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  • Examplepage for repair manual 6-cylinder diesel engine (3.0 l engine, common rail)
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  • Examplepage for repair manual 6-cylinder diesel engine (3.0 l engine, common rail)
  • Examplepage for repair manual 2 6-cylinder diesel engine (3.0 l engine, common rail)
  • Examplepage for repair manual 3 6-cylinder diesel engine (3.0 l engine, common rail)

6-cylinder diesel engine (3.0 l engine, common rail)

For Amarok

Original Volkswagen repair manual


34,87 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

45.258 KB

483 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mountings, Engine cover panel, Cylinder block (pulley end), Crankshaft, Pistons and conrods, Cover for timing chain, Chain drive, Valve gear, Sump, oil pump, Oil filter, oil pressure switch, Coolant pump, regulation of cooling system, Radiator, radiator fan, Turbocharger, Vacuum system, Injectors/high-pressure accumulator (rail), Intake manifold, Lambda probe and SCR system (selective catalytic reduction). Show more
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Repair manual Amarok 6-cylinder diesel engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Safety information
    1
  • 1.1 Safety regulations for working on fuel supply
    1
  • 1.2 Safety measures when working on vehicles with start/stop system
    1
  • 1.4 Safety precautions when working on the cooling system
    2
  • 1.5 Safety precautions when working on ignition system
    2
  • 1.6 Safety precautions when working on exhaust system
    3
  • 2 Identification
    4
  • 2.1 Engine number/engine data
    4
  • 3 Repair notes
    5
  • 3.1 Rules for cleanliness
    5
  • 3.2 General information
    5
  • 3.3 General repair notes
    6
  • 3.4 Foreign objects in engine
    6
  • 3.5 Contact corrosion
    6
  • 3.6 Nuts and bolts
    7
  • 3.7 Routing and attachment of lines
    7
  • 3.8 Fitting radiator and condensers
    7
  • 3.9 Checking vacuum system
    7
  • Removing and installing engine
    9
  • 1 Removing and installing engine
    9
  • 1.1 Removing engine
    9
  • 1.2 Securing engine on engine and gearbox support
    20
  • 1.3 Installing engine
    23
  • 2 Assembly mountings
    28
  • 2.1 Assembly overview – assembly mountings
    28
  • 2.2 Removing and installing engine mounting
    30
  • 2.3 Removing and installing gearbox mounting
    37
  • 2.4 Supporting engine in installation position
    39
  • 3 Engine cover panel
    43
  • 3.1 Removing and installing engine cover
    43
  • Crankshaft group
    44
  • 1 Cylinder block (pulley end)
    44
  • 1.1 Assembly overview - cylinder block (pulley end)
    44
  • 1.2 Assembly overview - sealing flange, belt pulley end
    47
  • 1.3 Removing and installing poly-V belt
    49
  • 1.4 Removing and installing tensioner for poly V-belt
    51
  • 1.5 Removing and installing vibration damper
    52
  • 1.6 Removing and installing bracket for ancillaries
    54
  • 1.7 Removing and installing engine support
    57
  • 1.8 Renewing crankshaft oil seal - belt pulley end
    58
  • 1.9 Removing and installing sealing flange on pulley end
    59
  • 2 Cylinder block, gearbox end
    64
  • 2.1 Assembly overview - drive plate
    64
  • 2.2 Assembly overview - flywheel
    64
  • 2.3 Removing and installing drive plate
    65
  • 2.4 Removing and installing flywheel
    67
  • 2.5 Renewing crankshaft oil seal (gearbox end)
    69
  • 3 Crankshaft
    73
  • 3.1 Assembly overview - crankshaft
    73
  • 3.2 Crankshaft dimensions
    75
  • 3.3 Allocation of main bearing shells
    75
  • 3.4 Measuring axial clearance of crankshaft
    77
  • 3.5 Measuring radial clearance of crankshaft
    78
  • 3.6 Removing and installing sender wheel
    78
  • 3.7 Checking sender wheel
    79
  • 4 Balancer shaft
    81
  • 4.1 Assembly overview - balance shaft
    81
  • 4.2 Removing and installing balance shaft
    81
  • 5 Pistons and conrods
    89
  • 5.1 Assembly overview - pistons and conrods
    89
  • 5.2 Removing and installing pistons
    92
  • 5.3 Measuring piston projection at TDC
    93
  • 5.4 Checking pistons and cylinder bores
    95
  • 5.5 Checking radial clearance of conrods
    97
  • Cylinder head, valve gear
    98
  • 1 Cylinder head
    98
  • 1.1 Assembly overview - cylinder head
    98
  • 1.2 Assembly overview - cylinder head cover
    101
  • 1.3 Removing and installing cylinder head
    104
  • 1.4 Removing and installing cylinder head cover
    114
  • 1.5 Removing and installing injector seals
    120
  • 1.6 Checking compression
    121
  • 2 Cover for timing chain
    123
  • 2.1 Assembly overview - cover for timing chain
    123
