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  • Examplepage for repair manual 4-cylinder diesel engine (2.0 l engine, common rail)
  • Examplepage for repair manual 2 4-cylinder diesel engine (2.0 l engine, common rail)
  • Examplepage for repair manual 3 4-cylinder diesel engine (2.0 l engine, common rail)

4-cylinder diesel engine (2.0 l engine, common rail)

For Amarok

Original Volkswagen repair manual


35,25 €7% VAT incl.

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  • English

Immediately available for download

Language: English

Digital PDF file

19.548 KB

490 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mountings, Cylinder block (pulley end), Crankshaft, Auxiliary drive, Pistons and conrods, Fully enclosing toothed belt guard, Valve gear, Sump, oil pump, Engine oil cooler, Oil filter, oil pressure switch, Cooling system/coolant, Radiator, radiator fan, Turbocharger and Injectors/high-pressure accumulator (rail). Show more
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Repair manual Amarok 4-cylinder diesel engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Safety information
    1
  • 1.1 Safety precautions when working on fuel system
    1
  • 1.2 Safety regulations for working on fuel supply
    2
  • 1.3 Safety precautions when working on the cooling system
    3
  • 2 Identification
    5
  • 2.1 Engine number/engine data
    5
  • 3 Repair instructions
    7
  • 3.1 General notes
    7
  • 3.2 Rules for cleanliness
    8
  • 3.3 Instructions for working on fuel system
    8
  • 3.4 Notes on hose connections with screw-type clips
    10
  • Removing and installing engine
    12
  • 1 Removing and installing engine
    12
  • 1.1 Removing engine
    12
  • 1.2 Securing engine on engine and gearbox support
    28
  • 1.3 Installing engine
    30
  • 2 Assembly mountings
    34
  • 2.1 Assembly overview - assembly mountings
    34
  • Crankshaft group
    38
  • 1 Cylinder block (pulley end)
    38
  • 1.1 Assembly overview - cylinder block (pulley end)
    38
  • 1.2 Assembly overview - sealing flange, belt pulley end
    40
  • 1.3 Assembly overview - poly V-belt drive
    41
  • 1.4 Assembly overview - cover for poly V-belt
    47
  • 1.5 Removing and installing poly-V belt
    47
  • 1.6 Removing and installing tensioner for poly V-belt
    50
  • 1.7 Removing and installing bracket for ancillaries
    51
  • 1.8 Removing and installing vibration damper
    52
  • 1.9 Renewing crankshaft oil seal - belt pulley end
    53
  • 1.10 Removing and installing sealing flange on pulley end
    56
  • 1.11 Removing and installing cover for poly V-belt
    60
  • 2 Cylinder block, gearbox end
    62
  • 2.1 Assembly overview - cylinder block, gearbox end
    62
  • 2.2 Removing and installing flywheel
    64
  • 2.3 Removing and installing sealing flange on gearbox side
    66
  • 2.4 Removing and installing drive plate
    85
  • 3 Crankshaft
    88
  • 3.1 Assembly overview - crankshaft
    88
  • 3.2 Crankshaft dimensions
    89
  • 3.3 Measuring axial clearance of crankshaft
    90
  • 3.4 Measuring radial clearance of crankshaft
    91
  • 3.5 Renewing needle bearing in crankshaft
    91
  • 4 Auxiliary drive
    94
  • 4.1 Assembly overview - ancillary drive
    94
  • 4.2 Retrofitting preparation for ancillary drive
    94
  • 5 Pistons and conrods
    97
  • 5.1 Assembly overview - pistons and conrods
    97
  • 5.2 Checking pistons and cylinder bores
    99
  • 5.3 Measuring piston projection at TDC
    101
  • 5.4 Checking radial clearance of conrods
    103
  • 5.5 Bearing shells - installation position
    103
  • 5.6 Separating new conrod
    104
  • Cylinder head, valve gear
    106
  • 1 Cylinder head
    106
  • 1.1 Assembly overview - cylinder head
    106
  • 1.2 Assembly overview - cylinder head cover
    110
  • 1.3 Removing and installing cylinder head
    114
