t.
yi
VIII No. 3.1.1.1 German vehicle licensing regulations.
Co
Cop py
t. rig
gh
– Close fuse box cover on left under dash panel.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ Exhaust emissions test badges are omitted as of 1 January

2010; only the main inspection badges are then available.
♦ Existing exhaust emissions test badges will be removed from
the vehicle by the test centres at the next main inspection or
so-called "repair badges" will be affixed over them.
♦ No obligation of storage and submission exists for the exhaust
emissions test records if the exhaust emissions test record has
been transferred to the main inspection test report by the offi‐
cially recognised expert.

Amarok 2011 ➤
6 Glossary
These explanations only apply to „Maintenance Manual“. They
are not necessarily generally valid!
Letter „A“ ⇒ page 148
Letter „B“ ⇒ page 148
Letter „C“ ⇒ page 148
Letter „D“ ⇒ page 149
AG. Volkswagen AG d
Letter „E“ ⇒ page 149 lksw
agen oes
not
Vo gu
y
Letter „F“ ⇒ page 149 rise
d b ara
nte
tho eo
Letter „L“ ⇒ page 149 s au ra
c
s
ce
e
Letter „M“ ⇒ page 149

nl
pt
du
an
itte
Letter „O“ ⇒ page 149
y li
erm
ab
ility
Letter „P“ ⇒ page 150
ot p
wit
, is n
Letter „Q“ ⇒ page 150
h re
hole
spec
Letter „R“ ⇒ page 150
es, in part or in w
t to the co
Letter „S“ ⇒ page 150
Letter „T“ ⇒ page 150
rrectness of i
Letter „W“ ⇒ page 150
l purpos
Letter „X“ ⇒ page 151

Letter „A“
nf
ercia
orm
m
Term Explanation
atio
om
n in
c
All Season All-season tyres / all weather tyres An All Season Tyre is a tyre for all seasons.
or
thi
te
ABS The ABS is a regulating system in the brake system, that prevents locking when braking.
sd
iva
o
r
(anti-lock brake This helps to maintain directional stability and steerability.

rp
cu
o
m
system)
f
en
ng
t.
yi Co
ATF Gear oil for automatic gearbox Cop py
t. rig
(Automatic trans‐ yri
gh by
ht
mission fluid) cop Vo
by lksw
cted agen
ATF level Filling level of ATF in gearbox
Prote AG.
Letter „B“
Term Explanation
Broad-band probe The broad-band probe is also called universal lambda probe (ULP probe). The voltage
of the lambda probe output nearly increases linear. The lambda probe value is deter‐
mined by a change in voltage. This enables to measure the lambda probe value via a
larger measuring range (broad band). The probe is used as before catalytic converter
probe.
Letter „C“
Term Explanation
C - tyres C-mark is found on light truck tyres. Use correct inflation pressure when changing from
„Reinforced tyres“ to „C-mark tyres“.
CO Carbon monoxide is produced when fuels containing carbon are not combusted com‐
(Carbon monoxide) pletely.
148 6. Glossary
Amarok 2011 ➤
Term Explanation
CN Measurement unit for ignition quality of diesel fuel
(Cetane number)
Letter „D“
wage es n
Term Explanation
yV
olks ot g
ua
d b r n
DPF ri The diesel particulate filter is installedabehind
se
tee the catalytic converter and filters soot
ho
(Diesel particulate
aut particles from emissions. or
ac
filter) ss
ce
le
un
pt
DIN Deutsches Institut für Normung e.V. (German Standards Authority)
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
Letter „E“
h re
ole,
spec
Term Explanation
t to the co
Part No. Abbreviation for part number
EN European standard
rrectne
EOBD European onboard diagnosis
ESP Electronic stabilisation programme (prevents potential vehicle skidding by targeted in‐
s
tervention in the brake and engine management systems)
s o
cial p
f inform
mer
Letter „F“ atio