  • 2.2 Removing and installing timing chain cover
    127
  • 3 Chain drive
    138
  • 3.1 Assembly overview - camshaft timing chains
    138
  • 3.2 Assembly overview - drive chain for high pressure pump
    140
  • 3.3 Assembly overview - drive chain for oil pump
    141
  • 3.4 Assembly overview - intermediate drive
    142
  • 3.5 Removing camshaft timing chain from camshafts
    143
  • 3.6 Removing and installing camshaft timing chain
    155
  • 3.7 Removing and installing drive chain for high-pressure pump
    166
  • 3.8 Installing intermediate drive
    168
  • 4 Valve gear
    175
  • 4.1 Assembly overview - valve gear
    175
  • 4.2 Measuring axial play of camshaft
    181
  • 4.3 Measuring radial play of camshaft
    183
  • 4.4 Removing and installing camshaft
    184
  • 4.5 Renewing camshaft
    191
  • 4.6 Checking hydraulic compensation elements
    194
  • 4.7 Removing and installing valve stem seals
    196
  • 5 Inlet and exhaust valves
    206
  • 5.1 Reworking valve seats
    206
  • 5.2 Checking valve guides
    206
  • 5.3 Checking valves
    207
  • 5.4 Valve dimensions
    208
  • Lubrication
    209
  • 1 Sump, oil pump
    209
  • 1.1 Assembly overview - sump/oil pump
    209
  • 1.2 Engine oil:
    213
  • 1.3 Removing and installing oil level and oil temperature sender G266
    213
  • 1.4 Removing and installing lower part of sump
    214
  • 1.5 Removing and installing upper part of sump
    219
  • 1.6 Removing and installing oil pump
    223
  • 1.7 Removing and installing dipstick tube
    225
  • 2 Engine oil cooler
    227
  • 2.1 Assembly overview - engine oil cooler
    227
  • 2.2 Assembly overview - engine oil cooler temperature regulator
    228
  • 2.3 Removing and installing engine oil cooler
    229
  • 2.4 Removing and installing temperature regulator for engine oil cooler
    230
  • 3 Oil filter, oil pressure switch
    232
  • 3.1 Assembly overview - oil filter housing, oil pressure switch
    232
  • 3.2 Removing and installing oil pressure sender G10
    234
  • 3.3 Checking oil pressure
    235
  • 3.4 Removing and installing oil filter housing
    235
  • 3.5 Removing and installing oil pressure regulating valve N428
    237
  • 3.6 Removing and installing oil temperature sender 2 G664
    238
  • Cooling
    240
  • 1 Cooling system/coolant
    240
  • 1.1 Connection diagram - coolant hoses
    240
  • 1.2 Checking cooling system for leaks
    252
  • 1.3 Draining and adding coolant
    255
  • 2 Coolant pump, regulation of cooling system
    265
  • 2.1 Assembly overview - coolant pump
    265
  • 2.2 Assembly overview - thermostat
    266
  • 2.3 Assembly overview - coolant temperature sender
    267
  • 2.4 Assembly overview - coolant valve
    268
  • 2.5 Removing and installing coolant pump
    269
  • 2.6 Removing and installing map-controlled engine cooling thermostat F265
    271
  • 2.8 Removing and installing coolant temperature sender G62
    273
  • 2.9 Removing and installing coolant temperature sender 2 G802
    275
  • 2.10 Removing and installing coolant temperature sender 3 G812
    276
  • 2.11 Removing and installing coolant valve
    278
  • 3 Coolant pipes
    280
  • 3.1 Assembly overview - coolant pipes
    280
  • 3.2 Removing and installing coolant pipes
    281
  • 4 Radiator, radiator fan
    292
  • 4.1 Assembly overview - radiator / radiator fan
    292
  • 4.2 Assembly overview – radiator cowl and radiator fan
    294
  • 4.3 Removing and installing radiator
    294
  • 4.4 Removing and installing radiator cowl with radiator fan
    298
  • 4.5 Removing and installing radiator fan V7
    300
  • Turbocharging/supercharging
    302
  • 1 Turbocharger
    302
  • 1.1 Assembly overview - turbocharger
    302
  • 1.2 Removing and installing turbocharger
    306
  • 2 Charge air system
    314
  • 2.1 Assembly overview - charge air system
    314
  • 2.2 Removing and installing charge air cooler
    315
  • 2.3 Removing and installing charge pressure sender G31
    317
  • 2.4 Removing and installing intake air temperature sender G42
    317
  • 2.5 Checking charge air system for leaks
    318
  • Mixture preparation - injection
    322
  • 1 Injection system
    322
  • 1.1 Filling/bleeding fuel system
    322
  • 1.2 Checking fuel system for leaks
    322
  • 2 Vacuum system
    324
  • 2.1 Connection diagram - vacuum system
    324
  • 2.2 Checking vacuum system
    324
  • 3 Injectors/high-pressure accumulator (rail)
    326
  • 3.1 Assembly overview - injectors
    326
  • 3.2 Assembly overview - fuel rail
    327
  • 3.3 Adapting correction values for injectors
    331
  • 3.4 Testing injectors
    332
  • 3.5 Testing jammed-open injectors
    332
  • 3.6 Checking return flow rate of injectors with engine running