  • 1.4 Removing and installing cylinder head cover
    124
  • 1.5 Removing and installing injector seals
    131
  • 1.6 Removing and installing vacuum pump
    133
  • 1.7 Checking compression
    134
  • 2 Toothed belt drive
    136
  • 2.1 Assembly overview - toothed belt
    136
  • 2.2 Removing and installing toothed belt
    138
  • 3 Fully enclosing toothed belt guard
    150
  • 3.1 Assembly overview - fully enclosing toothed belt guard
    150
  • 3.2 Removing and installing front toothed belt guard (fully enclosing)
    153
  • 3.3 Removing and installing lower toothed belt guard (fully enclosed)
    156
  • 3.4 Removing and installing rear toothed belt guard (fully enclosing)
    157
  • 4 Air supply for toothed belt drive
    162
  • 4.1 Assembly overview - air supply for toothed belt drive
    162
  • 4.2 Removing and installing blower of air supply for toothed belt drive
    162
  • 4.3 Removing and installing air filter housing of air supply for toothed belt drive
    163
  • 4.4 Removing and installing console of air supply for toothed belt drive
    164
  • 5 Valve gear
    165
  • 5.1 Assembly overview - valve gear
    165
  • 5.2 Measuring axial play of camshaft
    168
  • 5.3 Measuring radial play of camshaft
    169
  • 5.4 Removing and installing camshaft
    169
  • 5.5 Removing and installing camshaft oil seal
    179
  • 5.6 Checking hydraulic compensation elements
    185
  • 5.7 Removing and installing valve stem seals
    185
  • 6 Inlet and exhaust valves
    191
  • 6.1 Reworking valve seats
    191
  • 6.2 Checking valve guides
    191
  • 6.3 Valve dimensions
    192
  • Lubrication
    193
  • 1 Sump, oil pump
    193
  • 1.1 Assembly overview - sump/oil pump
    193
  • 1.2 Removing and installing oil sump
    195
  • 1.3 Removing and installing oil pump
    203
  • 1.4 Removing and installing oil level and oil temperature sender G266
    205
  • 1.5 Removing and installing dipstick tube
    206
  • 2 Engine oil cooler
    208
  • 2.1 Checking engine oil cooler for leaks
    208
  • 3 Oil filter, oil pressure switch
    211
  • 3.1 Assembly overview - oil filter
    211
  • 3.2 Removing and installing oil filter housing
    213
  • 3.3 Removing and installing oil pressure switch F1
    216
  • 3.4 Checking oil pressure and oil pressure switch
    217
  • 4 Oil circuit
    221
  • 4.1 Removing and installing oil supply line, bi-turbo
    221
  • 4.2 Removing and installing oil pressure line for turbocharger, mono-turbo
    224
  • 5 Balancer shaft module
    227
  • 5.1 Assembly overview - balancer shaft module
    227
  • 5.2 Removing and installing balance shaft module
    231
  • Cooling
    240
  • 1 Cooling system/coolant
    240
  • 1.1 Connection diagram - coolant hoses
    240
  • 1.2 Assembly overview - coolant hoses
    245
  • 1.3 Checking cooling system for leaks
    247
  • 1.4 Draining and adding coolant
    249
  • 2 Coolant pump, regulation of cooling system
    259
  • 2.1 Assembly overview - coolant pump, thermostat
    259
  • 2.2 Assembly overview - electric coolant pump
    260
  • 2.3 Removing and installing coolant pump
    262
  • 2.4 Removing and installing 4/2-way valve with thermostat
    266
  • 2.5 Removing and installing coolant temperature sender G62
    272
  • 2.6 Removing and installing radiator outlet coolant temperature sender G83
    273
  • 2.7 Removing and installing electric coolant pump
    275
  • 2.8 Removing and installing Y-thermostat
    280
  • 3 Radiator, radiator fan
    283
  • 3.1 Assembly overview - radiator/radiator fan
    283
  • 3.2 Assembly overview – radiator cowl and radiator fan
    285
  • 3.3 Removing and installing radiator
    285
  • 3.4 Removing and installing radiator cowl with radiator fan
    289
  • Turbocharging/supercharging
    292
  • 1 Turbocharger
    292
  • 1.1 Assembly overview - turbocharger
    292
  • 1.2 Removing and installing turbocharger
    301