om
n
c
i
or
Term Explanation
thi
te
sd
va
FAME Fatty acid methyl ester

i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
Letter „L“
gh ht
pyri by
Vo
co lksw
by
Term Explanation
cted agen
Prote AG.
LongLife service The LongLife service enables extremely long inspection or oil change intervals, de‐
pending on individual driving style and the conditions under which the vehicle is used.
For the LongLife service a special engine oil is required.
LEV Low Emission Vehicle
Letter „M“
Term Explanation
M&S § 36 of the StVZO (Germany) defines the identification of a winter tyre as „M&S“.
MIL American designation for MI lamp -K83-
(Malfunction Indica‐
tor Light)
Letter „O“
Term Explanation
OBD The OBD monitors all components influencing the exhaust emissions quality.
(Onboard diagno‐
sis)
6. Glossary 149
Amarok 2011 ➤
Letter „P“
Term Explanation
PR number Abbreviation for production control number, it identifies among other things optional
equipment, country-specific deviations etc.
Letter „Q“
Term Explanation
QG0 Vehicles are „not“ fitted at the factory with components for LongLife service. For main‐
tenance, the time or distance dependent intervals (non-flexible intervals) apply.
QG1 Vehicles are fitted at the factory with active LongLife service. This means vehicles have
a flexible service interval display and are fitted with the following components:
♦ Flexible service interval display in dash panel insert
QG2 The LongLife service is not active at the factory. This means, vehicles have a non-flexible
service interval display (time or distance dependent service intervals) and are fitted with
the following components:
♦ Non-flexible service interval display in dash panel insert
♦ Brake pad wear indicator (if fitted)
Letter „R“ agen

AG. Volkswagen AG d
oes
olksw not
y V gu
Term Explanation rise
d b ara
nte
ho eo
RON Measurement unit of the knock resistance
s aut
of petrol ra
c
(Research Octane s
ce
le
Number)
un
pt
an
d
itte
RF „REINFORCED“, reinforced tyre, additional designation for tyres with increased load
y li
erm
ab
capacity
ility
ot p
wit
is n
h re
ole,
spec
Letter „S“
t to the co
Term Explanation
SAM (South Ameri‐ South America
can countries) rrectne
Step-type probe The step-type probe is also called finger probe or planar lambda probe. The voltage of
s
the output signal of the lambda probe jumps rapidly. The lambda probe value is deter‐
s o
mined by a change in voltage. The probe is used as after catalytic converter probe.
cial p
f inform
mer
atio
om
Letter „T“
c
i
or
n thi
te
sd
a
Term Explanation
iv
o
pr
cum
r
TDI Turbo diesel engine with direct injection

fo
en
ng
(Turbo Diesel Injec‐

t.
yi Co
op
tion)
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Letter „W“
Term Explanation
ESI Extended servicing interval
150 6. Glossary
agen
AG. Volkswagen AG d
oes Amarok 2011 ➤
ksw not
by Vol
gu
ara
d
rise nte
tho eo
s au ra
c
s
ce
le
Letter „X“
un
pt
an
d
itte
y li
Term Explanation
erm
ab
ility
ot p
XL „Extra Load“, reinforced tyre, additional designation for tyres with increased load ca‐
wit
is n
pacity
h re
ole,
spec
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
co lksw
by
cted agen
Prote AG.
6. Glossary 151

Maintenance PDF

Diunggah oleh

Informasi Dokumen

Judul Asli

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Maintenance PDF

Diunggah oleh

Hak Cipta:

Format Tersedia

Service

Service Department. Technical Information

All rights reserved.

Copyright © 2011 Volkswagen AG, Wolfsburg D3E8027339B

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

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

3.4 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.6 Entries in service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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

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

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

Output kW at rpm 90/3750 120/4000

Bore ∅ mm 81,0 81,0

Injection/ignition TDI common rail TDI common rail

2.1 Information on LongLife service and

2.1.1 Service identification

the customer. wit

„QG1“ indicates „LongLife service“.

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

2.1.2 LongLife service

Vehicles with PR number „QG1“

With the LongLife system, a new technology was introduced by

Volkswagen commercial vehicles whereby an interval service is

only performed when the vehicle needs it.

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

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

For the LongLife service a special LongLife engine oil is required

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

2.1.3 Time or distance dependent service

the time or distance dependent service applies.

including an engine oil change.

Vehicles with PR number „QG0“

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

Life service. For maintenance the time or distance dependent

Vehicles with PR number „QG2“

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

dependent intervals (non-flexible intervals) are valid. These ve‐

♦ Non-flexible service interval display in dash panel insert

♦ Engine oil level sensor

Calculation of service intervals:

tion, oil temperature and load of diesel particulate filter are

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

are serviced according to time or distance dependent intervals,

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

2.2 Service tables, inland

2.2.1 Service intervals

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

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

sive wear of cylinders and it considerably reduces the

cleanliness of pistons. Short service intervals apply in this

extra service work must be performed in addition to the inspection

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

Interval service max. YES

All vehicles First inspection service af‐ NO

ter 3 years, then every 2

2.3 Service tables, export

2.3.1 Service intervals

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

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

Interval service max. YES

2) Whichever occurs first

Oil change intervals depending on sulphur content in fuel

Oil change intervals depending on sulphur content in fuel