    336
  • 3.7 Checking return flow rate of injectors at starter speed
    340
  • 3.8 Check pressure retention valve in fuel return line
    342
  • 3.9 Removing and installing injectors
    344
  • 3.10 Removing and installing high-pressure lines
    351
  • 3.11 Removing and installing fuel rail
    364
  • 4 Air filter
    368
  • 4.1 Assembly overview - air filter housing
    368
  • 4.2 Removing and installing air filter housing
    370
  • 5 Intake manifold
    372
  • 5.1 Assembly overview – intake manifold
    372
  • 5.2 Removing and installing intake manifold flap control unit GX14
    375
  • 5.3 Removing and installing intake manifold upper part
    377
  • 5.4 Removing and installing lower part of intake manifold
    380
  • 5.5 Removing and installing throttle valve module GX3
    381
  • 6 Senders and sensors
    383
  • 6.1 Removing and installing air mass meter G70
    383
  • 6.2 Removing and installing fuel pressure sender G247
    384
  • 6.3 Removing and installing fuel pressure regulating valve N276
    386
  • 6.4 Removing and installing pressure differential sender G505
    387
  • 6.5 Removing and installing fuel temperature sender G81
    389
  • 6.6 Removing and installing fuel pressure sender for low-pressure G410
    390
  • 6.7 Removing and installing intake manifold sender GX9
    391
  • 7 Engine control unit
    393
  • 7.1 Removing and installing engine control unit J623
    393
  • 8 High-pressure pump
    395
  • 8.1 Assembly overview - high-pressure pump
    395
  • 8.2 Removing and installing high-pressure pump
    397
  • 9 Lambda probe
    403
  • 9.1 Removing and installing Lambda probe 1 before catalytic converter GX10
    403
  • 9.2 Removing and installing control unit for NOx sender J583/NOx sender G295
    405
  • 9.3 Removing and installing control unit for NOx sender 2 J881/NOx sender 2 G687
    407
  • Exhaust system
    410
  • 1 Exhaust pipes and silencers
    410
  • 1.1 Assembly overview – silencers
    410
  • 1.2 Removing and installing exhaust pipe
    410
  • 1.3 Removing and installing rear silencer
    411
  • 1.4 Aligning exhaust system free of stress
    413
  • 1.5 Checking exhaust system for leaks
    413
  • 1.6 Installation position of clamp
    414
  • 2 Emission control
    415
  • 2.1 Assembly overview – emission control
    415
  • 2.2 Removing and installing catalytic converter
    417
  • 2.3 Removing and installing particulate filter
    420
  • 3 SCR system (selective catalytic reduction)
    424
  • 3.1 Assembly overview – reducing agent tank
    424
  • 3.2 Assembly overview - delivery module for reducing agent
    425
  • 3.3 Removing and installing reducing agent tank VX85
    426
  • 3.4 Removing and installing delivery unit for reducing agent metering system GX19
    429
  • 3.5 Removing and installing injector for reduction agent N474
    432
  • 3.6 Removing and installing control unit for reducing-agent heater J891
    435
  • 3.7 Draining reducing agent tank VX85
    436
  • 3.8 Removing and installing filler pipe for reducing agent tank VX85
    439
  • 4 Exhaust gas temperature regulation
    442
  • 4.1 Assembly overview – exhaust gas temperature regulation
    442
  • 4.2 Removing and installing exhaust gas temperature sender 1 G235
    444
  • 4.3 Removing and installing exhaust gas temperature sender 2 G448
    445
  • 4.4 Removing and installing exhaust gas temperature sender 3 G495
    446
  • 4.5 Removing and installing exhaust gas temperature sender 4 G648
    448
  • 5 Exhaust gas recirculation
    450
  • 5.1 Assembly overview – exhaust gas recirculation
    450
  • 5.2 Removing and installing exhaust gas recirculation cooler
    454
  • 5.3 Removing and installing exhaust gas recirculation pipes
    457
  • 5.4 Removing and installing exhaust gas recirculation temperature sensor G98
    459
  • 5.5 Installing repair kit for exhaust gas recirculation cooler
    460
  • 6 Exhaust manifold
    464
  • 6.1 Assembly overview - exhaust manifold
    464
  • 6.2 Removing and installing exhaust manifold
    465
  • Glow plug system
    469
  • 1 Glow plug system
    469
  • 1.1 Assembly overview - glow plug system
    469
  • 1.2 Removing and installing glow plug
    471
  • 1.3 Checking glow plug
    473
  • 1.4 Removing and installing automatic glow period control unit J179
    473
  • 1.5 Removing and installing Hall sender G40
    474
  • 1.6 Removing and installing engine speed sender G28
    474
Manufacturer's designation 6-cylinder diesel engine (3.0 l engine, common rail)
Manufacturer Volkswagen
Suitable for Amarok (2017 >) / Amarok (2017)
Suitable car types S6, S7
Engine code DDXB, DDXC, DDXD, DDXE
Category Reparaturanleitung

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