  • 1.3 Renewing seal between bi-turbo turbine housings
    311
  • 1.4 Checking vacuum unit for turbocharger, bi-turbo
    315
  • 1.5 Checking regulating flap potentiometer G584
    317
  • 1.6 Removing and installing charge pressure sender 2 G447
    320
  • 1.7 Removing and installing vacuum unit for turbocharger
    322
  • 1.8 Removing and installing charge pressure control solenoid valve N75
    337
  • 2 Charge air system
    339
  • 2.1 Assembly overview - charge air system
    339
  • 2.2 Removing and installing charge air cooler
    340
  • 2.4 Removing and installing exhaust gas flap valve N220
    342
  • 2.5 Checking charge air system for leaks
    343
  • Mixture preparation - injection
    347
  • 1 Injection system
    347
  • 1.1 Schematic overview - fuel system
    347
  • 1.2 Overview of fitting locations - injection system
    348
  • 1.3 Assembly overview - fuel system
    357
  • 1.4 Checking fuel system for leaks
    363
  • 1.5 Filling/bleeding fuel system
    364
  • 2 Vacuum system
    365
  • 2.1 Connection diagram – vacuum system
    365
  • 2.2 Checking vacuum system
    371
  • 3 Injectors/high-pressure accumulator (rail)
    381
  • 3.1 Overview of injectors
    381
  • 3.2 Adapting correction values for injectors
    381
  • 3.3 Removing and installing injectors
    382
  • 3.4 Removing and installing high-pressure lines
    393
  • 3.5 Removing and installing fuel rail
    396
  • 3.6 Checking return flow rate of injectors with engine running
    400
  • 4 Air filter
    404
  • 4.1 Assembly overview - air filter housing
    404
  • 4.2 Removing and installing air filter housing
    407
  • 5 Intake manifold
    409
  • 5.1 Assembly overview – intake manifold
    409
  • 5.2 Removing and installing intake manifold
    410
  • 5.3 Removing and installing throttle valve module GX3
    414
  • 6 Senders and sensors
    416
  • 6.1 Removing and installing air mass meter G70
    416
  • 6.2 Removing and installing exhaust pressure sensor 1 G450
    417
  • 6.3 Removing and installing fuel pressure regulating valve N276
    419
  • 6.4 Checking fuel pressure regulating valve N276
    422
  • 6.5 Removing and installing fuel pressure sender G247
    424
  • 7 Engine control unit
    428
  • 7.1 Removing and installing engine control unit J623
    428
  • 8 High-pressure pump
    429
  • 8.1 Assembly overview - high-pressure pump
    429
  • 8.2 Removing and installing high-pressure pump
    430
  • 8.3 Checking high-pressure pump
    433
  • Exhaust system
    437
  • 1 Exhaust pipes and silencers
    437
  • 1.1 Assembly overview – silencers
    437
  • 1.2 Checking exhaust system for leaks
    440
  • 1.3 Aligning exhaust system free of stress
    440
  • 2 Emission control
    442
  • 2.1 Assembly overview – emission control
    442
  • 2.2 Removing and installing particulate filter
    446
  • 2.3 Removing and installing catalytic converter
    453
  • 3 Exhaust gas recirculation
    457
  • 3.1 Assembly overview – exhaust gas recirculation
    457
  • 3.2 Removing and installing exhaust gas recirculation cooler
    459
  • 3.3 Removing and installing exhaust gas recirculation valve 1 GX5
    468
  • 3.5 Pressure loss test for exhaust gas recirculation cooler
    470
  • Glow plug system
    474
  • 1 Glow plug system
    474
  • 1.1 Assembly overview – glow plug system
    474
  • 1.2 Checking glow plug system
    476
  • 1.3 Removing and installing glow plug
    476
  • 1.4 Removing and installing engine speed sender G28
    479
  • 1.5 Removing and installing Hall sender G40
    481
Manufacturer's designation 4-cylinder diesel engine (2.0 l engine, common rail)
Manufacturer Volkswagen
Suitable for Amarok (2011) / Amarok (2013) / Amarok (2017 >) / Amarok (2017)
Suitable car types 2H, S6, S7
Engine code CDBA, CNEA, CSHA, CNFA, CNFB, CNEB
Category Reparaturanleitung

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